Johnson Controls 100 Series User manual

FORM 100.50-EG12 (918)

SERIES 100

SINGLE PACKAGE ROOFTOP UNITS

ENGINEERING GUIDE

70–105 Tons

Cooling and Heating (Gas, Electric, Water, and Steam)

R-410A

Mod G

LD16707

JOHNSON CONTROLS

FORM100.50-EG12 (918)

Nomenclature

ASHRAE

90.1

COMPLIANT

BASE MODEL NUMBER YPAL070–105

Approvals

A : Std. Product, Simplicity Elite

B : Special Product, Simplicity Elite

X : Std. Product, IPU

S : Special Product, IPU

E : R-410A 7 : 200 / 3 / 60

8 : 230 / 3 / 60

6 : 460 / 3 / 60

5 : 400 / 3 / 50

8 : 575 / 3 / 60

0 : 380 / 3 / 60

V : VAV, SZVAV

F : FlexSys™

B : Bottom Return

R : Rear Return

S : Side Return

C : Cooling Only

N : Natural Gas Heat

G : Natural Gas Heat SS HX

M : Modulating Gas Heat

E : Electric Heat

S : Steam Heat

H : Hot Water Heat

L : Scroll

P : Packaged Rooftop

A : Air-Cooled

Y : Johnson Controls

B : Bottom Supply

L : Left Supply

R : Right Supply

GN : No Gas Heat

L : Low (375 MBH)

M : Med (750 MBH)

H : High (1125 MBH)

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

Base Product Type Nominal (Ton)

Capacity

Application Refrigerant Voltage Supply

Openings

Return

Openings

Design Special Gas Heat

Capacity

JOHNSON CONTROLS

NOMENCLATURE ................................................................................................................................................... 2

INTRODUCTION...................................................................................................................................................... 5

FEATURES AND BENEFITS................................................................................................................................... 6

APPLICATION DATA ............................................................................................................................................. 13

PHYSICAL DATA................................................................................................................................................... 19

WEIGHT DATA....................................................................................................................................................... 22

COOLING PERFORMANCE DATA – 70 TON MODEL......................................................................................... 25

COOLING PERFORMANCE DATA – 75 TON MODEL......................................................................................... 30

COOLING PERFORMANCE DATA – 80 TON MODEL......................................................................................... 35

COOLING PERFORMANCE DATA – 90 TON MODEL......................................................................................... 40

COOLING PERFORMANCE DATA – 105 TON MODEL....................................................................................... 45

HEATING PERFORMANCE DATA – GAS/ELECTRIC HEAT............................................................................... 50

SUPPLY FAN DATA............................................................................................................................................... 51

COMPONENT STATIC PRESSURE DROPS ........................................................................................................ 53

GAS HEAT PRESSURE DROPS........................................................................................................................... 54

ELECTRIC HEAT PRESSURE DROPS ................................................................................................................ 55

EXHAUST FAN DATA............................................................................................................................................ 56

RETURN FAN DATA.............................................................................................................................................. 57

ELECTRICAL DATA .............................................................................................................................................. 58

CONTROLS ........................................................................................................................................................... 61

POWER WIRING: YPAL070–105 .......................................................................................................................... 70

FIELD CONTROL WIRING ................................................................................................................................... 73

GENERAL ARRANGEMENT DRAWING – 70–80 TON MODELS ...................................................................... 75

GENERAL ARRANGEMENT DRAWING – 90–105 TON MODELS .................................................................... 81

GENERAL ARRANGEMENT DRAWING - CURB LAYOUT ................................................................................. 87

HOT WATER/STEAM COIL CONNECTION LOCATIONS .................................................................................... 89

POWER/CONTROL ENTRY DRAWING – 70-105 TON MODELS........................................................................ 90

GUIDE SPECIFICATIONS ..................................................................................................................................... 91

FORM 100.50-EG12 (918)

Table of Contents

JOHNSON CONTROLS

THIS PAGE INTENTIONALLY LEFT BLANK.

FORM100.50-EG12 (918)

JOHNSON CONTROLS

FORM 100.50-EG12 (918)

Introduction

The Johnson Controls Series 100 Single Packaged Units –

designed to meet the demands of the market for today and

tomorrow.

Better Economy...

Lower total cost of ownership

• Johnson Controls provides a standard product offering that meets the latest ASHRAE

90.1 energy efciency requirements.

• Fully modulating gas heat and greater steps of capacity control offer superior off-

design performance while maintaining optimum occupant comfort.

• Accurate ventilation control ensures that no more than the proper amount of ventila-

tion air is utilized. This avoids the energy cost of conditioning excess outside air and

simultaneously monitors all other unit functions for maximized energy efciency.

• Flexible design congurations simplify the design process and allows the Series 100

to be applied to virtually any building application.

• Accessibility through double-wall access doors, spacious compartments and sup-

portive oors improves serviceability.

Better Ecology...

Indoor air quality features for the indoor environment

• A double-sloped stainless steel drain pan with a single drain con-

nection ensures that all condensate is voided from the drain pan. It

is also visible and accessible for periodic inspection and cleaning re-

quired by the ASHRAE 62 IAQ standard.

• Double-wall construction of the roof, oor, doors, and walls pre-

vents insulation bers from entering the conditioned air. The inner liner

also facilitates periodic cleaning of the unit to prevent harmful build-up

of bacteria or contaminants.

• The single package unit control center uses microprocessor log-

ic to analyze and optimize ventilation decisions and perform demand

ventilation, airow compensation, and airow measurement to main-

tain the air quality at a healthy level.

LD07431

The Single Package Unit User Interface uses

microprocessor logic to optimize operation of the

Series 100 unit.

JOHNSON CONTROLS

FORM100.50-EG12 (918)

Features and Benefits

AIRFLOW CONFIGURATIONS

Variable Air Volume (VAV) – Series 100 units are available for variable air volume (VAV)

applications. Control can be used with a zone sensor or building automation system. Sup-

ply fans are controlled to the supply duct static pressure setpoint, which can be reset via a

building automation system (BAS) or through a 0–5VDC analog input on the unit controller

for optimized duct static pressure control. The static pressure transducer is provided in the

single package unit, and 5/16-inch or 1/4-inch plastic tubing and static pressure sensor

must be supplied by others and installed approximately 3/4 down the longest duct run.

FlexSys™Underfloor Air VAV – Series 100 units are configurable for underfloor air VAV

applications. Control can be used with a zone sensor or building automation system. Sup-

ply fans are controlled to the supply duct static pressure setpoint, which can be reset via

a BAS, or through a 0–5VDC analog input on the unit controller for optimized duct static

pressure control. The static pressure transducer is provided in the single package unit,

and 5/16-inch or 1/4-inch plastic tubing and static pressure sensor must be supplied by

others and installed approximately 3/4 down the longest duct run. Refer to 100.50-EG8

engineering guide for more detailed information on this application.

Single Zone Variable Air Volume (SZVAV)– Series 100 units are available for single

zone variable air volume (SZVAV) applications. Control can be used with a zone sensor

or a BAS. Supply fans are controlled based on zone temperature.

COOLING AND HEATING CONFIGURATIONS

Cooling Only – For applications where no heat is required, or heating is provided else-

where within the building HVAC system, cooling only units include an empty discharge

plenum. Supply duct connections are configurable for bottom, left or right discharge. The

supply air temperature sensor is included and factory-installed.

Staged Gas Heat – For applications requiring gas heat for morning warm-up, or other

heating needs, a staged natural gas furnace is available. The furnace is located in the

discharge plenum, downstream of the supply fan. The supply air temperature sensor is

located across the face of the supply duct opening in the unit. Furnaces are designed in

375 MBH modules with two stages in each. For 70–105 ton units, optional Propane Con-

version Kits contain the necessary orifices and gas valve/parts to convert staged heat only

(not modulating) from natural gas to propane. Ignition and safety controls are included

and factory-wired. Units with staged gas heat are ETL listed.

Modulating Gas Heat – For applications requiring gas heat for morning warm-up, supply

air tempering or other heating needs, a modulating natural gas furnace is available for

finer temperature control. The furnace is located in the discharge plenum, downstream of

the supply fan. The supply air temperature sensor is located across the face of the sup-

ply duct opening in the unit. Furnaces are designed in 375 MBH modules in 8:1 turndown

increments. Three are available for the YPAL070–105 (8:1, 16:1 or 24:1 turndown). Igni-

tion and safety controls are included and factory-wired. Units with modulating gas heat

are ETL listed.

Electric Resistance Heat – For applications where electric heat is desired, a slip-in elec-

tric resistance heat element is available in sizes from 80–250 kW depending on the single

package unit model size. The number of stages varies by size and voltage, but all have a

minimum of two stages of capacity. Units with electric heat are ETL listed.

JOHNSON CONTROLS

FORM 100.50-EG12 (918)

Hot Water Heat – For applications where hot water is available for heating, a hot water

heating coil is available. A range of coil fin count selections are available to properly size the

heating for the application. Units with hot water heat are ETL listed.

Steam Heat – For applications where steam is available for heating, a steam heating coil

is available. A range of coil fin count selections are available to properly size the heating

for the application. Units with steam heat are ETL listed.

POWER OPTIONS

Single-Point Supply with Terminal Block –This configuration is standard, and includes

three terminals for the incoming 3-phase power and is the standard configuration for the

Series 100 product. It includes the enclosure, terminal-block, and interconnecting wiring

to the compressors, heater and furnace controls, all fans, etc. In this configuration, code

requires that a means of disconnect (not provided) must be installed at the site within line-

of-sight of the equipment.

Single-Point Supply with Non-Fused Disconnect Switch –This option is the same as

the single-point with terminal block option except it includes a unit-mounted through-the-

door manual non-fused disconnect switch with an external, lockable handle (in compli-

ance with Article 440-14 of N.E.C.). This option provides a means to isolate the unit power

voltage for servicing. Others must supply separate external fusing which must comply with

the National Electric Code and/or local codes.

Dual-Point Supply with Terminal Block – This option includes enclosure, terminal blocks

circuited to the supply and exhaust fans and control transformer and a second set of

terminal blocks with interconnecting wiring to the compressors, heat (if applicable) and

condenser.

Convenience Outlet – This options includes a powered 115V GFCI convenience outlet

that can be used for powering tools or lights for servicing. A protective cover plate is in-

cluded while not in use. The outlet is located on the bottom left hand corner of the power

panel.

CONTROL FEATURES AND OPTIONS

Microprocessor-Based Single Package Unit Controller –All Series 100 units are

equipped with a factory-installed, programmed and commissioned unit controller with all I/O

capabilities and control sequences. The controls include all on-board diagnostic, safety and

control features to operate the single package unit. A multimedia card interface is included

for software upgrades and can be used for data logging to simplify equipment troubleshoot-

ing. Communication ports are included as standard with three alarm outputs, a shutdown

contact, remote start/stop input, smoke ventilation controls, analog inputs for supply air

temperature and duct static pressure rest, along with a variety of other capabilities.

Standard Ambient – YPAL070–105 models operate down to 45.0°F as standard.

Low Ambient on Circuits One, [One and Two], or [One, Two, and Three] – This op-

tion includes low ambient control of the first [first and second] [first, second, and third]

circuit(s) down to 0.0°F through the use of suction and discharge pressure transducers

on the circuit(s).

Pressure Transducers with Readout Capability –This option includes suction and dis-

charge pressure transducers on each circuit and provides pressure readout of all circuits

at the unit control panel.

JOHNSON CONTROLS

FORM100.50-EG12 (918)

Wall-Mount Zone Sensor – A 10 kOhm thermister type III NTC zone sensor for wall

mounting. This zone sensor is for sensing temperature only, and does not include any

setpoint adjustment features.

COMMUNICATIONS

BACnet®MS/TP (RS-485) Communications – This communication option is standard on

every Series 100 unit. Communications to the unit are through a twisted pair, and the wire

terminations are on the primary unit control board. See supplemental information for the

available control points and PICS/Bibbs statements of conformity.

Modbus™RTU Communications – This communication option is standard on every Se-

ries 100 unit and can be used in lieu of the BACnet communications (only one can be

used at a time). See supplemental information for the available control points.

FILTER OPTIONS

Filter Options – Two-inch throwaway, cleanable, carbon coated MERV 8 or pleated

MERV 8 filters in an angled rack are available. For higher filtration requirements, optional

rigid filter racks are available with 12-inch 65% (MERV 11) or 95% (MERV 14) efficient

rigid filters. Two-inch MERV 8 pre-filters are included with rigid filter options. The rigid filter

rack option is available without filter media where field-supplied filters are required.

OUTSIDE AIR DAMPER OPTIONS

Manual Damper – This option includes a manually adjustable outside air damper. It is

manually adjustable at the unit by setting a mechanical stop between 0–100%.

Two-Position – This outside air damper option is controlled to a two positions, opened

and closed. Determination of the damper position is based on the occupancy schedule. In

the occupied mode, the outside air damper is positioned to the manually configured point

(set by mechanical stop). In the unoccupied mode, the damper is fully closed.

Modulating Economizer – This option includes modulating outdoor air and return air

dampers that are software interlocked (YPAL070–105 software interlock) and positioned

by fully modulating, solid state damper actuators. Control of the damper is via a standard

ambient outdoor air dry bulb sensor, or optional single or comparative enthalpy controls.

Airflow Measurement – Optional outside airflow measurement is available on units

equipped with a Modulating Economizer.

CO2Sensors – Optional carbon dioxide sensors for occupied space that operate demand

ventilation control opening outside air dampers to ventilate building. The CO2sensors can

operate in a single or comparative control scheme.

Rain Hoods on Outside Air Intakes – For all options with outside air intake openings,

rain hoods are provided as standard to keep moisture from entering the equipment. The

rain hoods are an integral part of the unit and are rotated into place at the jobsite.

RELIEF SYSTEM

Barometric Relief – This option does not include an exhaust or return fan, but rather

uses barometric relief dampers to exhaust air from the building. The dampers will open

relative to the building pressure. The opening pressure is adjustable via a spring tension

adjustment.

Features and Benefits (Cont'd)

Zone Sensor

JOHNSON CONTROLS

FORM 100.50-EG12 (918)

On/Off Powered Exhaust –This option provides simple building pressure control. It can

be controlled via a building pressure signal, or via outside air damper control. This option

is not available for VAV units.

Modulating Powered Exhaust with Damper Control – This option consists of a con-

stant-speed exhaust fan with a discharge damper that is modulated to control the flow

of exhaust air. The damper control logic is based on the building static pressure setpoint

within the single package unit controller. The static pressure transducer is provided in

the return plenum of the single package unit, and 5/16-inch or 1/4-inch plastic tubing and

static pressure sensor must be supplied by others and installed in a representative loca-

tion in the building.

Modulating Powered Exhaust with a VFD – This option consists of a VFD to modulate the

speed of the exhaust fan to control the flow of exhaust air. The VFD control logic is based

on the building static pressure setpoint within the single package unit controller. The static

pressure transducer is provided in the return plenum of the single package unit, and 5/16-

inch or 1/4-inch plastic tubing and static pressure sensor must be supplied by others and

installed in a representative location in the building.

Powered Return Fan with Exhaust – This option uses single width, single inlet (SWSI)

plenum fan(s) to control building pressure. The fan motors are driven by a VFD to maintain

a constant return plenum pressure. An exhaust hood with a modulating control damper

is used to maintain building pressure via the building static pressure. The static pressure

transducer is provided in the return plenum of the single package unit, and 5/16-inch or

1/4-inch plastic tubing and static pressure sensor must be supplied by others and installed

in a representative location in the building. The powered return fan is also available with-

out the exhaust capabilities. For units with no exhaust capabilities, the HVAC system must

provide alternate means of controlling building pressure.

SUPPLY FAN OPTIONS

Double Width, Double Inlet (DWDI) Forward-Curved Supply Fan – The standard sup-

ply air blower in the YPAL070–80 models is a forward-curved supply fan. This fan is good

for medium static pressures and high airflows.

DWDI Airfoil Supply Fan –The standard supply air blower in the YPAL090–105 is an

airfoil blade supply fan. This fan is also available as an option on YPAL070–080 for higher

static conditions. This fan offers higher efficiency and lower sound in certain applications.

Fan Skid Isolation – The entire supply fan assembly is isolated from the unit base with

one- (standard) or two-inch deflection springs, or one (standard) or two-inch deflection

springs with seismic restraints.

Supply and Exhaust Fan Motors – Premium efficiency ODP and premium efficiency

TEFC motors are available all meeting the Energy Policy Act of 1992 (EPACT).

Supply Fan VFD and Manual Bypass – For VAV applications, VFDs are provided to

modulate airflow. Optional manual bypass can also be provided to allow full airflow in the

event of a VFD failure.

Direct Drive Plenum (DDP) Fan – A direct drive plenum (DDP) supply fan provides out-

standing reliability and efficiency, eliminating the possibility of conditioned air supply inter-

ruption due to a broken belt and the pollution of conditioned air with belt dust. The supply

fan can be optionally equipped with a piezo ring to precisely measure the amount of air

delivered to the conditioned space. The speed of the supply fan is controlled by a VFD.

JOHNSON CONTROLS

FORM100.50-EG12 (918)

EVAPORATOR SECTION

Double Sloped Stainless Steel Drain Pan – The Series 100’s stainless steel drain pan is

factory-mounted and installed on every unit. A condensate drain trap is needed, and must

be provided and installed in the field by others.

LD08022

NOTE

This is a visual reference only. Actual drain pan pitch will vary.

FIGURE 1 - DRAIN PAN DETAIL

Double Wall Construction – Double-wall construction is the standard construction of the

Series 100 and incorporates powder coated outer panels and corner post for maximum

exterior surface protection.

Factory Shrink-wrap – All Series 100 single package units are shipped from the factory

with factory-fresh shrink-wrap packaging. No longer does the contractor need to worry

about dirt and debris clogging up condenser coils or moisture leaking into the air handler

on the units way to the job site or rigging yard.

Copper Fins – For more extreme climates that aggressively can attack aluminum, cop-

per tube evaporator coils with copper fins are available. (This is not recommended for

units in areas where they may be exposed to acid rain or environments where ammonia

is present)

CONDENSER FEATURES AND OPTIONS

Scroll Compressors – Reliable, efficient, trouble-free operation is the true measure of

a single package unit’s value. That’s why Johnson Controls Series 100 Single package

units use established scroll compressor technology to deliver dependable, economical

performance in a wide range of applications. With the Series 100 Single package units,

you get the latest generation of compressor enhancements added to the scroll’s inherent

strengths. The simplicity of a hermetic scroll compressor allows the use of fewer moving

parts to minimize breakdown.

Multiple Compressor Staging – Through the use of the scroll compressor, the Series

100 has the ability to stage it’s cooling by enabling and disabling multiple single stage

compressors on multiple circuits.

Compressor Circuiting – The Series 100 is designed so that only 2 scroll compressors

are in tandem within one refrigeration circuit. This means more reliable compressors,

and less equipment down time. With multiple circuits, if a compressor should ever fail on

one circuit, the other circuit/s will remain operational to maintain occupied loads. In sizes

70–105T, the Series 100 has three independent refrigeration circuits per unit.

Condenser Fan Motors – The condenser fan motors used on the Series 100 unit are

Totally Enclosed Air Over (TEAO) to provide maximum durability through any season.

Features and Benefits (Cont'd)

Other manuals for 100 Series

This manual suits for next models

Table of contents

Other Johnson Controls Air Conditioner manuals

Johnson Controls

Johnson Controls DU-15 User manual

Johnson Controls

Johnson Controls GCGD18S User manual

Johnson Controls

Johnson Controls DSH024C Series Owner's manual

Johnson Controls

Johnson Controls York ZN-06 User manual

Johnson Controls

Johnson Controls TCGD18 THRU 60 Quick start guide

Johnson Controls

Johnson Controls YORK YH9FZC09BAH-AFX User manual

Johnson Controls

Johnson Controls YORK YV2VYH010KAR-D-X User manual

Johnson Controls

Johnson Controls 5 J ZE Series User manual

Johnson Controls

Johnson Controls IC1006B21S Series Installation and operation manual

Johnson Controls

Johnson Controls 14.5 SEER SERIES Guide

Johnson Controls

Johnson Controls HIC1006B21S User manual

Johnson Controls

Johnson Controls LX Series Quick start guide

Johnson Controls

Johnson Controls YCD Series User manual

Johnson Controls

Johnson Controls DEQ 024 User manual

Johnson Controls

Johnson Controls AFFINITY 340968-XIM-A-0108 User manual

Johnson Controls

Johnson Controls YXV SERIES User manual

Johnson Controls

Johnson Controls York VIR 40A User manual

Johnson Controls

Johnson Controls ZJ SERIES User manual

Johnson Controls

Johnson Controls YORK YH9FXC18BAH-FX User manual

Johnson Controls

Johnson Controls HVWHP072B32S User manual

Johnson Controls

Johnson Controls YJHJXH024BARR-FX User manual

Johnson Controls

Johnson Controls RAC Series Quick start guide

Johnson Controls

Johnson Controls Hitachi MW-NP282A3 User manual

Johnson Controls

Johnson Controls MagnaDRY DK-15 User manual

Popular Air Conditioner manuals by other brands

Spheros

Spheros CC 355 instructions

Bosch

Bosch Climate 5000 SCI 24 CAS/ OU- OUE owner's manual

Panasonic

Panasonic CS-E12HKEW operating instructions

nedis

nedis ACMB1WT7 quick start guide

Samsung

Samsung AR KV Series User & installation manual

Daikin

Daikin FCFV50A Operation manual

Fujitsu

Fujitsu Inverter ASBA30JFC operating manual

Toshiba

Toshiba RAS-M10SMUV-E installation manual

Daikin

Daikin FXLQ20MAVE Operation manual

Hitachi

Hitachi RAS-E24CAK instruction manual

CIAT

CIAT Magister 2 Series Installation, Operation, Commissioning, Maintenance

Bestron

Bestron AAC6000 instruction manual

Hisense

Hisense 7K Use and Installation Instructions

Frigidaire

Frigidaire FFRE0533S1E0 Use & care guide

Samsung

Samsung AS09HM3N user manual

Frigidaire

Frigidaire CRA073PU11 use & care

Soleus Air

Soleus Air GB-PAC-08E4 operating instructions

McQuay

McQuay MCK020A Technical manual