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
GAS HEAT PRESSURE DROPS ........................................................................................................................... 54
ELECTRIC HEAT PRESSURE DROPS ................................................................................................................ 55
EXHAUST FAN DATA ............................................................................................................................................ 56
RETURN FAN DATA .............................................................................................................................................. 57
ELECTRICAL DATA .............................................................................................................................................. 58
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
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 efciency requirements.
• Fully modulating gas heat and greater steps of capacity control offer superior offdesign performance while maintaining optimum occupant comfort.
• Accurate ventilation control ensures that no more than the proper amount of ventilation air is utilized. This avoids the energy cost of conditioning excess outside air and
simultaneously monitors all other unit functions for maximized energy efciency.
• Flexible design congurations 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 connection 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 prevents 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 logic to analyze and optimize ventilation decisions and perform demand
ventilation, airow compensation, and airow measurement to maintain 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
5
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. Supply 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. Supply 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 Conversion 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 supply 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). Ignition 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 electric 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.
6
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 lineof-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-thedoor manual non-fused disconnect switch with an external, lockable handle (in compliance 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 included 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 troubleshooting. 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
7
FORM100.50-EG12 (918)
Features and Benefits (Cont'd)
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 Series 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.
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.
Zone Sensor
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.
CO2 Sensors – Optional carbon dioxide sensors for occupied space that operate demand
ventilation control opening outside air dampers to ventilate building. The CO2 sensors 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.
8
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 constant-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 location 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 5/16inch 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 without 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 outstanding reliability and efficiency, eliminating the possibility of conditioned air supply interruption 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
9
FORM100.50-EG12 (918)
Features and Benefits (Cont'd)
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, copper 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.
10
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
Hot Gas Bypass – This options permits continuous, stable operation at capacities below
the minimum step of unloading by introducing an artificial load on the evaporator. For
models YPAL070–105, it is used on the lead circuit.
Replaceable Core Liquid Line Driers – Liquid line driers are standard on the Series 100
single package unit. An option is provided for replaceable core driers.
Post-Coated Fins – Optional coil-coating used on condenser coils for seashore and other
corrosive applications (with the exception of strong alkalis, oxidizers, wet bromide, chlorine and fluorine in concentrations greater than 100 ppm).
Compressor Sound Blankets – Optional compressor acoustic sound blankets are available for sound sensitive applications.
ROOF CURBS
Full Perimeter Roof Curbs – This option includes a knock-down 14-inch high roof curb
for use with wood nailer (by others). Roof curb supports the entire perimeter of the unit.
Partial Perimeter Roof Curbs – This option includes a knock-down 14-inch high roof
curb for use with wood nailer (by others). Roof curb supports the air handling section with
a separate support under the condenser end.
CABINET FEATURES AND OPTIONS
Double-Wall Access Doors - Full-sized access doors provide easy access into the unit
for routine maintenance and inspection. Solid wall liners encase insulation and prevent
damage and erosion into the airstream.
Diffuser Section – An optional diffuser section is available downstream of the supply
fan in the extended discharge plenum cabinet option. The diffuser section distributes the
airflow from the fan evenly across the downstream filter bank to optimize filter life and
effectiveness. The diffuser design is optimized to provide uniform flow at minimal airside
pressure loss.
Downstream Final Filter Rack – An optional 90–95% efficient MERV 14 12-inch rigid
filter rack and filters is available downstream of the supply fan and diffuser segment for
hospital applications (YPAL070–105 only). A magnahelic pressure gauge is included and
visible from the outside of the unit for servicing and code compliance.
Blank Section – An optional blank section is available downstream of the supply fan and
diffuser section.
ACCESSORIES
Filter Switch – An optional dirty filter alarm can be provided that will provide an alarm
when the filters require cleaning.
Magnahelic Filter Pressure Gauge – On units equipped with downstream filtration, a
magnahelic filter gauge is included and visible on the exterior of the unit. The filter gauge
measures the air pressure drop for through the rigid filter bank to indicate when replace-
ment is required.
JOHNSON CONTROLS
11
FORM100.50-EG12 (918)
Features and Benefits (Cont'd)
YPAL070–105 MODEL
Rainhoods to
prevent moisture
from entering the
unit
Optional airflow
measurement
station
Centrifugal fan
powered exhaust fan
or optional plenum
return fan
Doors on both
sides of unit and
tie backs for unit
servicing
00567VIP
Angled or
rigid flat filter
section
Distributor tubes
protected in plastic
sleeves
Optional
horizontal
supply air
openings
Condenser wire
screen Optional
louvers available
Angled evaporator
Double-sloped
stainless steel
IAQ drain pan
and intermediate
drain pan
Complete
double-wall
construction of
walls, floors,
ceiling, and
panels
V-banked condenser
coils to protect from
hail damage
coil for lower face
velocities
Optional
replaceable core
filter driers
12
Factory-installed
single package
unit controller
JOHNSON CONTROLS
Application Data
GENERAL
The Series 100 Single Packaged units are designed for outdoor installation. When selecting a site for installation, be guided by the following conditions:
• Unit must be installed on a level surface.
• For the outdoor location of the unit, select a place having a minimum sun exposure
• Also avoid locations beneath windows or between structures.
• Optional condenser coil protection should be used for seashore locations or other harsh
• The unit should be installed on a roof that is structurally strong enough to support the
FORM 100.50-EG12 (918)
and an adequate supply of fresh air for the condenser.
environments.
weight of the unit with a minimum of deection. It is recommended that the unit(s) be
installed not more than 15 feet from a main support beam to provide proper structural
support and to minimize the transmission of sound and vibration. Ideally, the center
of gravity should be located over a structural support or building column.
• Location of unit(s) should also be away from building ue stacks or exhaust ventilators to prevent possible reintroduction of contaminated air through the outside air
intakes.
• Be sure the supporting structures will not obstruct the duct, gas or wiring connections.
• Proper service clearance space of 6 feet around the perimeter of the unit, 8 feet on
one side for coil servicing, and 12 feet to any adjacent units is required to eliminate
cross contamination of exhaust and outdoor air, and for maintenance tasks such as
coil pull and cleaning. No obstructions should be above the condensing unit section.
LOCATION
Of the many factors that can effect the location of equipment, some of the most important
to consider are Structural, Acoustical and Service clearances. Proper attention should be
made at the design stage to ensure proper structural support. In cases where equipment
is being replaced, be aware of building design to insure support is adequate for the ap-
plication.
The next most important consideration in applying single package units equipment is that
of sound from the equipment. Special care should be made to keep the single package
unit away from sound sensitive areas such as conference rooms, auditoriums and executive offices and any other room that may have potential for tenant occupancy. Possible
locations could be above hallways, mechanical or utility rooms.
Finally, service clearances should be maintained in single package unit design to insure
safe access to the unit. Unit clearances are designed so that technicians have enough
space between units, building walls, and edges of building to gain access safely. In cases
where space is limited, please call your local Johnson Controls representative for additional information.
JOHNSON CONTROLS
13
FORM100.50-EG12 (918)
Application Data (Cont'd)
96"
LD08044
NOTES
1. Under certain conditions these clearances may be encroached upon.
2. This is a visual reference for all Series 100 units.
RIGGING
Proper rigging and handling of the equipment is mandatory during unloading and setting
it into position to retain warranty status.
Spreader bars must be used by cranes to prevent damage to the unit casing. All lifting lugs
must be used when lifting the single package unit unit. Fork lifts will damage the single
package unit and are not recommended.
Care must be taken to keep the unit in the upright position during rigging and to prevent
damage to the watertight seams in the unit casing. Avoid unnecessary jarring or rough
handling.
UNIT PLACEMENT
• Elevated – Elevated roof curbs or dunnage steel can be used to support the unit in
order to raise it to specic heights. When this type of placement is required, be sure
to keep unit access in mind. Cat walks or other forms of unit access may be required
to one or both sides of the unit, depending on your area of the country and the local
codes that are enforced. Please check with local ofcials to ensure the application
conforms to local codes and regulations.
• Ground Level Locations – It is important that the units be installed on a substantial
base that will not settle, causing strain on the refrigerant lines and sheet metal and
resulting in possible leaks. A one-piece concrete slab with footers extended below
the frost line is highly recommended. Additionally, the slab should be isolated from
the main building foundation to prevent noise and vibration transmission to the building structure.
For ground level installations, precautions should be taken to protect the unit from
tampering by, or injury to, unauthorized persons. Erecting a fence around the unit is
common practice.
• Roof curb – Johnson Controls offers optional roof curbs designed specically for the
Series 100 footprint. These curbs come in full perimeter or open condenser models
and are shipped disassembled and require eld assembly and installation. For bottom supply and return openings, the curbs have matching connections to ease installation. A pipe chase that matches the single package unit pipe chase is also included
in the curb footprint for through-the-curb utility connections.
The curb should be located according to the location recommendations above, and
properly sealed to prevent moisture and air leakage into and out of the duct system.
Flexible collars should be used when connecting the duct work to prevent unit noise
transmission and vibration into the building.
Duct work should be supported independently of the unit.
14
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
TABLE 1 - SUPPLY AIR DUCT CONNECTION CONFIGURATIONS
UNIT CONFIGURATION
Cooling onlyXXX
Cool/gas heatXX
YPAL
070–105
Cool/electric heatX
Cool/hydronic heatX
Cooling onlyXXX
Cool/hydronic heatXXX
STANDARD CABINET
EXTENDED CABINET
SUPPLY AIR
BOTTOMLEFTRIGHT
TABLE 2 - RETURN AIR DUCT CONNECTION CONFIGURATIONS
UNIT CONFIGURATION
No exhaustXXXX
Barometric relief
YPAL
070–105
damper
Powered exhuast
fan (all types)
Powered return fanX
BOTTOMLEFTRIGHTFRONT
XXX
XXX
RETURN AIR
UNIT ORIENTATION
For applications with multiple single package units located in close proximity on the roof,
the orientation of the unit may be important to reduce the potential for re-entrainment of
outside airflow. Regardless of the outside air and exhaust air openings on a unit, all single
package unit applications can permit recirculation of exhaust air to the return, if applied
improperly.
HORIZONTAL APPLICATIONS
The spectrum of applications for single package units in today’s market is continuing to
grow wider by the day. Flexibility in unit design and construction is a must in today’s mar-
ket in order to insure safe and sound applications of HVAC equipment. If the application
calls for horizontal supply and return air, Johnson Controls can ship it from the factory
as a horizontal unit. This option eliminates the need for field modification of equipment
saving time and money. The Series 100 can support a left discharge on all units and/or
right discharge on all cooling only units and hydronic heat units with an extended cabinet.
Return air can be brought through the end or side return air inlet making the unit specific
to building needs.
NOTE
This diagram is provided as a visual reference of the Series 100 discharge & return air openings & locations for all sizes. Please refer to the
dimensional data for exact size & location of panels and openings.
JOHNSON CONTROLS
LD08045
15
FORM100.50-EG12 (918)
Application Data (Cont'd)
ECONOMIZER
The economizer section is used to maintain indoor air quality, and also to reduce energy
consumption by using outdoor air cooling in lieu of mechanical cooling. If outdoor air is
appropriate for cooling, but not sufficient for the cooling demand, mechanical cooling will
stage on as necessary until the cooling load is met.
Dual (comparative or differential) enthalpy operation is the most accurate and efficient
means of economizer operation. The IPU controller monitors the return and outside air
energy content, and selects the lower of the two for operation.
VAV SUPPLY AIR PRESSURE CONTROL
Traditional packaged single package unit systems use inlet guide vanes (IGVs) for duct
static pressure control. These control supply duct pressure by modulating dampers (introducing losses and inefficiencies) on the inlet of the fan, open and closed. Johnson
Controls variable frequency drives (VFDs) offer superior fan speed control and quieter,
energy efficient operation.
FIGURE 2 - TRADITIONAL OVERHEAD VAV AIR DELIVERY SYSTEM
For VAV applications, the Johnson Controls Series 100unit uses a VFD to modulate fan
speed and maintain a constant duct static pressure. VFDs offer superior control over the
operation of the unit at part load, and offer the additional benefits of quieter and more efficient operation when compared to IGV.
FLEXSYS
™
The traditional approach to HVAC design in commercial buildings has been to supply
conditioned air through extensive overhead duct networks to an array of diffusers spaced
evenly in the ceiling. In Figure 1, the conditioned air is both supplied and returned at ceiling level. Ceiling plenums must be designed large enough to accommodate the supply
ducts that run through them. Return air is typically configured as ceiling plenum return
without any ductwork. This type of air distribution, known as the “well-mixed” type, is the
most common system in use. This conventional HVAC system is designed to promote
complete mixing of supply air with room air, thereby maintaining the entire volume of all air
in the space (from floor to ceiling) at the desired space setpoint temperature. In addition,
to meet IAQ requirements, an adequate supply of fresh outside air must be introduced to
this mix. A key disadvantage to this control strategy is that it has no provisions to accommodate different temperature preferences among the building occupants or to provide
preferential ventilation in the occupied zone.
16
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
FIGURE 3 - JOHNSON CONTROLS FLEXSYS UNDERFLOOR AIR DELIVERY
SYSTEM
With the Johnson Controls FlexSys Underfloor Air System, conditioned air is ducted to the
underfloor plenum. As shown in Figure 3 on page 17, this conditioned air flows freely
throughout the plenum to individual supply discharge outlets. Unlike the larger single supply duct outlets typical of overhead systems, underfloor systems are configured to have a
large number of smaller supply outlets, in close proximity to the building occupants. These
adjustable outlets provide an opportunity for nearby occupants to have some amount of
control over thermal comfort conditions in their local environment. Air is returned from the
room at ceiling level (unducted plenum return is shown). The resulting overall floor-toceiling airflow pattern takes advantage of the natural buoyancy produced by heat sources
in the space and more efficiently removes heat loads and contaminants from the space,
particularly for cooling applications. In fact, some of the most important advantages of
underfloor systems over ceiling-based systems occur during cooling conditions, which
are required year-round in the vast majority of interior office space in many parts of the
United States.
HARSH ENVIRONMENTS – CONDENSER AND EVAPORATOR COIL PROTECTION
For harsh environmental conditions such as seashore applications, Johnson Controls offers two types of coil protection: copper fin evaporator coils and post coated condenser
coils. Johnson Controls recommends that for corrosive environments that copper fins be
used to protect the evaporator coils. In areas where chemicals that can corrode copper
are present, such as ammonia, Johnson Controls recommends that post coated condenser coild be used for maximum protection.
BUILDING PRESSURE CONTROL SYSTEMS
Building pressure control systems are often necessary when economizers are used to
bring in outdoor air. Without proper building exhaust, the building may become over pressurized. The pressure control system maintains the proper building pressure by expelling
the appropriate amount of air from the building.
Return fans – For high return static applications, such as buildings with ducted return
systems, a powered return fan may be necessary to maintain building pressure control.
Johnson Controls offers a powered return fan that is located in the return plenum. This fan
operates coincidentally with the supply fan and draws return air back through the return
ductwork and into a pressurized plenum. A control damper modulates to exhaust air out
of the building and maintain the building pressure. A second control damper modulates to
provide return air from the ductwork to the unit air mixing section.
JOHNSON CONTROLS
17
FORM100.50-EG12 (918)
Application Data (Cont'd)
The return fan configuration is available in two forms: with and without an exhaust damper. The option with the exhaust damper provides a means of building exhaust at the unit.
In some applications, the exhaust system is located elsewhere and the unit is not required
to provide building exhaust. In these situations, the Series 100 can be offered without the
exhaust damper to help reduce installed costs.
Exhaust/relief fans – In this application, a powered exhaust fan may be suitable, however careful consideration of the fan type is necessary. Johnson Controls offers a centrifugal powered exhaust fan to perform this function. Some manufacturers use a propeller
exhaust fan, which cannot handle the static pressure requirements.
For systems with moderate to low return static pressure, an exhaust fan is recommended.
The benefit of the exhaust fan is that it does not run all of the time, and may facilitate com-
pliance with the ASHRAE 90.1 fan motor horsepower requirement.
The exhaust fan operates in parallel with the supply fan. In this arrangement, the supply
fan handles the full static pressure requirements of the system. For normal building pressure control, the exhaust fan operates to draw air from the return plenum and exhaust it
out of the building.
The exhaust fan configuration is available in two forms, modulating and non-modulating.
Modulating is the most common and recommended for the majority of applications, while
non-modulating should be used only in certain circumstances.
In the modulating exhaust system, the volume of airflow exhausted from the building is
proportional to the entering volume of outside air. Control is accomplished via either a
discharge damper or a VFD. Johnson Controls recommends the use of a VFD to reduce
energy consumption, sound levels and improved reliability due to fewer moving parts.
In the non-modulating exhaust system, the exhaust airflow is constant whenever the exhaust fan is operating. This type of control should only be used to either assist a smoke
purge system or when a system requires a constant volume of exhaust airflow.
ACOUSTICAL CONSIDERATIONS
The Series 100 unit is designed for lower sound levels than competitive units by using flexible fan connections, fan spring isolators, double-wall construction, multiple fan options,
and lower speed and horsepower fans. For VAV applications, VFDs are used instead of
inlet guide vanes. Additional sound attenuation can be obtained using compressor sound
blankets when necessary.
Even with these equipment design features, the acoustical characteristics of the entire
installation must never be overlooked. Additional steps for the acoustical characteristics
of a single package unit installation should be addressed during the design phase of a
project to avoid costly alterations after the installation of the equipment. During the design
phase of a project, the designing engineer should consider, at a minimum, the impact of
the equipment location, single package unit installation, building structure, and duct work.
Capacity Steps (Qty x %)6x164x16, 2x184x17, 2x154x18, 2x153x14, 3x19
SUPPLY FAN AND DRIVE
Quantity1111/11/1
TypeFCFCFCAFAF
Size28-2528-2528-253232
Motor Size Range (min. to max. HP)10–5010–5010–5010–5010–50
Airow Range (min. to max. CFM)14,000–29,000 15,550–29,000 15,000–32,000 17,500–36,000 21,000–36,000
Static Pressure Range (min. to max. ESP)0–4 inches0–4 inches0–4 inches0–6 inches0–6 inches
OPTIONAL AIRFOIL SUPPLY FAN
Quantity1/11/11/11/11/1
TypeAFAFAFAFAF
Size3232323232
Motor Size Range (min. to max. HP)15–5015–5015–5015–5015–50
Airow Range (min. to max. CFM)
Static Pressure Range (min. to max. ESP)
OPTIONAL DIRECT DRIVE PLENUM (DDP) SUPPLY FAN
Quantity
Type
Size
Motor Size Range (min. to max. HP)
Airow Range (min. to max. CFM)
Static Pressure Range (min. to max. TSP)
EXHAUST FAN
Quantity22222
TypeFCFCFCFCFC
Size18-1818-1818-1818-1818-18
Motor Size Range (min. to max. HP10–2010–2010–2010–2010–20
Airow Range (min. to max. CFM)4,000–32,000 4,000–32,000 4,000–32,000 4,000–32,000 4,000–32,000
Static Pressure Range (min. to max. ESP)0–2 inches0–2 inches0–2 inches0–2 inches0–2 inches
OPTIONAL EXHAUST FAN
Quantity2/12/12/12/12/1
TypeFCFCFCFCFC
Size20-1820-1820-1820-1820-18
Motor Size Range (min. to max. HP, total
for two fans)
Airow Range (min. to max. CFM)4,000–36,000 4,000–36,000 4,000–36,000 4,000–36,000 4,000–36,000
Static Pressure Range (min. to max. iwg)0–2 inches0–2 inches0–2 inches0–2 inches0–2 inches
OPTIONAL RETURN FAN
Quantity2/22/22/22/22/2
TypePlenumPlenumPlenumPlenumPlenum
Size270270270270270
Motor Size Range (min. to max. HP, total
for two fans)
Airow Range (min. to max. CFM)4,000–32,000 4,000–32,000 4,000–32,000 4,000–36,000 4,000–36,000
Static Pressure Range (min. to max. iwg)0–3 inches0–3 inches 0–3 inches0–3 inches0–3 inches
Size (square feet)56.956.956.956.956.9
Number of Rows/Fins per Inch4/173/173/173/175/17
Tube Diameter/Surface
CONDENSER COIL (R-410A)
Size (square feet)164164164164164
Number of Rows/Fins per Inch1/211/211/211/211/21
Tube Diameter/Surface
CONDENSER FANS
Quantity66666
TypeProp.Prop.Prop.Prop.Prop.
Diameter (inch)3636363636
Power (HP each)22222
FILTERS - 2-INCH THROWAWAY (PRE-FILTER POSITION)
Quantity10/1510/1510/1512/1812/18
Size (length x width) (inch)25x16/25x2025x16/25x2025x16/25x2025x16/25x2025x16/25x20
Total Filter Face Area (square feet)77.177.177.192.592.5
FILTERS - 2-INCH CLEANABLE (PRE-FILTER POSITION)
Quantity10/1510/1510/1512/1812/18
Size (length x width) (inch)25x16/25x2025x16/25x2025x16/25x2025x16/25x2025x16/25x20
Total Filter Face Area (square feet)77.177.177.192.592.5
Quantity10/1510/1510/1512/1812/18
Size (length x width) (inch)25x16/25x2025x16/25x2025x16/25x2025x16/25x2025x16/25x20
Total Filter Face Area (square feet)77.177.177.192.592.5
1. Electric heat steps and airow range depends on voltage and size. Consult Table 13 on page 50 for minimum allowable airow. Consult
Table 31 on page 60 for the number of steps for a given voltage and unit size.
Weights are for components only and need to be added to the extended cabinet weights. The diffuser is required in the extended cabinet for
any unit with hot water or nal lter option.
TABLE 5 - APPROXIMATE BASE OPERATING WEIGHTS (LBS)
MODEL SIZE70758090105
Approximate Unit Weight1046110433104491079910935
NOTES
1. Unit base weights include the following features: sheet metal, control panels, refrigerant, compressors, condenser assemblies, mini-
mum capacity supply fan, and 2-inch throwaway lter.
2. Base weights shown represent approximate operating weights and have a ±10% accuracy. To calculate weight for a specic congura-
tion, use YORKworks or contact a Johnson Controls sales representative.
TABLE 6 - COMPONENT WEIGHTS (LBS)
MODEL SIZE70758090105
CABINET
Sheet Metal69946994699469136913
Control Panel200200200200200
OA Damper (30 x 84)11011 0110120120
RA Damper (30 x 84)110110110120120
Right Side OA Hood4646465454
Left Side OA Hood4646465454
Rear OA Hood8282828282
Tray & Liner181181181198198
OA Filters Back Top88888
OA Filters Back Bottom88888
OA Filters Right Top22222
OA Filters Right Bottom22222
OA Filters Left Top22222
OA Filters Left Bottom22222
POWER EXHAUST
Exhaust Motor Base, 256 T Frame3030303030
Exhaust Fan
JOHNSON CONTROLS
23
FORM100.50-EG12 (918)
Weight Data (Cont’d)
TABLE 6 – COMPONENT WEIGHTS (LBS) (CONT'D)
MODEL SIZE70758090105
POWER EXHAUST (CONT'D)
Comefri 15-15 FC Class R194194194194194
Comefri 15-15 FC Class II280280280280280
Comefri 18-18 FC Class R306306306306306
Comefri 18-18 FC Class II396396396396396
Return Fan490490490490490
Barometric, (24 x 76)4545455555
Modulating, (24 x 76)7575759090
Fan skid4646464949
Exhaust Hood919191102102
HEATING OPTIONS
Electric Heat - 80kW (Max)430430430430430
Electric Heat - 108kW (Max)450450450450450
Electric Heat - 150kW (Max)470470470470470
Electric Heat - 200kW (Max)490490490490490
Electric Heat - 250kW (Max)510510510510510
Gas Heat - 375 MBH (Max)162162162162162
Gas Heat - 750 MBH (Max)324324324324324
Gas Heat - 1125 MBH (Max)486486486486486
Hot Water Coil318318318318318
Steam Coil236236236236236
1. The weight given is the total weight of all eight aluminum coils and all eight copper coils, respectively. Indicates that particular option is
not available with that model size.
2. The 0–100% AMS option needs some predetermined minimum airow rate to work.
2
2222222222
5151515151
6666666666
125125125140140
24
JOHNSON CONTROLS
Cooling Performance Data – 70 Ton Model
TABLE 7 - COOLING PERFORMANCE DATA* – 70 TON MODEL
NOTES *Includes 2-inch pleated lters. ** Power exhaust pressure drops are for sizing supply fan.
1. Return air opening pressure drop does not include an exhaust fan. Use the value in the Powered Exhaust column to determine return air
pressure drop attributed to the exhaust fan assembly.
2. Front return is not available with barometric relief, exhaust fans or return fans.
3. Pressure drop for rigid lter rack includes a 2-inch throwaway pre-lter.
Dual Direct Drive
Plenum (DDP)
Supply Fan
Safety Grate
Downstream of
Acoustiweir
Bottom
Pre-filters
Screen
™
Final Filter
12-in.
MERV 14*
Inlet
JOHNSON CONTROLS
53
FORM100.50-EG12 (918)
Gas Heat Pressure Drops
TABLE 19 - GAS HEAT AIR PRESSURE DROPS
Size (MBH)
Size
70
75
80
90
105
Airflow
CFM Std. Air
14,0000.050.080.09
16,0000.070.110.11
18,0000.090.140.14
20,0000.110.170.17
22,0000.140.200.21
24,0000.160.240.25
26,0000.190.280.29
28,0000.220.330.34
30,0000.250.380.39
32,0000.290.430.45
14,0000.050.080.09
16,0000.070.110.11
18,0000.090.140.14
20,0000.110.170.17
22,0000.140.200.21
24,0000.160.240.25
26,0000.190.280.29
28,0000.220.330.34
30,0000.250.380.39
32,0000.290.430.45
14,0000.050.080.09
16,0000.070.110.11
18,0000.090.140.14
20,0000.110.170.17
22,0000.140.200.21
24,0000.160.240.25
26,0000.190.280.29
28,0000.220.330.34
30,0000.250.380.39
32,0000.290.430.45
18,0000.070.110.11
20,0000.090.130.14
22,0000.110.160.17
24,0000.130.190.20
26,0000.150.220.23
28,0000.170.260.27
30,0000.200.300.31
32,0000.230.340.35
34,0000.260.380.40
36,0000.290.430.45
18,0000.070.110.11
20,0000.090.130.14
22,0000.110.160.17
24,0000.130.190.20
26,0000.150.220.23
28,0000.170.260.27
30,0000.200.300.31
32,0000.230.340.35
34,0000.260.380.40
36,0000.290.430.45
3757501125
54
JOHNSON CONTROLS
Electric Heat Pressure Drops
TABLE 20 - ELECTRIC HEAT AIR PRESSURE DROPS
MODEL
YPAL070–080
YPAL090–105
AIRFLOW
CFM STD.
AIR
14,0000.020.030.040.05
16,0000.030.040.060.07
18,0000.040.060.070.09
20,0000.050.070.090.11
22,0000.060.080.110.13
24,0000.070.100.130.16
26,0000.080.120.150.19
28,0000.090.130.180.22
30,0000.110.150.200.25
32,0000.120.170.230.28
18,0000.060.070.090.12
20,0000.070.090.110.15
22,0000.080.110.130.19
24,0000.100.130.160.22
26,0000.120.150.190.26
28,0000.130.180.220.30
30,0000.150.200.250.35
32,0000.170.230.280.39
34,0000.200.260.320.44
36,0000.220.290.360.50
80 KW108 KW150 KW200 KW250 KW
ELECTRIC HEATER AIR PRESSURE DROP (IWG)
FORM 100.50-EG12 (918)
TABLE 21 - ELECTRIC HEATER SIZE AVAILABILITY BY UNIT SIZE
MODEL80kW108kW150kW*200kW*250kW*
YPAL070–080XXXX
YPAL090–105**XXXX
*150–250kW electric heat not available in 200-230V congurations.
**For 208V YPAL105, contact Johnson Controls.
JOHNSON CONTROLS
55
FORM100.50-EG12 (918)
Exhaust Fan Data
EXHAUST FAN MOTOR SIZING INSTRUCTIONS
In order to determine the proper exhaust fan motor size, add the return duct static pressure to the appropriate damper pressure drop value in Table 16 on page 53 to get the
total static pressure applied to the exhaust fan. Based on the exhaust fan airflow and total
static pressure, determine the brake horsepower (BHP) and RPM of the exhaust fan.
TABLE 22 - DUAL 18 X 18 FORWARD-CURVED FAN
TOTAL STATIC PRESSURE (IWG)
CFM
STD. AIR
60000.42910.73981.15011.65962.16832.7763
80000.73161.14061.54851.95662.46433.0717
100001.23491.64292.14992.55623.06273.6691
120001.93922.34562.95223.45813.96354.5688
140002.84353.34913.95494.56055.16565.7704
160003.94764.65335.15795.96316.66817.3727
180005.25176.25776.76197.46618.37079.1752
200007.05608.06198.86629.469810.273711.2779
220009.160410.166011.370612.074012.777313.6809
2400011.764812.770114.0748
2600014.7693
NOTE: For performance at operating points not included in these tables, consult your local Johnson Controls representative.
0.250.500.751.001.251.50
BHPRPMBHPRPMBHPRPMBHPRPMBHPRPMBHPRPM
TABLE 23 - EXHAUST FAN PERFORMANCE
FAN TYPE18X1820X18
YPAL070–080XX
YPAL090–105XX
TABLE 24 - DUAL 20 X 18 FORWARD-CURVED FAN
TOTAL STATIC PRESSURE (IWG)
CFM
STD. AIR
120001.32951.93732.54453.25143.95774.6635
140001.93182.53883.24533.95154.75745.5630
160002.63443.34074.14664.95225.75766.6629
180003.53714.34295.14836.05356.95847.8633
200004.63995.44536.45037.35518.35979.3642
220005.94286.84787.85258.85709.961311.0654
240007.54588.55059.554910.659111.763112.9670
260009.448810.453211.557412.761313.965215.1689
2800011.551912.656013.860015.063716.367317.6709
3000013.955115.258916.462617.766219.069720.4730
3200016.758318.161819.465420.768822.172123.6753
3400019.961521.364822.768224.171525.6746
3600023.464724.967926.471027.9742
NOTE: For performance at operating points not included in these tables, consult your local Johnson Controls representative.
0.250.500.751.001.251.50
BHPRPMBHPRPMBHPRPMBHPRPMBHPRPMBHPRPM
56
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
Return Fan Data
TABLE 25 - YPAL070–105: 270 SWSI AIRFOIL FAN
TOTAL STATIC PRESSURE (IWG)
CFM
STD. AIR
160005.49667.310569.2113911.2121713.31295
180006.610418.611268.6112612.9127716.11618
200007.9111910.2119812.5127214.9134218.81709
220009.6119912.0127314.5134317.1141021.71803
2400011.5128314.0135116.8141719.5148124.91900
2600013.7136916.4143019.3149322.2155425.11611
2800016.2145619.0151222.0157125.2162928.41684
3000019.0154422.0159725.1165128.5170531.91759
3200022.2163325.4168328.6173332.1178435.71835
3400025.7172329.1177032.5181736.1186439.81912
3600029.7181333.3185936.91902
NOTE: For performance at operating points not included in these tables, consult your local Johnson Controls representative.
1.01.52.02.53.0
BHPRPMBHPRPMBHPRPMBHPRPMBHPRPM
TABLE 26 - RETURN FAN PERFORMANCE
FAN TYPE2X270
YPAL070–080X
YPAL090–105X
JOHNSON CONTROLS
57
FORM100.50-EG12 (918)
Electrical Data
ELECTRICAL SERVICE SIZING
In order to determine the electrical service required for the cooling only Series 100 single
package unit, use the appropriate calculations listed below from UL 1995. Based on the
configuration of the single package unit, the calculations will yield different minimum circuit ampacity (MCA) and maximum overcurrent protection (MOP).
Using the following load definitions and calculations, determine the correct electrical sizing for your unit. All concurrent load conditions must be considered in the calculations, and
you must use the highest value for any combination of loads.
Load Definitions:
• LOAD1 is the current of the largest motor – compressor or fan motor.
• LOAD2 is the sum of the remaining motor currents that may run concurrently with
LOAD1.
• LOAD3 is the current of the electric heaters – zero for cooling only units.
• LOAD4 is the sum of any remaining currents greater than or equal to 1.0 amp.
Use the following calculations to determine MCA and MOP for units supplied with a singlepoint power connection:
MCA = (1.25 x LOAD1) + LOAD2 + LOAD3 + LOAD4
MOP = (2.25 x LOAD1) + LOAD2 + LOAD3 + LOAD4
If the MOP does not equal a standard current rating of an overcurrent protective device,
then the marked maximum rating is to be the next lower standard rating. However, if the
device selected for MOP is less than the MCA, then select the lowest standard maximum
fuse size greater than or equal to the MCA.
TABLE 27 - COMPRESSOR DATA (R-410A)
COMPRESSORNOMINAL VOLTAGE
MODEL
YPAL 70 TON
YPAL 75 TON
YPAL 80 TON
YPAL 90 TON
YPAL 105 TON
NOTE: *RLA data is per compressor
QTYMODEL
6ZP12033.323917.912512.880
2ZP15451.330023.115019.9109
4ZP13748.124518.612514.7100
4ZP15451.330023.115019.9109
2ZP13748.124518.612514.7100
4ZP18255.834026.917323.7132
2ZP15451.330023.115019.9109
3ZP18226.917323.7132
3ZP23630.822925.0180
208/230460575
RLALRARLALRARLALRA
58
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
TABLE 28 - SUPPLY, RETURN, AND EXHAUST FAN MOTOR DATA
The control system for the Johnson Controls Series 100 single package unit is fully selfcontained and based around a single package unit controller. To aid in unit setup, mainte-
nance, and operation, the single package unit controller is equipped with a user interface
that is based around a 4 line x 20 character backlit LCD display. The LCD displays plain
language text in a menu-driven format to facilitate use.
Based on the unit type (Variable Air Volume (VAV) or Single Zone VAV (SZVAV)), the
Johnson Controls Series 100 Single Package units can be operated by a space temperature sensor or stand alone. A field wiring terminal block is provided to facilitate unit setup
and installation.
In lieu of the hardwired control options, the single package unit controller can be connected to and operated by a Building Automation System (BAS).
The IPU Controller uses the latest technology and provides complete control for the unit
along with standard BACnet® MS/TP and Modbus™ RTU communications. The IPU also
has an SD card slot that can be used to capture historic data on unit operation.
If required, the unit can be equipped with an optional field installed gateway which allows
N2 or Echelon® communications. The E-Link gateway device is field installed and purchased through the Advanced Order Management System (AOMS).
YK-ELNKE01-0 – E-Link for Echelon
YK-ELNKE00-0 – E-Link for N2
UNOCCUPIED / OCCUPIED SWITCHING
Depending on application, the unit can be indexed between unoccupied and occupied
modes of operation by one of three methods, hardwired input, internal time clock, or BAS.
A contact-closure input is provided for hardwiring to an external indexing device such as
a central time clock or a manual switch. The unit controller is also equipped with a built in
7-day time clock which can be used, in lieu of the contact closure input, to switch the unit
between Unoccupied and Occupied modes of operation.
The internal time clock is fully configurable via the user interface and includes Holiday
scheduling. In addition to the hardwired input or the internal time clock, the unit can also
be indexed between unoccupied and occupied modes of operation via a BAS command.
GAS HEATING OPERATION
Units supplied with gas heat can be equipped with one, two, or three independently operated burner modules. Each module is a fully self-contained furnace with all necessary
ignition controls, safeties, and gas valves. The IPU single package unit controller determines how the furnaces are started and stopped and prevents furnace operation if the
Supply Fan airflow is not sufficient or if the Supply Air Temperature is excessively high.
If a furnace module receives a signal to start from the IPU controller, the ignition control
engages the furnace inducer (draft) fan for a 30-second pre-purge cycle. At the end of
the 30-second pre-purge, the ignition control will stop the furnace and allows the inducer
fan to operate for a 30-second post-purge. Each furnace contains a direct spark ignition
system and included safeties for flame and inducer fan verification, high temperature and
flame roll-out.
JOHNSON CONTROLS
61
FORM100.50-EG12 (918)
Controls (Cont'd)
HYDRONIC HEAT
If the unit is configured with either of the wet heat options (steam or hot water) the single
package unit controls will modulate the hydronic valve to maintain a supply air set point.
In the event temperatures off the hydronic coil are below 34.0°F the fans will be shut down
and the hydronic valve will open 100%. This function is an automatic reset so as the temperature rises above 36.0°F, the unit will automatically begin normal operation.
ELECTRIC HEATING OPERATION
For units equipped with electric heaters, the unit can control up to six stages of electric
heat which are staged on based on heating demand calculates by the IPU controller.
MORNING WARM-UP
Morning warm-up can be initialized by BAS or by the IPU controller if the internal scheduling is used. If the internal scheduling is used, the morning warm-up start time is calculated
through an adaptive algorithm. When morning warm-up is required, the IPU controller
energizes the VAV heat relay, starts the supply fan and qualifies the return air tempera-
ture (RAT) for 5 minutes. The internal heat source (gas, hot water/steam, or electric) is
controlled to maintain the RAT to the return air (RA) heating setpoint, morning warm-up
ends when occupancy occurs (BAS, internal scheduling, or contact closure), or when the
maximum morning warm-up time has expired.
ECONOMIZER OPERATION
The unit can be equipped with one of three types of optional economizers, dry bulb, single
enthalpy, or comparative enthalpy. When the unit controller determines that outside air
is suitable for economizing, the unit controller will control the outside air (OA) damper(s)
open to provide economizer cooling. If economizer cooling alone is insufficient for the
cooling load, the unit controller will stage up compressors, one at a time, to meet demand.
The control logic for the three types of economizers is as follows:
Dry Bulb Economizer
The dry bulb economizer is the default economizer control scheme. With the dry bulb
economizer, the unit controller monitors the outside air temperature (OAT) only and compares it to a reference temperature setting. Outside air is deemed suitable for economizing when the OAT is determined to be less than the reference temperature setting. This
method of economizing is effective, but is prone to some change-over inefficiencies due
to the fact that this method is based on sensible temperatures only and does not take
outside air moisture content into consideration.
Single Enthalpy Economizer
With the optional single enthalpy economizer, the unit controller monitors the OA enthalpy
in addition to the OAT and compares it to a reference enthalpy setting and a reference temperature setting. Outside air is deemed suitable for economizing when the OA enthalpy is
determined to be less than the reference enthalpy setting and the OAT is less than the reference temperature setting. This method of economizing allows the reference temperature
setting to be set higher than the dry bulb economizer and is consequently a more efficient
single package unit economizer.
62
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
Dual Enthalpy Economizer
With the optional dual enthalpy economizer, the unit controller monitors and compares the
OA and RA enthalpies in addition to comparing the OAT to the reference temperature setting. Outside air is deemed suitable for economizing when the OA enthalpy is determined
to be less than the RA enthalpy and the OAT is less than the reference temperature setting. This method of economizing is the most accurate and provides the highest degree of
energy efficiency for a packaged single package unit economizer.
VENTILATION CONTROL SEQUENCES
Minimum OA Damper Position (VAV Units)
With VAV units, there are two minimum OA damper positions, one when the unit is at full
speed and the second when the unit is at approximately half speed. These two points allow the control to linearly reset the position of the OA damper in response to fan speed.
When the unit goes into the occupied mode of operation, the unit controller will monitor the
speed of the supply fan and open the OA damper to a calculated minimum position based
on the fan speed. This minimum position will vary as the speed of the fan changes. The
damper will remain at this calculated position as long as the unit is in the occupied mode,
and the economizer is not suitable for cooling.
Air Measurement Stations
When the unit is equipped with an air measurement station, the unit controller will control
the OA damper to a measured flow rate through the air measurement station.
When the unit goes into the occupied mode of operation, the unit controller will control the
OA damper to maintain the minimum airflow setpoint through the air measurement station.
The unit controller will control the OA damper to this flow rate as long as the unit is in the
occupied mode, and the economizer is not suitable for cooling.
Demand Ventilation
If optional CO2 sensors are connected to the unit, the unit controller can reset the minimum OA damper position(s) or minimum flow rate based on demand.
The unit controller will monitor the CO2 level within the building. If the CO2 level rises
above the CO2 setpoint, the controller will temporarily increase the minimum OA damper
position or minimum OA flow rate to increase ventilation. If the CO2 level drops below the
CO2 setpoint, the controller will decrease the minimum OA damper position or minimum
OA flow rate to decrease ventilation. Demand ventilation will remain active as long as the
unit is in the occupied mode of operation.
EXHAUST CONTROL SEQUENCES
Barometric
The optional barometric exhaust system consists of a lightweight barometric relief damper
installed on the end of the unit in the RA section. As more outside air is introduced into
the controlled zone due to economizer and ventilation control sequences, the pressure
inside the building rises. As building static pressure increases to overcome any exhaust
duct static pressure, air will be allowed to escape through the barometric relief damper.
Because this type of exhaust is not powered, the amount of air exhausted will be limited
to the static pressure that will need to be overcome.
This optional variable volume powered exhaust system consists of a fixed speed fan
configured with a proportionally controlled discharge damper. The single package unit
controller monitors the pressure inside the building and controls the exhaust damper and
the exhaust fan. If the building pressure rises, the exhaust damper is proportionally controlled open and the exhaust fan is controlled ON. If the building pressure falls, the exhaust damper is proportionally controlled closed and the exhaust fan is controlled OFF.
The position of the exhaust damper in which the exhaust fan is controlled ON and OFF
as well as the building pressure setpoint is user selectable from the single package unit
user interface.
Powered Variable Volume Exhaust-Variable Frequency Drive (VFD) Controlled
This optional variable volume powered exhaust system consist of an exhaust fan driven
by a variable frequency drive (VFD), which is controlled by the single package unit controller. The single package unit controller monitors the pressure within the building. As the
pressure rises, the VFD is controlled to increase exhaust fan speed. As the pressure falls,
the VFD is controlled to decrease exhaust fan speed. The building pressure setpoint is
user selectable from the single package unit user interface. ON/OFF control is maintained
the same as exhaust-discharge damper control stated above.
Return Fan Controlled
This optional variable volume powered return fan system consists of two return fans controlled by one VFD that is controlled by the single package unit control center. The VFD is
controlled to maintain a slightly positive pressure over the mixing box section to prevent
reverse flow. As the return and/or exhaust air dampers open, the return plenum pressure
drops, the fan will speed up to maintain pressure. When the return and/or exhaust air
dampers close, the return plenum pressure increases causing the VFD to slow the fan
speed down.
LOW AMBIENT/HEAD PRESSURE CONTROL OPERATION
The single package unit controller continuously monitors the OAT to determine if mechanical cooling should be allowed. As a safety, if the OAT falls to or below the low ambient lockout temperature, mechanical cooling is prevented from operating. For units with
economizers, the low ambient lockout temperature is typically low enough that mechani-
cal cooling will rarely be required. However, for some applications mechanical cooling is
required when the OAT is lower than the low ambient lockout temperature.
For these applications, the unit must be equipped with optional low ambient controls. For
optional low ambient operation, the single package unit controller monitors the refrigeration system discharge pressure and controls the speed of the condenser fans. If the
discharge pressure falls, the speed of the first condenser fan on the refrigeration circuit
is reduced to maintain acceptable condensing pressures in the refrigeration system. With
the optional low ambient controls, mechanical cooling is allowed down to outside air temperatures of 0.0°F.
64
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
SMOKE PURGE SEQUENCES
General
The controls of the Series 100 are designed as standard with a ventilation override se-
quence to remove, exhaust, or ventilate smoke, fumes, or other airborne contaminates
from the occupied space. This feature offers three selectable operations: purge, pressur-
ization, and evacuation. The sequence is activated via one of three binary inputs. Some
typical contact closures are smoke detectors, fire alarms, manual switches, etc.
Note: All cooling and heating modes are disabled during smoke purge.
Purge – Purge shall be used to displace the air inside the space with fresh outside air.
When this sequence is started, the following will occur:
Start the supply fan if not already on. (Note: With VAV and FlexSys™ units, the fan speed
will be controlled to maintain the active duct pressure setpoint.) Start the return fan if not
already on. Start the exhaust fan if not already on, and set the VFD to 100%. Set the OA
damper position to 100%. Set the exhaust damper to 100%.
Pressurization – Pressurization shall be used to pressurize the building or space in
order to force the air inside the space through the walls to adjacent spaces or outside
the building envelope. When this sequence is started, the following will occur:
Start the supply fan if not already on. (Note: With VAV and FlexSys units, the fan speed
shall be controlled to maintain the active duct pressure setpoint.) Stop the return fan if on.
Stop the exhaust fan if on, and set exhaust/return fan VFD to 0%. Set the OA damper to
100%. Set the exhaust damper to 0%.
Evacuation – Evacuation shall be used to evacuate (negatively pressurize) the building
or space in order to draw air through the walls from adjacent spaces or outside the
building envelope. When this sequence is started, the following shall occur:
Stop the supply fan if on. Start the return fan if not already on. Start the exhaust fan if not
already on, and set the exhaust/return fan VFD to 100%. Set the OA damper to 0%. Set
the exhaust damper to 100%.
SPECIFIC SEQUENCES
(See the Installation, Operation, and Maintenance manual (100.50-NOM9) for further detail.)
Variable Air Volume (VAV) Mode
Occupied Cooling – In the occupied cooling mode, the unit controller monitors the RAT
and compares it to the RAT cooling setpoint. The RAT cooling setpoint is entered into the
unit controller through the setpoint key, cooling subsection of the user interface. If the RAT
is equal to or greater than the RAT cooling setpoint plus 0.5°F, the unit controller will place
the unit in the occupied cooling mode. The unit will remain in the occupied cooling mode
until the RAT is equal to or less than the RAT cooling setpoint minus 0.5°F.
Occupied Heating – In the occupied heating mode, the unit controller monitors the RAT
and compares it to the RAT heating setpoint. The RAT heating setpoint is entered into the
unit controller through the set points key heating subsection of the user interface. If the
RAT is equal to or less than the RAT heating setpoint minus 0.5°F, the unit controller will
place the unit in the occupied heating mode. The unit will remain in the occupied heating
mode until the RAT is equal to or greater than the RAT heating setpoint plus 0.5°F.
JOHNSON CONTROLS
65
FORM100.50-EG12 (918)
Controls (Cont'd)
Unoccupied Cooling – In the unoccupied cooling mode, the unit controller will monitor
the zone temperature and compare it to the unoccupied zone cooling setpoint. The unoccupied zone cooling setpoint is set through the setpoints key, cooling subsection of the
user interface. If the zone temperature is equal to or greater than the unoccupied zone
cooling setpoint temperature plus 0.5°F, the unit controller will place the unit in the unoccupied cooling mode. The unit will remain in the unoccupied cooling mode until the zone
temperature is equal to or less than the unoccupied zone cooling setpoint minus 0.5°F.
Unoccupied Heating – In order for the unoccupied heating to function, the night set back
setting must be set to enable. This can be done through the program key, heating subsection of the user interface. In the unoccupied heating mode the unit controller will monitor
the zone temperature and compare it to the unoccupied zone heating setpoint. The unoccupied zone heating setpoint is set through the set points key, heating subsection of the
user interface. If zone temperature is equal to or less than the unoccupied zone heating
setpoint minus 0.5°F, the unit controller will place the unit in the unoccupied heating mode.
The unit will remain in the unoccupied heating mode until the zone temperature is equal
to or greater than the unoccupied zone heating setpoint plus 0.5°F.
FIGURE 4 - OPERATIONAL MODE: VARIABLE AIR VOLUME (VAV)
66
LD20073
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
Single Zone VAV (SZVAV) Mode
Units configured for SZVAV operation shall contain a supply fan VFD. The unit shall switch
between cooling mode, heating mode, and standby mode based on zone temperature.
In cooling mode, the supply fan speed shall be varied based on zone temperature. If the
zone temperature gets warmer, the supply fan speed shall increase. Conversely, if the
zone temperature gets cooler, the supply fan speed shall decrease. In heating mode, the
supply fan shall run at full speed. When the zone temperature is satisfied, the unit is neither in cooling mode nor heating mode, and the supply fan shall run at minimum speed.
Control of cooling and heating stages shall operate as described in the following section.
Unit Mode Determination (Hardwired or Communicated) – The unit compares
the analog wired zone temp or communicated zone temp input to the occupied zone
cooling, occupied zone heating, unoccupied zone cooling, or unoccupied zone heating
setpoints to determine the sub-mode of operation. Figure 5 on page 67 shows what
the unit mode would be based on the difference between the zone temperature and the
zone temperature setpoints.
The only difference between hardwired and communicated is the method the unit controller uses to determine the zone temperature. In the hardwired mode the input is an analog
input to the control. In the communicated mode the input is a serial input from a bas control system.
FIGURE 5 - OPERATIONAL MODE: SINGLE ZONE VAV (SZVAV)
JOHNSON CONTROLS
LD19888
67
FORM100.50-EG12 (918)
Controls (Cont'd)
COOLING OPERATION
Zone Sensor Control
If a zone sensor controls the unit, the single package unit controller shall maintain the
zone temperature setpoint. This setpoint is user selectable at the single packaged unit
User Interface.
When a zone sensor is used for control, the single package unit controller will monitor
the temperature within the space and control the unit accordingly. A closed-loop staging
algorithm is used to stage compressors up and down as required to maintain the desired
zone temperature setpoint. If the unit is equipped with an economizer, outside air condi-
tions are continuously monitored by the control to determine if conditions are suitable for
economizing. If conditions are suitable for economizing, the single package unit controller
will modulate the outside air damper in addition to staging compressors up and down to
maintain the zone temperature setpoint.
HEATING OPERATION
Zone Sensor Control
If a zone sensor controls the unit, the single package unit controller shall maintain all zone
temperature setpoints. These setpoints are user selectable at the single package unit
user interface.
When a zone sensor is used for control, the single package unit controller will monitor
the temperature within the space and control the unit accordingly. A closed-loop staging
algorithm is used to stage heating steps up and down as required to maintain the desired
zone temperature setpoint. If the unit is equipped with an economizer, outside air condi-
tions are continuously monitored by the control to determine if conditions are suitable for
economizing. If conditions are suitable for economizing, the single package unit controller
will modulate the outside air damper in addition to staging heating steps up and down to
maintain the zone temperature setpoint.
68
JOHNSON CONTROLS
TABLE 34 - THREE PHASE POWER SUPPLY CONDUCTOR SIZE RANGE
1. All eld wiring must be provided through a eld-supplied fused disconnect switch to the unit terminals (or optional molded disconnect
switch).
2. All electrical wiring must be made in accordance with all N.E.C. and/or local code requirements.
3. Minimum Circuit Ampacity (MCA) is based on U.L. Standard 1995, Section 36.14 (N.E.C. Section 440.34).
4. Maximum Dual Element Fuse size is based on U.L. Standard 1995, Section 36.15 (N.E.C. Section 440.22)
5. Use copper conductors only.
6. On units with an optional disconnect switch, the supplied disconnect switch is a “Disconnecting Means” as dened in the N.E.C. Section
100, and is intended for isolating the unit from the available power supply to perform maintenance and troubleshooting. This disconnect
switch is not intended to be a Load Break Device.
FIGURE 6 - SINGLE-POINT POWER SUPPLY WIRING
70
JOHNSON CONTROLS
SINGLE-POINT POWER SUPPLY WIRING
WITH NON-FUSED DISCONNECT
FORM 100.50-EG12 (918)
NOTES
1. All eld wiring must be provided through a eld-supplied fused disconnect switch to the unit terminals (or optional molded disconnect
switch).
2. All electrical wiring must be made in accordance with all N.E.C. and/or local code requirements.
3. Minimum Circuit Ampacity (MCA) is based on U.L. Standard 1995, Section 36.14 (N.E.C. Section 440.34).
4. Maximum Dual Element Fuse size is based on U.L. Standard 1995, Section 36.15 (N.E.C. Section 440.22)
5. Use copper conductors only.
6. On units with an optional disconnect switch, the supplied disconnect switch is a “Disconnecting Means” as dened in the N.E.C. Section
100, and is intended for isolating the unit from the available power supply to perform maintenance and troubleshooting. This disconnect
switch is not intended to be a Load Break Device.
ld06415
FIGURE 7 - SINGLE-POINT POWER SUPPLY WIRING WITH NON-FUSED DISCONNECT
JOHNSON CONTROLS
71
FORM100.50-EG12 (918)
Power Wiring: YPAL070–105 (Cont'd)
DUAL-POINT POWER SUPPLY WIRING
NOTES
1. All eld wiring must be provided through a eld-supplied fused disconnect switch to the unit terminals (or optional molded disconnect
switch).
2. All electrical wiring must be made in accordance with all N.E.C. and/or local code requirements.
3. Minimum Circuit Ampacity (MCA) is based on U.L. Standard 1995, Section 36.14 (N.E.C. Section 440.34).
4. Maximum Dual Element Fuse size is based on U.L. Standard 1995, Section 36.15 (N.E.C. Section 440.22)
5. Use copper conductors only.
6. On units with an optional disconnect switch, the supplied disconnect switch is a “Disconnecting Means” as dened in the N.E.C. Section
100, and is intended for isolating the unit from the available power supply to perform maintenance and troubleshooting. This disconnect
switch is not intended to be a Load Break Device.
FIGURE 8 - DUAL-POINT POWER SUPPLY WIRING
72
JOHNSON CONTROLS
Field Control Wiring
FORM 100.50-EG12 (918)
FIGURE 9 - FIELD CONTROL WIRING
JOHNSON CONTROLS
ld08184
73
FORM100.50-EG12 (918)
Field Control Wiring (Cont'd)
FIGURE 10 - FIELD CONTROL WIRING
74
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
13’-5”
11’ - 5 13/16”41’ - 2”
10’
7’ - 8 7/8”
General Arrangement Drawing – 70–80 Ton Models
BOTTOM SUPPLY / BOTTOM RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
of the Condensing Unit.
1. 10’ Clearance Minimal Over The Top
2. Only One Adjacent Wall Can Exceed
NOTES
FIGURE 11 - GENERAL ARRANGEMENT DRAWING
JOHNSON CONTROLS
Unit Height.
Units
3. 12’ Clearance Required to Adjacent
One Side.
4. 8’ Service Access Recommended on
Where Applicable, are Folded Inside
Unit for Shipment.
5. Economizer and Exhaust Hoods,
LD08128
75
FORM100.50-EG12 (918)
13’ - 5”
10’
41’ - 2”
11’ - 5 13/16”
7’ - 8 7/8”
General Arrangement Drawing – 70–80 Ton Models (Cont'd)
LEFT SUPPLY / LEFT RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
of the Condensing Unit.
Unit Height.
Units
One Side.
Where Applicable, are Folded Inside
Unit for Shipment.
1. 10’ Clearance Minimal Over The Top
2. Only One Adjacent Wall Can Exceed
3. 12’ Clearance Required to Adjacent
4. 8’ Service Access Recommended on
5. Economizer and Exhaust Hoods,
NOTES
FIGURE 12 - GENERAL ARRANGEMENT DRAWING
76
JOHNSON CONTROLS
LEFT SUPPLY / FRONT RETURN
13’ - 5”
10’
41’ - 2”
11’ - 5 13/16”
7’ - 8 7/8”
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
FORM 100.50-EG12 (918)
of the Condensing Unit.
Unit Height.
Units
1. 10’ Clearance Minimal Over The Top
2. Only One Adjacent Wall Can Exceed
3. 12’ Clearance Required to Adjacent
4. 8’ Service Access Recommended on
NOTES
FIGURE 13 - GENERAL ARRANGEMENT DRAWING
JOHNSON CONTROLS
One Side.
Where Applicable, are Folded Inside
Unit for Shipment.
5. Economizer and Exhaust Hoods,
LD08130
77
FORM100.50-EG12 (918)
13’ - 5”
10’
46’ - 5”11’ - 5 13/16”
7’ - 8 7/8”
31”
General Arrangement Drawing – 70–80 Ton Models (Cont'd)
EXTENDED CABINET / BOTTOM SUPPLY / BOTTOM RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
of the Condensing Unit.
Unit Height.
Units
One Side.
Where Applicable, are Folded Inside
Unit for Shipment.
er. If the Diffuser Factory Option is Not
Installed, Clearance, Downstream of
the Supply Fan Outlet is Required to
Provide Adequate Airow and Reduce
Air Pressure Drop.
1. 10’ Clearance Minimal Over The Top
2. Only One Adjacent Wall Can Exceed
3. 12’ Clearance Required to Adjacent
4. 8’ Service Access Recommended on
5. Economizer and Exhaust Hoods,
NOTES
6. Clearance Downstream of the Diffus-
FIGURE 14 - GENERAL ARRANGEMENT DRAWING
78
JOHNSON CONTROLS
EXTENDED CABINET / LEFT SUPPLY / LEFT RETURN
13’ - 5”
10’
46’ - 5”
11’ - 5 13/16”
7’ - 8 7/8”
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
FF = Final Filter
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
FORM 100.50-EG12 (918)
of the Condensing Unit.
Unit Height.
Units
One Side.
Where Applicable, are Folded Inside
Unit for Shipment.
1. 10’ Clearance Minimal Over The Top
2. Only One Adjacent Wall Can Exceed
3. 12’ Clearance Required to Adjacent
4. 8’ Service Access Recommended on
5. Economizer and Exhaust Hoods,
6. Clearance Downstream of the Diffus-
NOTES
FIGURE 15 - GENERAL ARRANGEMENT DRAWING
er. If the Diffuser Factory Option is Not
Installed, Clearance, Downstream of
the Supply Fan Outlet is Required to
Provide Adequate Airow and Reduce
Air Pressure Drop.
ld08137
JOHNSON CONTROLS
79
FORM100.50-EG12 (918)
13’ - 5”
10’
46’ - 5”
11’ - 5 13/16”
7’ - 8 7/8”
General Arrangement Drawing – 70–80 Ton Models (Cont'd)
EXTENDED CABINET / LEFT SUPPLY / FRONT RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
of the Condensing Unit.
Unit Height.
Units
One Side.
Where Applicable, are Folded Inside
Unit for Shipment.
er. If the Diffuser Factory Option is Not
Installed, Clearance, Downstream of
the Supply Fan Outlet is Required to
Provide Adequate Airow and Reduce
Air Pressure Drop.
1. 10’ Clearance Minimal Over The Top
2. Only One Adjacent Wall Can Exceed
3. 12’ Clearance Required to Adjacent
4. 8’ Service Access Recommended on
5. Economizer and Exhaust Hoods,
NOTES
6. Clearance Downstream of the Diffus-
FIGURE 16 - GENERAL ARRANGEMENT DRAWING
80
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
12’ - 5”
10’
43’ - 4 3/4”
11’ - 5 13/16”
7’ - 8 7/8”
General Arrangement Drawing – 90–105 Ton Models
BOTTOM SUPPLY / BOTTOM RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
of the Condensing Unit.
1. 10’ Clearance Minimal Over The Top
NOTES
FIGURE 17 - GENERAL ARRANGEMENT DRAWING
JOHNSON CONTROLS
Unit Height.
Units
2. Only One Adjacent Wall Can Exceed
3. 12’ Clearance Required to Adjacent
One Side.
4. 8’ Service Access Recommended on
Where Applicable, are Folded Inside
Unit for Shipment.
5. Economizer and Exhaust Hoods,
ld08131
81
FORM100.50-EG12 (918)
12’ - 5”
10’
43’ - 4 3/4”
11’ - 5 13/16”
7’ - 8 7/8”
General Arrangement Drawing – 90–105 Ton Models (Cont'd)
LEFT SUPPLY / LEFT RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
of the Condensing Unit.
Unit Height.
Units
One Side.
Where Applicable, are Folded Inside
Unit for Shipment.
1. 10’ Clearance Minimal Over The Top
2. Only One Adjacent Wall Can Exceed
3. 12’ Clearance Required to Adjacent
4. 8’ Service Access Recommended on
5. Economizer and Exhaust Hoods,
NOTES
FIGURE 18 - GENERAL ARRANGEMENT DRAWING
82
JOHNSON CONTROLS
LEFT SUPPLY / FRONT RETURN
12’ - 5”
10’
43’ - 4 3/4”
11’ - 5 13/16”
7’ - 8 7/8”
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
FORM 100.50-EG12 (918)
1. 10’ Clearance Minimal Over The Top
NOTES
FIGURE 19 - GENERAL ARRANGEMENT DRAWING
JOHNSON CONTROLS
of the Condensing Unit.
Unit Height.
Units
One Side.
2. Only One Adjacent Wall Can Exceed
3. 12’ Clearance Required to Adjacent
4. 8’ Service Access Recommended on
Where Applicable, are Folded Inside
Unit for Shipment.
5. Economizer and Exhaust Hoods,
ld08133
83
FORM100.50-EG12 (918)
12’ - 5”
10’
49’ - 10 3/4”
11’ - 5 13/16”
7’ - 8 7/8”
36”
General Arrangement Drawing – 90–105 Ton Models (Cont'd)
EXTENDED CABINET / BOTTOM SUPPLY / BOTTOM RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
FF = Final Filter
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
of the Condensing Unit.
Unit Height.
1. 10’ Clearance Minimal Over The Top
2. Only One Adjacent Wall Can Exceed
NOTES
3. 12’ Clearance Required to Adjacent
Units
One Side.
Where Applicable, are Folded Inside
4. 8’ Service Access Recommended on
5. Economizer and Exhaust Hoods,
Unit for Shipment.
er. If the Diffuser Factory Option is Not
Installed, Clearance, Downstream of
the Supply Fan Outlet is Required to
Provide Adequate Airow and Reduce
Air Pressure Drop.
6. Clearance Downstream of the Diffus-
FIGURE 20 - GENERAL ARRANGEMENT DRAWING
84
JOHNSON CONTROLS
12’ - 5”
10’
49’ - 10 3/4”
11’ - 5 13/16”
7’ - 8 7/8”
EXTENDED CABINET / LEFT SUPPLY / LEFT RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
FF = Final Filter
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
FORM 100.50-EG12 (918)
of the Condensing Unit.
Unit Height.
Units
One Side.
Where Applicable, are Folded Inside
Unit for Shipment.
er. If the Diffuser Factory Option is Not
Installed, Clearance, Downstream of
the Supply Fan Outlet is Required to
Provide Adequate Airow and Reduce
Air Pressure Drop.
1. 10’ Clearance Minimal Over The Top
2. Only One Adjacent Wall Can Exceed
3. 12’ Clearance Required to Adjacent
4. 8’ Service Access Recommended on
5. Economizer and Exhaust Hoods,
6. Clearance Downstream of the Diffus-
NOTES
FIGURE 21 - GENERAL ARRANGEMENT DRAWING
JOHNSON CONTROLS
LD08137
85
FORM100.50-EG12 (918)
12’ - 5”
10’
49’ - 10 3/4”
11’ - 5 13/16”
7’ - 8 7/8”
General Arrangement Drawing – 90–105 Ton Models (Cont'd)
EXTENDED CABINET / LEFT SUPPLY / BOTTOM RETURN
SECTION DESCRIPTIONS:
EE = Economizer
FE = Fan Exhaust
MB = Mixing Box
_F = Filter Segments
CC = Cooling Coils
FS = Supply Fan
FF = Final Filter
DP = Discharge Plenum
CO = Condenser Section
CP = Control Panel
of the Condensing Unit.
Unit Height.
1. 10’ Clearance Minimal Over The Top
2. Only One Adjacent Wall Can Exceed
NOTES
3. 12’ Clearance Required to Adjacent
Units
One Side.
Where Applicable, are Folded Inside
4. 8’ Service Access Recommended on
5. Economizer and Exhaust Hoods,
Unit for Shipment.
er. If the Diffuser Factory Option is Not
Installed, Clearance, Downstream of
the Supply Fan Outlet is Required to
Provide Adequate Airow and Reduce
Air Pressure Drop.
6. Clearance Downstream of the Diffus-
FIGURE 22 - GENERAL ARRANGEMENT DRAWING
86
JOHNSON CONTROLS
General Arrangement Drawing - Curb Layout
CURB LAYOUT DRAWING / 70–80 TON MODEL
FORM 100.50-EG12 (918)
CURB LAYOUT DRAWING / 90–105 TON MODEL
NOTES
1. Unit must be installed square and level.
2. Curb conguration for “bottom” return and “bottom” supply.
3. These drawings are not intended as construction documents for the eld fabricated roof curbs. Johnson
Controls will not be responsible for the unit t up, leak integrity, or sound level for installation using eld
fabricated roof curbs.
4. The YPAL unit does not have a base pan under the condensing section of the unit. Field fabricated roof
curbs must have a cap on the top of the condensing section of the curb to prevent moisture from entering
the space. The cap design must be sloped away from the supply duct opening to the end of the unit for the
drainage of the moisture off of the top of the cap.
FIGURE 23 - GENERAL ARRANGEMENT DRAWING
JOHNSON CONTROLS
87
FORM100.50-EG12 (918)
General Arrangement Drawing - Curb Layout (Cont'd)
EXTENDED CURB LAYOUT DRAWING / 70–80 TON MODEL
EXTENDED CURB LAYOUT DRAWING / 90–105 TON MODEL
NOTES
1. Unit must be installed square and level.
2. Curb conguration for “bottom” return and “bottom” supply.
3. These drawings are not intended as construction documents for the eld fabricated roof curbs. Johnson Controls will not be responsible
for the unit t up, leak integrity, or sound level for installation using eld fabricated roof curbs.
4. The YPAL unit does not have a base pan under the condensing section of the unit. Field fabricated roof curbs must have a cap on the top
of the condensing section of the curb to prevent moisture from entering the space. The cap design must be sloped away from the supply
duct opening to the end of the unit for the drainage of the moisture off of the top of the cap.
The requirements of the General Conditions, Supplementary Conditions, Division 1 and
drawings apply to all work herein.
Provide Microprocessor-controlled, air-cooled, double-wall construction outdoor packaged single package unit air conditioning product of the scheduled capacities and performance as shown and indicated on the Drawings, including but not limited to:
1. Single-piece single package unit package
2. Charge of refrigerant and oil
3. Electrical power and control connections
4. Supply and return duct connections
FORM 100.50-EG12 (918)
5. Factory start-up
Quality Assurance
All units are tested, rated or certified, as applicable, in accordance with the following standards, guidelines and codes:
1. All units shall meet the latest ASHRAE 90.1 minimum energy-efciency requirements (EER)
2. All units shall meet the latest ASHRAE 62 requirements for ventilation and indoor
air quality.
3. All units shall be rated in accordance with the ARI Standard 340/360
4. All units shall be tested to ANSI/UL 1995 and CAN/CSA C22.2 No. 236 standards
5. Gas heating units shall be designed in conform to ANSI Z21.47-2006/CSA2.3-2006
standards and be carry the ETL listed.
6. Units shall be ETL and ETL Canada listed
Manufacturers: The design shown on the drawing is based upon products of the manu-
facturer scheduled. Alternate equipment manufacturers shall be acceptable if equipment
meets the scheduled performance and complies with these specifications. If equipment
manufactured by manufacturer other than that scheduled is utilized, then the Mechanical
Contractor shall be responsible for coordinating with the General Contractor and all affected Subcontractors to insure proper provisions for installation of the furnished unit. This
coordination shall include, but not be limited to, the following:
1. Structural supports for units.
2. Roof curb transition.
3. Piping size and connection/header locations.
4. Electrical power requirements and wire/conduit and overcurrent protection sizes.
5. All costs incurred to modify the building provisions to accept the furnished units.
JOHNSON CONTROLS
91
FORM100.50-EG12 (918)
Guide Specifications (Cont'd)
Warranty: Manufacturer shall warrant all equipment and material of its manufacture
against defects in workmanship and material for a period of eighteen (18) months from
date of shipment.
1. The warranty shall include parts only during this period.
2. The warranty shall not include parts associated with routine maintenance, such as
belts, air lters, etc.
Delivery and Handling
Unit shall be delivered to the job site fully assembled, wired, and charged with refrigerant
and oil by the manufacturer.
Unit shall be stored and handled per Manufacturer’s instructions.
All handling and storage procedures shall be per manufacturer’s recommendations.
Submittals
Shop Drawings: Shop drawing submittals shall include, but not limited to, the following:
drawings indicating components, dimensions, weights, required clearances, and location,
type and size of field connections, and power and control wiring connections.
Product Data: Product data shall include dimensions, weights, capacities, ratings, fan
performance, motor electrical characteristics, and gauges and finishes of materials.
Documentation:
1. Fan curves with specied operating point clearly plotted shall be provided.
2. Product data of lter media, lter performance data, lter assembly, and lter frames
shall be provided.
3. Electrical requirements for power supply wiring; including wiring diagrams for inter-
lock and control wiring shall be supplied. Factory and eld-installed wiring shall be
clearly indicated.
4. Operation and maintenance documentation shall be supplied in accordance with
Section 01830 – Operation and Maintenance, including but not limited to instruc-
tions for lubrication, lter replacement, compressor, motor and drive replacement,
coil cleaning, lter maintenance, spare parts lists, and wiring diagrams.
Warranties
Equipment shall include the manufacturer’s warranty not less than eighteen months from
the date of shipment.
Extended parts warranty [optional] shall be included for an additional 1 [5] years
Extended parts and labor warranty [optional] shall be included for an additional 1 [5] years
EQUIPMENT
Product Specification
Summary: Completely factory assembled unitized construction packaged single package
unit air conditioning unit including a factory-mounted and wired unit controller and sensors, single-point power connection 460V [208V/230V/575V] three-phase, 60Hz power
supply, outdoor air handling section with return and supply openings, discharge plenum,
direct-expansion refrigerant condensing section.
92
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
Factory Test: The refrigerant circuit shall be pressure-tested, evacuated and fully charged
with refrigerant and oil. The completed refrigerant circuit shall undergo a factory helium
leak test and undergo an automated operational run test and quality inspection prior to
shipment. The unit controller shall be configured and run tested at the factory to minimize
field setup time. If the unit is not configured and tested, then the manufacturer shall provide field start up and testing to ensure that the controller is functioning properly.
Unit Construction
Base Rail: The unit shall include an integral design base rail with lifting points clearly
marked and visible on the base rail and a 1-1/4-inch FPT connection for condensate
drainage. The unit base shall be designed with a recessed curb mounting location. The
recessed curb-mounting surface shall provide a continuous surface for field application of
curb gasketing to create a weather tight seal between the curb and unit.
Casing: Casing shall be complete post and panel construction with exterior skin. All pan-
els, doors, walls, uprights, floor panels and roofing shall be one-inch thick; 1-1/2 pound
density insulation. Units are specifically designed for outdoor installation.
Roof: The unit roof shall be bowed with the peak in the middle of the unit and sloped
to both sides of the unit for drainage. A drip lip shall run the length of the unit to prevent
water drainage down the side of the unit. Roof and sidewall seams shall be continuously
caulked and covered with formed galvanized seam caps. All panel fasteners shall be secured through standing seams to prevent fastener penetrations that are exposed to the
air stream.
Paint: Exterior painted surfaces are designed to withstand a minimum of 1,000 salt spray
hours when tested in accordance with ASTM B-117.
Markings and Diagrams: All necessary tags and decals to aid in the service and/or indicating caution areas shall be provided. Electrical wiring diagrams shall be attached to the
control panel access door.
Documentation: Installation and maintenance manuals shall be supplied with each unit.
Access Doors: Double wall access doors shall be provided in the fan, coil, filter and inlet
sections of the unit on both sides of the unit. Doors shall be double-wall construction with
a solid liner and a minimum thickness of 1-inch. Doors shall be attached to the unit with
piano-type stainless steel hinges. Latches shall be positive-action, creating an airtight
seal between the door and unit. Panels and doors shall be completely gasketed with
a closed-cell, neoprene gasket. Door tiebacks shall be provided for all doors to secure
doors while servicing.
Economizer Type
Select None or One of the Following
1. No Outside Air: the unit has no provisions for outside ventilation air.
2. Manual Outside Air Damper: A manually adjustable outside air damper capable of
admitting 0–25% outside air shall be provided.
3. Two-Position Outside Air Damper: A two position damper outside air damper ca-
pable of admitting 0–25% outside air shall be provided. The minimum position shall
be manually adjustable from 0–25%. Control shall be based on the occupied mode
of the unit. For occupied mode, the damper shall be open to the minimum position
and for unoccupied, it shall be closed.
JOHNSON CONTROLS
93
FORM100.50-EG12 (918)
Guide Specifications (Cont'd)
4. Modulating Economizer: The economizer segment shall be designed to use outside air for cooling and ventilation and provide a means of exhausting air from the
air-handling unit. The segment shall consist of parallel acting low-leak dampers. The
return air, outside air and exhaust air dampers shall be sized for 100% of nominal
unit airow. The exhaust air damper assembly shall have a factory-assembled rain
hood. The rain hood shall have a drip-lip the full width of the hood to channel moisture away from the air being drawn into the unit.
Economizer Leakage
Select One of the Following
1. Damper assemblies are low-leak design. Damper blades are fabricated from a minimum of 16-gauge galvanized steel. Blade edges are covered with vinyl seals.
2. Damper assemblies have a maximum leakage rate of 10 CFM/ft2 at 1.0 inch water gauge (iwg) when tested in accordance with AMCA Standard 500, and have a
longevity of 60,000 damper opening and closing cycles, complying with the requirements of California Title 24.
Select One of the Following Types of Building Pressure Control
1. No Building Exhaust/Relief: The unit has no provisions to exhaust building return
air.
2. Barometric Relief Damper: Building air exhaust shall be accomplished through
barometric relief dampers installed in the return air plenum. The dampers open relative to the building pressure. The opening pressure shall be adjustable.
3. On/Off Fan Powered Exhaust: A twin double width, double inlet (DWDI) Class II
forward-curved centrifugal exhaust fan shall be provided to exhaust building return
air to relieve building static pressure. The fans shall be constant volume and operate based on either a building static pressure, or outside air damper position.
4. Powered Exhaust with Modulating Discharge Damper: A twin DWDI Class II
forward-curved centrifugal exhaust fan shall be provided to exhaust building return
air to relieve building static pressure. The fans shall operate at a constant volume
and operate based on building static pressure. Exhaust airow shall be modulated
via a parallel-acting control damper. The exhaust air dampers shall be sized for
100% of the exhaust airow.
5. Powered Exhaust with Variable Frequency Drive (VFD): A twin DWDI Class II
forward-curved centrifugal exhaust fan shall be provided to exhaust building re-
turn air to relieve building static pressure. Exhaust airow shall be modulated via a
factory-installed and commissioned variable frequency drive (VFD) with the same
nameplate horsepower as the supply fan motor.
6. Power Return Fan: Two single width, single inlet (SWSI) plenum fans shall be pro-
vided to draw return air from the building to the single package unit. An access door
shall be provided on at least one side of the unit for fan/motor access. The return fan
shall operate to maintain a constant pressure within the return plenum.
7. Power Return Fan: Two SWSI plenum fans shall be provided to draw return air
from the building to the single package unit. An access door shall be provided on
at least one side of the unit for fan/motor access. The return fan shall operate to
maintain a constant pressure within the return plenum. A discharge damper shall be
provided to modulate building exhaust. The damper shall be controlled via building
pressure. The return damper shall linked with the outside air damper to modulate
volumes of return and outside airows.
94
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
For Powered Exhaust or Return Fan Options Above, Use The Following
1. Fan Motor: Fan motors shall be NEMA design ball-bearing types with electrical
characteristics and horsepower as specied. Motors shall be 1750 RPM, open drip-
proof type [TEFC]. [Optional shaft grounding rings on motors increase motor longevity when applied with a VFD.] The motor shall be located within the unit on an
adjustable base.
Mountings: Fan and fan motor shall be internally mounted and isolated on a full
width isolator support channel using 1-inch springs [2-inch springs and seismic restraints]. The fan discharge shall be connected to the fan cabinet using a flexible
connection to insure vibration-free operation.
Bearings and Drives: Fan bearings shall be self-aligning, pillow block or flanged
type regreaseable ball bearings and shall be designed for an average life (L50) of
at least 200,000 hours. All bearings shall be factory lubricated and equipped with
standard hydraulic grease fittings and lube lines extended to the motor side of the
fan. Fan drives shall be selected for a 1.5 service factor and anti-static belts shall be
furnished. All drives shall be fixed pitch. Fan shafts shall be selected to operate well
below the first critical speed and each shaft shall be factory coated after assembly
with an anti-corrosion coating.
Filter Section
Select a Filter Rack, Filter Media, and Switch if Desired
1. Angled Filter Rack: Two-inch throwaway lters shall be provided in an angled lter
rack.
2. Angled Filter Rack: Two-inch cleanable lters shall be provided in an angled lter
rack.
3. Angled Filter Rack: Two-inch MERV 8 carbon media lters shall be provided in an
angled lter rack.
4. Angled Filter Rack: Two-inch high efciency (30%) MERV 8 pleated lters shall be
provided in an angled lter rack.
5. Flat Filter Rack: 60–65% Efcient MERV 11 Rigid Filters with a two-inch high ef-
ciency MERV 8 pleated pre-lters shall be provided in a at lter rack.
6. Flat Filter Rack: 90–95% Efcient MERV 14 Rigid Filters with a two-inch high ef-
ciency MERV 8 pleated pre-lters shall be provided in a at lter rack.
7. Dirty Filter Alarm: A dirty lter switch shall be provided and wired to the single
package unit control panel. Upon closure of the switch, the controller shall display
a dirty lter fault. The setting of the switch can be changed manually to close at a
specied pressure drop across the lters.
Evaporator Section
1. Cooling Coil: Evaporator coils shall be direct expansion type with intertwined circu-
iting to assure complete coil face activity during part load operation. Coil tubes shall
be 3/8-inch OD copper, with internally enhanced tubes. Fins shall be enhanced mechanically expanded to bond with the copper tubes. Coil casing shall be fabricated
from heavy gauge galvanized steel. All coils shall be pressure tested at a minimum
of 450 psig.
JOHNSON CONTROLS
95
FORM100.50-EG12 (918)
Guide Specifications (Cont'd)
2. IAQ Drain Pan: The main coil drain pan shall be double-sloped stainless steel with
a condensate connection through the base rail of the unit. Clearance between the
evaporator coil and the drain pan shall allow for easy access to the drain pan for
cleaning, and shall be visible for inspection without the removal of components.
3. Intermediate Drain Pan: Coils with nned height greater than 48 inches shall have an intermediate drain pan extending the entire nned length of the coil. The intermediate pans shall have drop tubes to guide condensate to the main drain pan.
Supply Fan Section
1. Fan: The fan section shall be equipped with a single DWDI forward-curved [airfoil
optional on 70–85T but standard on 90–105T] centrifugal type wheels. An access
door shall be provided on both sides of the unit for fan/motor access.
a. Mountings: Fan and fan motor shall be internally mounted and isolated on a
full width isolator support channel using 1-inch [2-inch optional] springs [with
optional seismic restraints]. The fan discharge shall be connected to the fan
cabinet using a flexible connection to insure vibration-free operation.
b. Bearings and Drives: Fan bearings shall be self-aligning, pillow block or
flanged type regreaseable ball bearings and shall be designed for an average
life (L50) of at least 200,000 hours. All bearings shall be factory lubricated and
equipped with standard hydraulic grease fittings and lube lines extended to the
motor side of the fan. Fan drives shall be selected for a 1.5 service factor and
anti-static belts shall be furnished. All drives shall be fixed pitch. Fan shafts shall
be selected to operate well below the first critical speed and each shaft shall be
factory coated after assembly with an anti-corrosion coating.
c. Optional VFD Manual Bypass: A three contactor manual bypass shall be pro-
vided to permit replacement of the VFD in the event of a power failure.
2. Direct Drive Plenum (DDP) Supply Fan: The fan section shall be equipped with a
Single Width Single Inlet (SWSI) airfoil plenum wheel. Plenum fans shall be direct
drive. An access door shall be provided on both sides of the unit for fan/motor access.
a. Mountings: Fan and fan motor shall be internally mounted and isolated on a full
width isolator support channel using 1-inch springs [2-inch springs and seismic
restraints].
b. Acoustiweir™: Unit shall include a discharge air (DA) sound attenuation barrier.
The passive sound attenuator barrier shall be mounted on the downstream side
of the supply fan and shall block line-of-sight between the fan and the unit discharge opening. If not available, manufacturer must provide a sound attenuator
of at least 3 feet in length.
c. Thrust Restraints: Provide horizontal thrust restraints between air handling
unit casing and fan housing.
d. Seismic Snubber: Unit shall be supplied with seismic snubbers on the SWSI
plenum fan.
e. Supply Fan Airflow Measurement: The SWSI supply fan shall be supplied with
an airflow measurement device. Airflow measurement device shall be ca¬pable
of measurement accuracy of +/-5%. Airflow measurement ring and trans¬ducer
shall be supplied for integration into a field-supplied controller.
f. Fan Inlet Screen: Unit shall be provided with a fan inlet screen.
96
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
g. Safety Grate: Safety grates capable of supporting a 300 pound center load
shall be provided over bottom supply air (SA) opening.
3. Fan Motor: Fan motors shall be NEMA design ball-bearing types with electrical
characteristics and horsepower as specied. Motors shall be 1750 RPM, open drip-
proof type [TEFC optional]. [Optional shaft grounding rings on motors increase motor longevity when applied with a VFD.] The motor shall be located within the unit
on an adjustable base.
4. Variable Air Volume (VAV) Fan Control: Variable Air Volume (VAV) supply fan con-
trol shall be accomplished by using a VFD matched to the supply fan motor HP. The
VFD shall include an integral DC line reactor to reduce harmonic distortion in the
incoming and outgoing power feeds. If a DC line reactor is not provided, an AC line
reactor must be provided. Inlet guide vanes shall not be acceptable. VFD control
keypads shall be located in the control cabinet for accessibility and servicing while
the unit is operating.
Discharge Plenum
Select One of the Following Heat/No Heat Configurations:
1. Cooling Only: The discharge air temperature sensor shall be located in the dis-
charge plenum and be located such that it accurately measures the supply air temperature. Walls shall be lined with a solid liner to prevent erosion of the insulation
and separate insulation from the air stream.
2. Staged Gas Heat: The heating section shall include an induced draft furnace in two
stages [four stages or six stages] of heating capacity.
Heat Exchanger: The heat exchanger shall be constructed of tubular aluminized
steel [stainless steel], with stainless steel flue baffles and flue assembly.
Burner and Ignition Control: The burner shall include a direct-driven induced-draft
combustion fan with energy efficient intermittent pilot spark ignition, redundant main
gas valves with pressure regulator.
Combustion Air Fan: The inducer fan(s) shall maintain a positive flow of air through
each tube, to expel the flue gas and to maintain a negative pressure within the heat
exchanger relative to the conditioned space.
Safety Devices: A high limit controller with automatic reset to prevent the heat exchanger from operating at an excessive temperature shall be included. A centrifugal
switch on the induced draft fan motor shaft shall prevent ignition until sufficient airflow is established through the heat exchanger. A rollout switch shall provide secondary airflow safety protection. The rollout switch shall discontinue furnace operation if
the flue becomes restricted.
3. Modulating Gas Heat: The heating section shall include an induced draft furnace
JOHNSON CONTROLS
Flue: The furnace flue shall be shipped loose to protect it from damage during transit. The flue shall be field-mounted by the installing contractor. The flue outlet shall be
located above the unit to help prevent recycling of combustion gases back through
the heat exchanger. Agency Certification: Gas heating sections are ETL listed to both
US and Canadian safety standards.
in 8:1 modulation [16:1, 24:1] of heating capacity.
Heat Exchanger(s): The heat exchanger(s) shall be constructed of tubular aluminized steel [stainless steel], with stainless steel flue baffles and flue assembly.
97
FORM100.50-EG12 (918)
Guide Specifications (Cont'd)
Burner(s) and Ignition Control: The burner(s) shall include a direct-driven induceddraft combustion fan with energy efficient intermittent pilot spark ignition, redundant
main gas valves with pressure regulator.
Combustion Air Fan(s): The inducer fan(s) shall maintain a positive flow of air
through each tube, to expel the flue gas and to maintain a negative pressure within
the heat exchanger relative to the conditioned space.
Safety Devices: A high limit controller with automatic reset to prevent the heat exchanger from operating at an excessive temperature shall be included. A centrifugal
switch on the induced draft fan motor shaft shall prevent ignition until sufficient airflow is established through the heat exchanger. A rollout switch shall provide secondary airflow safety protection. The rollout switch shall discontinue furnace operation if
the flue becomes restricted.
Flue: The furnace flue shall be shipped loose to protect it from damage during transit. The flue shall be field-mounted by the installing contractor. The flue outlet shall be
located above the unit to help prevent recycling of combustion gases back through
the heat exchanger.
Agency Certification: Gas heating sections are ETL listed to both US and Canadian
safety standards.
4. Electric Heat: An electric slip-in heater is installed within the single package unit
discharge plenum to provide the heating requirements per the schedule shown on
the plans. The electric heater is wired in such a manner as to provide a minimum of
two steps of capacity.
Heat Exchanger: The furnace is an industrial grade design using an open coil made
of the highest-grade resistance wire containing 80% nickel and 20% chromium. The
resistance coils are adequately supported in the air stream using ceramic bushings
in the supporting framework. Terminals of the coil are stainless steel with high temperature ceramic bushings.
Safety Devices: The primary high temperature protection is a manual reset type
thermal cut out. Secondary protection is a manual reset type thermal cut out. Secondary protection is a replaceable thermal link.
Agency Certification: The operation of the electric heater is an integral part of the
single package units control system. Power connection to the heater is through the
power panel for the unit. Electric heat is ETL certified to both US and Canadian safety
standards.
5. Hot Water Heating Coil: A hot water coil shall be installed in the single package
unit discharge plenum.
Construction: The hot water coil shall have 8 [10, 12, 14] fins per inch, 2 tubes per
circuit, and an 2-inch inlet and outlet connection. Primary surface shall be 1/2-inch
OD copper tube, staggered in direction of airflow. Connections have 1/4-inch FPT
drain plug on each connection. A structural galvanized steel casing shall protect the
coil. An intermediate coil support shall be provided. The coil shall be circuited to
provide free draining and venting, through one vent and drain. Freezestat shall be
provided to prevent coil freeze-up.
Testing: Completed coil, including headers, connections and return bends shall be
tested with 325 pounds compressed air under water. Coils shall be designed for operation at 250 psig design working pressure.
98
JOHNSON CONTROLS
FORM 100.50-EG12 (918)
6. Steam Heating Coil: A steam heating coil shall be installed in the single package
unit discharge plenum.
Construction: The steam coil shall be constructed in the non-freeze style. The
steam coil shall have six fins per inch, an 2-inch inlet, and 1-1/2-inch outlet connection. Tubes shall be 1-inch OD seamless copper tubing with a minimum wall thickness of 0.035-inch and expanded into the fin collars for maximum fin-tube bond.
Inner distributing tubes shall be 5/8-inch OD seamless copper tubing with a minimum
wall thickness of 1/4 inch. All header connections shall be of red brass or steel, with
male pipe threads and silver braze to headers. Casing shall be galvanized steel. The
core shall be pitched in the direction of the condensate connection for proper drainage. Freezestat shall be provided to prevent coil freeze-up.
Testing: The completed coil, including headers and connections, shall be tested
underwater with 325 pounds. compressed air to ensure a leak free coil.
7. Diffuser Section: For applications with an extended discharge plenum with down-
stream ltration or heating, a diffuser section is provided. A diffuser shall be included
to distribute the airow from the fan evenly across the heating coil or lter bank to
optimize coil/lter life and effectiveness. The diffuser shall be sized for 50% free
area and provide adequate upstream and downstream clearance to minimize air-
side pressure drop.
For Extended Discharge Plenums, Select One of the Following:
1. Downstream Final Filter Rack: A 12-inch rigid lter rack and lters shall be provid-
ed downstream of the supply fan and diffuser segment for hospital applications. The
lter shall be 90–95% efcient MERV 14. A magnahelic pressure gauge shall be
included and visible from the outside of the unit for servicing and code compliance.
2. Blank Section: A blank section shall be provided downstream of the supply fan and
diffuser section.
Condenser Section
1. Condenser Fans: Condenser fans shall be matched up with compressors to op-
timize system control. Condenser fans shall be propeller type, directly driven by
permanently lubricated TEAO motor.
2. Condenser Coil: Microchannel condenser coils shall be constructed of parallel ow
aluminum alloy tubes metallurgically brazed to enhanced aluminum alloy ns. Coils
are congured in a V-bank conguration, with individual at coils rotated from the
vertical plane for protection from hail damage for each condensing circuit. Condens-
ing coils shall have a subcooler for more efcient, stable operation.
3. Compressors: Units shall use industrial-duty hermetic scroll compressors, piped
and charged with P.O.E. oil and R-410A refrigerant. Compressors shall have an
enlarged liquid carrying capacity to withstand rugged operating conditions. Compressor frame shall be cast iron, with cast iron xed and orbiting scrolls. Each com-
pressor shall feature a solid state protection module, designed to protect the compressor from over-temperature and over-current conditions. Compressors shall be
vibration-isolated from the unit, and installed in an easily accessible area of the unit.
All compressor-to-pipe connections shall be brazed to minimize potential for leaks.
Each compressor shall include a replaceable suction screen, discharge line check
valve, and oil sight glass.
JOHNSON CONTROLS
99
FORM100.50-EG12 (918)
Guide Specifications (Cont'd)
4. Low Ambient: Compressors shall operate down to 0.0°F [optional] by monitor-
ing the refrigeration system discharge pressure and adjusting condenser airow
to maintain the proper head pressure to protect compressor operation. Refrigerant
pressure transducers shall be included and provide the discharge pressure on the
single package unit control display.
5. In-Line Liquid Line Driers [replaceable core liquid line driers]: Refrigerant piping includes check valves, thermal expansion valves with replaceable thermostatic
elements, high and low pressure switches, anti-recycling timing device to prevent
compressor restart for 5 minutes after shutdown.
6. Condenser Wire Grill [optional louvered condenser enclosure or no enclo-sure]: The condenser section shall be enclosed by a wire grill [louvered or none]
condenser enclosure on the three exposed sides. Paint nish shall match the color
and salt spray specications of the unit exterior.
7. Hot Gas Bypass: Hot gas bypass piping shall be provided to enable compressor
unloading to as low as 5% to better match cooling demand at low loads, prevent
excessive cycling of the compressor, and reduce the risk of coil freeze-up.
8. Compressor sound treatment [optional]: Compressor sound blankets shall be
provided to attenuate radiated sound from the compressors.
9. Service Valves [optional]: Liquid, suction and discharge service valves shall be
included to provide a means of isolating the refrigerant charge in the system so that
the refrigeration system may be serviced without removing the charge of the unit.
Controls
1. Enclosure: Unit shall be shipped complete with factory congured, installed, wired
and tested single package unit controller housed in a rain and dust tight enclosure
with hinged, latched, and gasket sealed door.
2. Basic Controls: Control shall include automatic start, stop, operating, and pro-
tection sequences across the range of scheduled conditions and transients. The
single package unit controller shall provide automatic control of compressor start/
stop, energy saver delay and anti-recycle timers, condenser fans, and unit alarms.
Automatic reset to normal operation after power failure. Software stored in nonvolatile memory, with programmed setpoints retained in lithium battery backed real
time clock (RTC) memory for minimum 5 years. Eighty character liquid crystal display, descriptions and numeric data in English (or metric) units. The sealed keypad
shall include buttons for setpoints, display, entry, unit options & clock, and an on/
off switch.
3. Diagnostics: Upon startup, the controller shall run through a self-diagnostic check
to verify proper operation and sequence loading. The single package unit controller shall continually monitor all input and output points on the controller to maintain
proper operation. The unit shall continue to operate in a trouble mode or shut down
as necessary to prevent an unsafe condition for the building occupants, or to prevent damage to the equipment. In the event of a unit shutdown or alarm, the operating conditions, date and time shall be stored in the shutdown history to facilitate
service and troubleshooting.
100
JOHNSON CONTROLS
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