INSTALLATION
MANUAL - 50Hz
SUNLINE™ 2000
GAS/ELECTRIC SINGLE PACKAGE
AIR CONDITIONERS
MODELS: DM180, 240 & 300
(Export)
CONTENTS
See the following page for a complete Table of Contents.
NOTES, CAUTIONS AND WARNINGS
The installer should pay particular attention to the words:
NOTE, CAUTION, and WARNING. Notes are intended to
clarify or make the installation easier. Cautions are given
to prevent equipment damage. Warnings are given to
alert installer that personal injury and/or equipment dam-
age may result if installation procedure is not handled
properly.
ISO 9001
Certified Quality
Management System
CAUTION: READ ALL SAFETY GUIDES BEFORE YOU
BEGIN TO INSTALL YOUR UNIT.
SAVE THIS MANUAL
356214-XIM-A-0108
356214-XIM-A-0108
LIST OF FIGURES
LIST OF TABLES
Fig. #
Pg. #
Tbl. #
Pg. #
5
8
FIELD WIRING - DM ELECTRIC/ELECTRIC AND
GAS/ ELECTRIC UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6
7
EXTERNAL SUPPLY CONNECTION EXTERNAL
SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DM ELECTRICAL DATA -WITHOUT POWERED
CONVENIENCE OUTLET. . . . . . . . . . . . . . . . . . . . . . . . . 21
BOTTOM SUPPLY CONNECTION EXTERNAL
SHUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9
DM ELECTRICAL DATA -WITH POWERED
CONVENIENCE OUTLET. . . . . . . . . . . . . . . . . . . . . . . . . 22
12 SUPPLY AIR BLOWER PERFORMANCE (15 TON) -
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
13 SUPPLY AIR BLOWER PERFORMANCE (20 TON) -
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
15 UNIT CLEARANCES AND RAIN HOOD DIMENSIONS
(15, 20 & 25 TON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
14 SUPPLY AIR BLOWER PERFORMANCE (15 TON) -
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
15 SUPPLY AIR BLOWER PERFORMANCE (20 TON) -
18 PRESSURE DROP ACROSS A DRY INDOOR COIL VS
SUPPLY AIR CFM FOR ALL UNIT TONNAGES . . . . . . . 35
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
16 SUPPLY AIR BLOWER PERFORMANCE (25 TON) -
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Johnson Controls Unitary Products
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356214-XIM-A-0108
GENERAL
YORK Model DM units are either single package air
conditions equipped with optional factory installed elec-
tric heaters, or single package gas-fired central heating
furnaces with cooling unit. Both are designed for out-
door installation on a rooftop or slab.
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could
result in serious injury, death, or property dam-
age.
The units are completely assembled on rigid, perma-
nently attached base rails. All piping, refrigerant
charge, and electrical wiring is factory installed and
tested. The units require electric power, gas connec-
tion, duct connections, installation of combustion air
inlet hood, flue gas outlet hoods and fixed outdoor air
intake damper (units without economizer or motorized
damper option only) at the point of installation.
- Do not store or use gasoline or other flamma-
ble vapors and liquids in the vicinity of this or
any other appliance.
- WHAT TO DO IF YOU SMELL GAS:
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any
phone in your building.
The supplemental electric heaters have nickel-chrome
elements and utilize single point power connection.
• Leave the building immediately.
• Immediately call your gas supplier from a neigh-
bor’s phone. Follow the gas supplier’s instructions.
These gas-fired heaters have aluminized-steel or
optional stainless steel, tubular heat exchangers with
spark ignition with proven pilot. All gas heaters are
shipped from the factory equipped for natural gas use,
but can be field converted to L.P./ Propane with Kit
Model # 1NP0418. See Gas Heat Application Data
Table.
• If you cannot reach the gas supplier, call the fire
department.
- Installation and service must be performed by
a qualified installer, service agency or the
gas supplier.
SAFETY CONSIDERATIONS
INSPECTION
Due to system pressure, moving parts and electrical
components, installation and servicing of air condition-
ing equipment can be hazardous. Only qualified,
trained, service personnel should install, repair, main-
tain or service this equipment.
As soon as a unit is received, it should be inspected for
possible damage during transit. If damage is evident,
the extent of the damage should be noted on the car-
rier's freight bill. A separate request for inspection by
the carrier's agent should be made in writing.
Observe all precautions in the literature, on labels and
tags accompanying the equipment whenever working
on air conditioning equipment. Be sure to follow all
other safety precautions that apply.
REFERENCE
Additional information on the design, installation, oper-
ation and service of this equipment is available in the
following reference forms:
Wear safety glasses and work gloves, and follow all
safety codes. Use a quenching cloth and have a fire
extinguisher available for all brazing operations.
•
•
Technical Guide - 262257
General Installation - 175240
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Johnson Controls Unitary Products
356214-XIM-A-0108
RENEWAL PARTS
®
Contact your local York Parts Distribution Center for
authorized replacement parts.
APPROVALS
IMPROPER INSTALLATION MAY CREATE A
CONDITION WHERE THE OPERATION OF
THE PRODUCT COULD CAUSE PERSONAL
INJURY OR PROPERTY DAMAGE.
Design certified by CSA as follows:
•
For use as a cooling unit only with or without
optional electric heat.
The installer should pay particular attention to the
words: NOTE, CAUTION and WARNING. Notes are
intended to clarify or make the installation easier. Cau-
tions are given to prevent equipment damage. Warn-
ings are given to alert installer that personal injury and/
or equipment damage may result if installation proce-
dure is not handled properly.
•
•
•
•
For use as a forced air furnace with cooling unit
For outdoor installation only.
For installation on combustible material.
For use with natural gas or propane gas.
THIS PRODUCT MUST BE INSTALLED IN
STRICT
COMPLIANCE
WITH
THE
ENCLOSED
INSTALLATION
INSTRUC-
TIONS AND ANY APPLICABLE LOCAL,
STATE, AND NATIONAL CODES INCLUD-
ING, BUT NOT LIMITED TO, BUILDING,
ELECTRICAL, AND MECHANICAL CODES.
Johnson Controls Unitary Products
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PRODUCT NOMENCLATURE
15-25 Ton Sunline & Magnum™ & MagnaDRY™ Model Number Nomenclature
D M 180 N24 A 7 A AA 1 0 1 2 4 A
Product Category
Product Style
A = Style A
D = A/C, Single Pkg., R-22
Product Identifier
Configuration Options (not required for all units)
These four digits will not be assigned until a quote is requested, or an order placed.
M = 8.5-9.0 EER A/C
SS Drain Pan
CPC Controller, DFS, APS
Johnson Controller, DFS, APS
Nominal Cooling Capacity
Honeywell Controller, DFS, APS
Novar Controller, DFS, APS
180 = 15 Ton
240 = 20 Ton
300 = 25 Ton
Simplicity IntelliComfort Controller
Simplicity IntelliComfort Controller w/ModLinc
2" Pleated filters
Heat Type and Nominal Heat Capacity
4" Pleated filters
BAS Ready Economizer (2-10 V.D.C. Actuator Without a Controller)
Double Wall Construction
C00 = Cooling Only. No field installed
electric heat
Any Combination of Additional Options that Don’t Have an Option Code Pre-assigned
Gas Heat Options
Product Generation
N24 = 240 MBH Output Aluminized Steel
N32 = 320 MBH Output Aluminized Steel
S24 = 240 MBH Output Stainless Steel
S32 = 320 MBH Output Stainless Steel
1 = First Generation
2 = Second Generation
Electric Heat Options
Additional Options
Hinged Filter Door & Tool Free Access Cabinet
E18 = 18 KW
E36 = 36 KW
E54 = 54 KW
E72 = 72 KW
Standard Cabinet
AA = None
BA = Hinged Filter Door & Tool Free Access Panels
BB = Phase Monitor, Hinged Filter Door & Tool Free
Access Panels
AB = Phase Monitor
AC = Coil Guard
AD = Dirty Filter Switch
BC = Coil Guard, Hinged Filter Door & Tool Free
Access Panels
Airflow
AE = Phase Monitor & Coil Guard
AF = Phase Monitor & Dirty Filter Switch
AG = Coil Guard & Dirty Filter Switch
AH = Phase Monitor, Coil Guard & Dirty Filter Switch
RC = Coil Guard & American Flag
TA = Technicoat Condenser Coil
TJ = Technicoat Evaporator Coil
TS = Technicoat Evaporator & Condenser Coils
BD = Dirty Filter Switch, Hinged Filter Door &
Tool Free Access Panels
A = Std. Drive
BE = Phase Monitor & Coil Guard, Hinged Filter
Door & Tool Free Access Panels
BF = Phase Monitor & Dirty Filter Switch, Hinged
Filter Door & Tool Free Access Panels
BG = Coil Guard & Dirty Filter Switch, Hinged Filter
Door & Tool Free Access Panels
B = Std. Drive/Single Input Econo.
C = Std. Drive/Single Input Econo./Power Exhaust
(Downflow Only)
D = Std. Drive/Motorized Damper
E = Std. Drive/Motorized Damper/Barometric Relief
J = Std. Drive/Single Input Econo./Barometric Relief
N = Hi Static Drive*
BH = Phase Monitor, Coil Guard & Dirty Filter Switch,
Hinged Filter Door & Tool Free Access Panels
P = Hi Static Drive/Single Input Econo.
Q = Hi Static Drive/Single Input Econo./Power Exhaust
(Downflow Only)
R = Hi Static Drive/Motorized Damper
K = Hi Static Drive/Motorized Damper/Barometric Relief
S = Hi Static Drive/Single Input Econo./Barometric Relief
ZZ = If desired option combination is not listed above, ZZ will be assigned and configuration options will be
located in digits 15-18.
Installation Options
Voltage
A = No Options Installed
B = Option 1
7 = 380/415-3-50
C = Option 2
D = Options 1 & 2
E = Option 3
F = Option 4
G = Options 1 & 3
H = Options 1 & 4
J = Options 1, 2 & 3
K = Options 1, 2, & 4
L = Options 1,3 & 4
M = Options 1, 2, 3, & 4
N = Options 2 & 3
P = Options 2 & 4
Q = Options 2, 3, & 4
R = Options 3 & 4
S = Option 5
* Note: 50 Hz, DM180 -300 Models
come standard with high
static drive package.
T = Options 1 & 5
U = Options 1, 3, & 5
V = Options 1, 4, & 5
W = Options 1, 3, 4, & 5
X = Options 3 & 5
Y = Options 4 & 5
Z = Options 3, 4 & 5
Options
1 = Disconnect
2 = Non-Pwr'd Conv. Outlet
3 = Smoke Detector S.A.
4 = Smoke Detector R.A.
5 = Pwr'd Conv. Outlet
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Johnson Controls Unitary Products
356214-XIM-A-0108
LIMITATIONS
INSTALLATION
These units must be installed in accordance with the
following national and local safety codes:
INSTALLATION SAFETY INFORMATION:
Read these instructions before continuing this appli-
ance installation. This is an outdoor combination heat-
ing and cooling unit. The installer must assure that
these instructions are made available to the consumer
and with instructions to retain them for future reference.
In U.S.A.:
•
•
•
National Electrical Code ANSI/NFPA No. 70.
National Fuel Gas Code Z223.1.
1. Refer to the unit rating plate for the approved type
of gas for this unit.
Gas-Fired Central Furnace Standard ANSI
Z21.47a.
2. Install this unit only in a location and position as
specified on Page 10 of these instructions.
•
Local gas utility requirements.
3. Never test for gas leaks with an open flame. Use
commercially available soap solution made specifi-
cally for the detection of leaks when checking all
connections, as specified on Pages 8, 16, 17 and
40 of these instructions.
In Canada:
•
•
•
•
Current Canadian Electrical Code C22.1.
Current Gas Installation Codes CSA-B149.1.
Local plumbing and waste water codes.
Other applicable local codes.
4. Always install unit to operate within the furnace's
intended temperature-rise range with the duct sys-
tem and within the allowable external static pres-
sure range, as specified on the unit name/rating
plate, specified on Page 42 of these instructions.
Refer to the Unit Application Data table and to the Gas
Heat Application Data table.
5. This equipment is not to be used for temporary
heating of buildings or structures under construc-
tion.
After installation, the unit must be adjusted to obtain a
temperature rise within the range specified on the unit
rating plate.
If components are to be added to a unit to meet local
codes, they are to be installed at the dealer's and/or
the customer's expense.
FIRE OR EXPLOSION HAZARD
FAILURE TO FOLLOW THE SAFETY WARN-
ING EXACTLY COULD RESULT IN SERIOUS
INJURY, DEATH OR PROPERTY DAMAGE.
Size of unit for proposed installation should be based
on heat loss/heat gain calculation made according to
the methods of the Air Conditioning Contractors of
America (ACCA).
NEVER TEST FOR GAS LEAKS WITH AN
OPEN FLAME. USE A COMMERICALLY
AVAILABLE SOAP SOLUTION MADE SPE-
CIFICALLY FOR THE DETECTION OF
LEAKS TO CHECK ALL CONNECTIONS. A
FIRE OR EXPLOSION MAY RESULT CAUS-
ING PROPERTY DAMAGE, PERSONAL
INJURY OR LOSS OF LIFE.
This equipment is not to be used for temporary heating
of buildings or structures under construction.
International:
•
Local Government/Agency Regulations
Johnson Controls Unitary Products
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TABLE 1: UNIT APPLICATION DATA
UNIT MODEL NUMBER
DM180
DM240
342/456
DM300
Voltage Variation,
380/415-3-50
1
Min. / Max.
Supply Air CFM, Min. / Max.
4,500 / 7,200
6,000 / 9,400
57 / 72
7,500 / 12,500
Wet Bulb Temperature (ºF) of Air on
Evaporator Coil, Min. / Max.
Dry Bulb Temperature (ºF) of Air on
Condenser Coil, Min. / Max.
0 / 125
1.
Utilization range “A” in accordance with ARI Standard 110.
LOCATION
6. Maintain level tolerance to 1/2 inch maximum
across the entire length or width of the unit.
Use the following guidelines to select a suitable loca-
tion for these units.
1. Unit is designed for outdoor installation only.
Excessive exposure of this furnace to contami-
nated combustion air may result in equipment
damage or personal injury. Typical contami-
nates include: permanent wave solutions, chlo-
rinated waxes and cleaners, chlorine based
swimming pool chemicals, water softening
chemicals, carbon tetrachloride, Halogen type
refrigerants, cleaning solvents (e.g. perchloro-
ethylene), printing inks, paint removers, var-
nishes, hydrochloric acid, cements and glues,
antistatic fabric softeners for clothes dryers,
masonry acid washing materials.
2. Condenser coils must have an unlimited supply of
air.
3. Where a choice of location is possible, position the
unit on either north or east side of building.
4. For ground level installation, use a level concrete
slab with a minimum thickness of 4 inches. The
length and width should be at least 6 inches
greater than the unit base rails. Do not tie slab to
the building foundation.
5. Roof structures must be able to support the weight
of the unit and its options and/or accessories. Unit
must be installed on a solid level roof curb or
appropriate angle iron frame.
If a unit is to be installed on a roof curb or special frame
other than a YORK roof curb, gasketing must be
applied to all surfaces that come in contact with the unit
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Johnson Controls Unitary Products
356214-XIM-A-0108
RIGGING AND HANDLING
Exercise care when moving the unit. Do not remove
any packaging until the unit is near the place of installa-
tion. Rig the unit by attaching chain or cable slings to
the round lifting holes provided in the base rails.
Spreaders, whose length exceeds the largest dimen-
sion across the unit, MUST BE USED. Refer to
Units may also be moved or lifted with a forklift, from
the side only, providing that an accessory skid is used.
LENGTH OF FORKS MUST BE A MINIMUM OF 90".
to the Figures 2 or 12 for approximate center of gravity.
FIGURE 2 - CENTER OF GRAVITY
Before lifting a unit, make sure that all panels
are in place and that its weight is distributed
equally on all cables so it will lift evenly.
An adhesive backed label is provided over the
outside of the combustion air inlet opening to
prevent moisture from entering the unit, which
could cause damage to electrical components.
Allow this closure label to remain in place until
the combustion air hood is to be installed (refer
CLEARANCES
All units require certain clearances for proper operation
and service. Installer must make provisions for ade-
quate combustion and ventilation air in accordance
with Section 5.3, Air for Combustion and Ventilation of
the National Fuel Gas Code, ANSI Z223.1 (in U.S.A.)
or Sections 7.2, 7.3 or 7.4 of Gas Installation Codes
CSA-B149.1 (in Canada) and/or applicable provisions
of the local building codes. Refer to Dimensions and
combustible construction, servicing, and proper unit
operation.
FIGURE 1 - TYPICAL RIGGING
Johnson Controls Unitary Products
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356214-XIM-A-0108
FIXED OUTDOOR AIR INTAKE DAMPER
This damper is shipped inside the return air compart-
ment. It is completely assembled and ready for installa-
tion. A damper baffle inside of the hood is adjustable to
provide variable amounts of outdoor air intake on units
that are not provided with an economizer or a motor-
ized damper option. Refer to the Fixed Outdoor
Do not permit overhanging structures or shrubs
to obstruct outdoor air discharge outlet, com-
bustion air inlet or vent outlets.
DUCTWORK
Gasketing and mounting screws are provided in a parts
bag attached to the hood assembly. Apply gasketing to
the three flange surfaces on the hood prior to installing
the hood. Extend gasketing 1/4 inch beyond the top
and bottom of the two side flanges to insure adequate
sealing.
Ductwork should be designed and sized according to
the methods in Manual Q of the Air Conditioning Con-
tractors of America (ACCA).
A closed return duct system shall be used. This shall
not preclude use of economizers or outdoor fresh air
intake. The supply and return air duct connections at
the unit should be made with flexible joints to minimize
noise.
Adjusting the damper to the desired air flow may be
done before mounting the hood into position or after
installation by removing the front hood panel or the
screen on the bottom of the hood. Damper baffle in
position 1 will allow approximately 10% outdoor air
flow, position 2 approximately 15% and, to allow
approximately 25%, remove the damper baffle.
The supply and return air duct systems should be
designed for the CFM and static requirements of the
job. They should NOT be sized to match the dimen-
sions of the duct connections on the unit.
On units with bottom return air application install the
damper assembly over the opening in the side return
air access panel. Remove and discard the opening
cover and the covering over the hood mounting holes
(used for shipping) before installing. Secure with the
screws provided.
When fastening ductwork to side duct flanges
on unit, insert screws through duct flanges
only. DO NOT insert screws through casing.
Outdoor ductwork must be insulated and
waterproofed.
On units with side return air applications, install the
damper assembly on the return air ductwork as close
to the unit as possible. Cut an opening 16 inches high
by 18 inches wide in the ductwork to accommodate the
damper. Using the holes in the hood flanges as a tem-
plate, drill 9/64 inch dia. (#26 drill) holes into the duct-
work and secure with the screws provided.
information concerning side and bottom supply and
return air duct openings.
NOTE: It is recommended that, in Canada, the outlet
duct be provided with a removable access
panel. It is recommended that this opening be
accessible when the unit is installed in service,
and of a size such that smoke or reflected light
may be observed inside the casing to indicate
the presence of leaks in the heat exchanger.
The cover should be attached in a manner
adequate to prevent leakage.
If outdoor air intake will not be required on
units with bottom return air applications, the
damper assembly should still be mounted on
the side return air access panel, per the
instructions above, to insure moisture is not
drawn into the unit during operation. The cov-
ering over the mounting holes only need be
removed. Do not remove the opening cover.
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356214-XIM-A-0108
COMPRESSORS
Units are shipped with compressor mountings factory-
adjusted and ready for operation.
Do not loosen compressor mounting bolts.
FILTERS
Two-inch or four-inch filters can be supplied with each
unit. Filters must always be installed ahead of the
evaporator coil and must be kept clean or replaced with
same size and type. Dirty filters will reduce the capacity
of the unit and will result in frosted coils or safety shut-
down. Minimum filter area and required sizes are
FIGURE 3 - FIXED OUTDOOR AIR DAMPER
CONDENSATE DRAIN
Plumbing must conform to local codes. Use a sealing
compound on male pipe threads. Install a condensate
drain line from the one-inch NPT female connection on
the unit to an open drain.
SERVICE ACCESS
The following removable panels provide access to all
serviceable components:
NOTE: The condensate drain operates in a negative
pressure in the cabinet. The condensate drain
line MUST be trapped to provide proper drain-
•
•
•
•
Compressor compartment
Electric Heat compartment
Gas Heat compartment (Two panels)
Side Supply & Return Air compartments
(Two panels)
•
•
•
•
Blower compartment (Three panels)
Main control box
Filter compartment
Outdoor Air compartment (Two panels)
location of these access panels.
FIGURE 4 - RECOMMENDED DRAIN PIPING
Make sure that all screws and panel latches
are replaced and properly positioned on the
unit to maintain an airtight seal.
Johnson Controls Unitary Products
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THERMOSTAT
TERMINALS
CONTROL
TERMINAL
BLOCK
W1
W1
W2
Y1
G
1
W2
Y1
2
Y2
OCC
P
P1
Y2
X
G
R
C
Smoke
Detector
R
SD
C
Jumper 3
R
SD
SD
C
4
RC
5
OCC
24 VAC
Class 2
6
X
TERMINALS ON
A LIMITED
NUMBER OF
THERMOSTATS
1
2
3
4
5
6
Second stage heating not required on single stage heating units.
Second stage cooling not required on single stage cooling units.
Jumper is required if there is no Smoke Detector circuit.
Jumper is required for any combination of R, RC, or RH.
OCC is an output from the thermostat to indicate the Occupied condition.
X is an input to the thermostat to display Error Status conditions.
FIGURE 5 - FIELD WIRING - DM ELECTRIC/ELECTRIC AND GAS/ ELECTRIC UNITS
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Johnson Controls Unitary Products
356214-XIM-A-0108
THERMOSTAT
with a separate branch circuit fed directly from the
meter panel and properly fused.
The room thermostat should be located on an inside
wall approximately 56 inches above the floor where it
will not be subject to drafts, sun exposure or heat from
electrical fixtures or appliances. Follow manufacturer's
instructions enclosed with thermostat for general instal-
lation procedure. A minimum of seven color-coded
insulated wires (#18 AWG) should be used to connect
thermostat to unit.
When connecting electrical power and control
wiring to the unit, waterproof type connectors
MUST BE USED so that water or moisture
cannot be drawn into the unit during normal
operation. The above waterproofing conditions
will also apply when installing a field-supplied
disconnect switch.
POWER AND CONTROL WIRING
Field wiring to the unit must conform to provisions of
the National Electrical Code, ANSI / NFPA No. 70 (in
U.S.A.), current Canadian Electrical Code C22.1 (in
Canada) and/or local ordinances. The unit must be
electrically grounded in accordance with NEC and CEC
(as specified above) and/or local codes. Voltage toler-
ances, which must be maintained at the compressor
terminals, during starting and running conditions, are
indicated on the unit Rating Plate and the Unit Applica-
tion Data table.
appropriate unit wiring diagram for control circuit and
power wiring information.
TABLE 2: CONTROL WIRE SIZES
1
Wire Size
18 AWG
Maximum Length
150 Feet
1.
From the unit to the thermostat and back to the unit.
The internal wiring harness furnished with this unit is
an integral part of a CSA design certified unit. Field
alteration to comply with electrical codes should not be
required.
OPTIONAL ELECTRIC HEAT
The factory-installed heaters are wired for single point
power supply. Power supply need only be brought into
the single point terminal block and thermostat wiring to
the low voltage terminal strip located in the upper por-
tion of the unit control box.
A fused disconnect switch should be field provided for
the unit. The switch must be separate from all other cir-
cuits. Wire entry at knockout openings require conduit
fittings to comply with NEC (in U.S.A.), CEC (in Can-
ada) and/or local codes. Refer to the Dimensions and
the wire supplied with the unit must be replaced,
replacement wire must be of the type shown on the wir-
ing diagram and the same minimum gauge as the
replaced wire.
These CSA approved heaters are located within the
central compartment of the unit with the heater ele-
ments extending into the supply air chamber. Refer to
Figure 13 for access panel location.
Fuses are supplied, where required, by the factory.
Some KW sizes require fuses and others do not. Refer
Electrical line must be sized properly to carry the load.
Use copper conductors only. Each unit must be wired
TABLE 3: ELECTRIC HEAT APPLICATION DATA
NOMINAL
HEATER SIZE
(KW)
VOLTAGE
3-PHASE,
50 HZ
MINIMUM CFM UNIT SIZE
15 TON
20 TON
25 TON
18
36
54
72
380/415
380/415
380/415
380/415
4500
4500
5000
5000
6000
6000
6000
6000
7500
7500
7500
7500
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OPTIONAL GAS HEAT
These gas-fired heaters have aluminized-steel or
optional stainless steel, tubular heat exchangers with
spark ignition with proven pilot.
All gas heaters are shipped from the factory equipped
for natural gas use, but can be field converted to L.P./
Propane with Kit Model # 1NP0418. See Gas Heat
Application Data Table.
TABLE 4: GAS HEAT APPLICATION DATA
Output Capacity (Mbh)
0 To
2,000 Feet
Above
2,000 To
4,500 Feet
Above
Temp.
Rise ºF
At
0 To
2,000 To
Gas
Rate
(Ft./Hr.)
2,000 Feet
Above
4,500 Feet
Above
Available
on Models
Sea Level
Sea Level
Full Input
Sea Level
Sea Level
Max.
Min.
150
175
Max.
Min.
135
160
Max.
240
280
Max.
213
Min.
Max.
50
300
350
270
320
15, 20 & 25 Ton
25 Ton
279
326
20
30
241
60
GAS PIPING
GAS CONNECTION
Proper sizing of gas piping depends on the cubic feet
per hour of gas flow required, specific gravity of the gas
and the length of run. "National Fuel Gas Code" Z223.1
(in U.S.A.) or the current Gas Installation Codes CSA-
B149.1 (in Canada) should be followed in all cases
unless superseded by local codes or gas utility require-
ments. Refer to the Pipe Sizing Table 5.
The gas supply line can be routed through the knock-
outs located on the front of the unit or through the
opening provided in the unit's base. Refer to the
access openings. Typical supply piping arrangements
are field-supplied.
The heating value of the gas may differ with locality.
The value should be checked with the local gas utility.
If gas supply line is routed through the unit's base
ensure that the burner assembly can be removed for
maintenance without disturbing the supply line. The
supply piping and fittings must lie below the bottom gas
manifold to avoid interference with the burner assem-
bly.
NOTE: There may be a local gas utility requirement
specifying a minimum diameter for gas piping.
All units require a one-inch pipe connection at
the entrance fitting.
Two grommets are shipped in the blower compartment
(in parts bag taped to the blower housing) of every unit
with gas heat and should be used in the knockouts
when the gas piping penetrates the front of the unit.
TABLE 5: PIPE SIZING
Nominal Iron Pipe Size
Length in Feet
1 in.
520
350
285
245
215
195
180
170
160
150
1-1/4 in.
1,050
730
10
20
30
40
50
60
70
80
90
100
After the gas supply piping has been installed, the bot-
tom opening in the unit should be sealed to prevent
water from leaking into the building.
590
500
Gas piping recommendations:
440
400
1. A drip leg and a ground joint union must be
installed in the gas piping.
370
350
2. When required by local codes, a manual shut-off
valve may have to be installed outside of the unit.
320
305
3. Use wrought iron or steel pipe for all gas lines. Pipe
compound should be applied sparingly to male
threads only.
Maximum capacity of pipe in cubic feet of gas per hour. (Based upon
a pressure drop of 0.3 inch water column and 0.6 specific gravity
gas).
14
Johnson Controls Unitary Products
356214-XIM-A-0108
supply piping system at test pressures equal to or
less than 1/2 psig (3.48kPa).
7. A 1/8 inch NPT plugged tap, accessible for test
gage connection, must be installed immediately
upstream of the gas supply connection to the fur-
nace.
Natural gas may contain some propane. Pro-
pane, being an excellent solvent, will quickly
dissolve white lead or most standard commer-
cial compounds. Therefore, a special pipe
compound must be applied when wrought iron
or steel pipe is used. Shellac base compounds
such as Gaskolac or Stalastic, and compounds
such as Rectorseal #5, Clyde's or John Crane
may be used.
4. All piping should be cleaned of dirt and scale by
hammering on the outside of the pipe and blowing
out the loose dirt and scale. Before initial start-up,
be sure that all of the gas lines external to the unit
have been purged of air.
5. The gas supply should be a separate line and
installed in accordance with all safety codes as
prescribed under "Limitations". After the gas con-
nections have been completed, open the main
shut-off valve admitting normal gas pressure to the
mains. Check all joints for leaks with soap solution
or other material suitable for the purpose. NEVER
USE A FLAME.
FIGURE 6 - EXTERNAL SUPPLY CONNECTION
EXTERNAL SHUT-OFF
FIRE OR EXPLOSION HAZARD
FAILURE TO FOLLOW THE SAFETY WARN-
ING EXACTLY COULD RESULT IN SERIOUS
INJURY, DEATH OR PROPERTY DAMAGE.
NEVER TEST FOR GAS LEAKS WITH AN
OPEN FLAME. USE A COMMERICALLY
AVAILABLE SOAP SOLUTION MADE SPE-
CIFICALLY FOR THE DETECTION OF
LEAKS TO CHECK ALL CONNECTIONS. A
FIRE OR EXPLOSION MAY RESULT CAUS-
ING PROPERTY DAMAGE, PERSONAL
INJURY OR LOSS OF LIFE.
FIGURE 7 - BOTTOM SUPPLY CONNECTION
EXTERNAL SHUT-OFF
L.P. UNITS, TANKS AND PIPING
6. The furnace and its individual manual shut-off
valve must be disconnected from the gas supply
piping system during any pressure testing of that
system at test pressures in excess of 1/2 psig
(3.48kPa).
All gas heat units are shipped from the factory
equipped for natural gas use only. The unit may be
converted in the field for use with L.P./propane gas
with accessory kit model number 1NP0418.
All L.P./propane gas equipment must conform to the
safety standards of the National Fire Protection Associ-
ation.
The furnace must be isolated from the gas supply
piping system by closing its individual manual shut-
off valve during any pressure testing of the gas
Johnson Controls Unitary Products
15
356214-XIM-A-0108
For satisfactory operation, L.P./propane gas pressure
must be 10.0 I.W.C. at the unit manifold under full load.
Maintaining proper gas pressure depends on three
main factors:
the blower compartment. These hoods must be
installed to assure proper unit function. All hoods must
be fastened to the outside of the gas heat access panel
with the screws provided in the bag also attached to
the blower housing.
1. The vaporization rate depends on (a) the tempera-
ture of the liquid and (b) the "wetted surface" area
of the container or containers.
The screen for the combustion air intake hood is
secured to the inside of the access panel opening with
four fasteners and the screws used for mounting the
hood to the panel. The top flange of this hood slips in
under the top of the access panel opening when install-
ing. Refer to Vent and Combustion Air Hood Figure 8.
2. The proper pressure regulation. (Two-stage regula-
tion is recommended from the standpoint of both
cost and efficiency.)
3. The pressure drop in the lines between regulators
and between the second stage regulator and the
appliance. Pipe size required will depend on the
length of the pipe run and the total load of all appli-
ances.
Each vent hood is installed by inserting the top flange
of the hood into the slotted opening in the access panel
and securing in place.
The products of combustion are discharged horizon-
tally through these two screened, hooded vent open-
ings on the upper gas heat access panel.
Complete information regarding tank sizing for vapor-
ization, recommended regulator settings, and pipe siz-
ing is available from most regulator manufacturers and
L.P./propane gas suppliers.
L.P./propane gas is an excellent solvent and special
pipe compound must be used when assembling piping
for this gas as it will quickly dissolve white lead or most
standard commercial compounds. Shellac base com-
pounds such as Rectorseal #5 are satisfactory for this
type of gas.
SLOTTED
OPENINGS IN
ACCESS PANEL
VENT AIR
OUTLET
HOODS
Check all connections for leaks when piping is com-
pleted, using a soap solution. NEVER USE A FLAME.
COMBUSTION
AIR INTAKE
HOOD
GAS HEAT
FIRE OR EXPLOSION HAZARD
ACCESS
PANELS
FAILURE TO FOLLOW THE SAFETY WARN-
ING EXACTLY COULD RESULT IN SERIOUS
INJURY, DEATH OR PROPERTY DAMAGE.
FIGURE 8 - VENT AND COMBUSTION AIR HOOD
NEVER TEST FOR GAS LEAKS WITH AN
OPEN FLAME. USE A COMMERICALLY
AVAILABLE SOAP SOLUTION MADE SPE-
CIFICALLY FOR THE DETECTION OF
LEAKS TO CHECK ALL CONNECTIONS. A
FIRE OR EXPLOSION MAY RESULT CAUS-
ING PROPERTY DAMAGE, PERSONAL
INJURY OR LOSS OF LIFE.
OPTIONAL ECONOMIZER/MOTORIZED DAMPER RAIN
HOOD
The instruction for the optional economizer/motorized
damper rain hood can be found in the kit. Use these
instructions when field assembling an economizer rain
hood onto a unit. The outdoor and return air dampers,
the damper actuator, the damper linkage, the outdoor
and return air divider baffles, and all the control sen-
sors are factory mounted as part of the "Factory
installed" economizer option.
VENT AND COMBUSTION AIR HOODS
Two vent hoods and a combustion air hood (with
screens) are shipped attached to the blower housing in
16
Johnson Controls Unitary Products
356214-XIM-A-0108
OPTIONAL POWER EXHAUST/BAROMETRIC RELIEF
DAMPER RAIN HOOD
POWER EXHAUST DAMPER SETPOINT
With power exhaust option, each building pressuriza-
tion requirement will be different. The point at which the
power exhaust comes on is determined by the econo-
mizer damper position (Percent Open). The Exhaust
Air Adjustment Screw should be set at the Percent
Open of the economizer damper at which the power
exhaust is needed. It can be set from 0 to 100%
damper open.
The instructions for the power exhaust/barometric relief
damper rain hood can be found in the kit. The exhaust
fan, all supporting brackets, angles, and the wiring are
factory installed as part of the power exhaust option.
OPTIONAL ECONOMIZER AND POWER EXHAUST
DAMPER SET POINT ADJUSTMENTS AND INFORMA-
TION
•
For a dual enthalpy operation, carefully turn the set
point adjusting screw fully clockwise past the "D"
setting.
Remove the economizer access panel from the unit.
Loosen but do not remove the two panel latches.
Locate the economizer control module, where the fol-
lowing adjustments will be made.
INDOOR AIR QUALITY AQ
Indoor Air quality (indoor sensor input): Terminal AQ
accepts a +2 to +10 Vdc signal with respect to the
(AQ1) terminal. When the signal is below it's setpoint,
the actuator is allowed to modulate normally in accor-
dance with the enthalpy and mixed air sensor inputs.
When the AQ signal exceeds it's setpoint setting and
there is no call for free cooling, the actuator is propor-
tionately modulated from the 2 to 10 Vdc signal, with 2
Vdc corresponding to full closed and 10 Vdc corre-
sponding to full open. When there is no call for free
cooling, the damper position is limited by the IAQ Max
damper position setting. When the signal exceeds it's
setpoint (Demand Control Ventilation Setpoint) setting
and there is a call for free cooling, the actuator modu-
lates from the minimum position to the full open posi-
tion based on the highest call from either the mixed air
sensor input or the AQ voltage input.
EXTREME CARE MUST BE EXCERCISED IN
TURNING ALL SETPOINT, MAXIMIUM, AND
MINIMUM DAMPER POSITIONING ADJUST-
MENT SCREWS TO PREVENT TWISTING
THEM OFF.
Check that the damper blades move smoothly without
binding; carefully turn the Minimum Position Adjusting
screw (found on the damper control module) fully
clockwise and then set the thermostat indoor fan switch
to the on position and then off, or energize and de-
energize terminals "R" to "G".
MINIMUM POSITION ADJUSTMENT
•
Optional CO Space Sensor Kit Part #
2
With thermostat set to indoor fan on position, or termi-
nals "R" to "G" energized, turn the Minimum Position
Adjusting screw (located on the damper control mod-
ule) counterclockwise until the desired minimum
damper position has been attained.
2AQ04700324
•
Optional CO Unit Sensor Kit Part # 2AQ04700424
2
Replace the economizer access panel.
OPTIONAL BAS-READY ECONOMIZER POWER
EXHAUST DAMPER SET POINT ADJUSTMENT
ENTHALPY SET POINT ADJUSTMENT
The enthalpy set point may now be set by selecting the
desired setpoint shown in the Enthalpy Setpoint Adjust-
ment Figure 9. Adjust as follows:
Remove the economizer access panel from the unit.
Loosen, but do not remove the two panel latches.
Locate the economizer actuator, where the following
adjustment can be made.
•
•
For a single enthalpy operation carefully turn the
set point adjusting screw (found on the damper
control module) to the "A", "B", "C" or "D" setting
corresponding to the lettered curve of the Enthalpy
Setpoint Adjustment Figure 9.
With power exhaust option, each building pressuriza-
tion requirement will be different. The point at which the
power exhaust comes on is determined by the econo-
mizer's outdoor damper position. The actuator's auxil-
iary switch adjustment screw should be set at the
damper position at which the power exhaust is needed.
The adjustment screw can be set between 25 to 85
degrees open.
For a dual enthalpy operation, carefully turn the set
point adjusting screw fully clockwise past the "D"
setting.
Replace the economizer access panel.
Johnson Controls Unitary Products
17
356214-XIM-A-0108
FIGURE 9 - ENTHALPY SETPOINT ADJUSTMENT
Exhaust Air
Adjustment
Screw
EXH
Set
N
N1
P1
T1
TR
TR1
Exhaust Air LED
Damper Min.
Position
Screw
24
Vac
HOT
24
Vac
COM
EXH
P
T
Min
Pos
Indoor Air Quality
Max. Adjustment
Screw
+
IAQ
Max
1
2
Indoor Air Quality
LED
IAQ
AQ1
SO+
AQ
SO
5
4
Indoor Air Quality
Min. Adjustment
Screw
IAQ
Min
3
Free
Cool
Free Cooling LED
SR
B
A
SR+
EF
EF1
C
D
Economizer Enthalpy
Set Point Adjustment
Screw
FIGURE 10 - HONEYWELL ECONOMIZER CONTROL W7212
18
Johnson Controls Unitary Products
356214-XIM-A-0108
B
E
F
C
D
A
A
C
FRONT
FRONT
D
B
FIGURE 11 - FOUR AND SIX POINT LOADS
TABLE 6: FOUR AND SIX POINT LOADS
Total
4 Point Loads (lbs)
Unit Size
Shipping
Weight
A
B
C
D
180 Gas
240 Gas
300 Gas
180 Elec
240 Elec
300 Elec
2300
2500
3130
2100
2300
2890
539
538
615
492
295
487
563
563
671
514
517
619
612
715
962
558
658
646
586
684
882
536
630
508
Total
6 Point Loads (lbs)
Unit Size
Shipping
Weight
A
B
C
D
E
F
180 Gas
240 Gas
300 Gas
180 Elec
240 Elec
300 Elec
2300
2500
3130
2100
2300
2890
351
334
418
320
307
415
367
350
438
335
322
471
392
426
533
358
392
528
416
502
628
380
462
551
399
481
603
364
442
492
375
407
510
343
375
433
FIGURE 12 - CENTER OF GRAVITY
Johnson Controls Unitary Products
19
356214-XIM-A-0108
TABLE 7: PHYSICAL DATA
MODELS
DM180
DM240
DM300
CENTRIFUGAL BLOWER (Dia. x Wd.)
FAN MOTOR HP
15x15
5.0
18x15
7.5
3
18x15
10
EVAPORATOR
BLOWER
ROWS DEEP
3
4
EVAPORATOR COIL FINS PER INCH
13.5
20.5
30
FACE AREA (Sq. Ft.)
15.5
25
PROPELLER DIA. (In.) (Each)
CONDENSER FAN
(Two Per Unit)
FAN MOTOR HP
NOM. CFM TOTAL
ROWS DEEP
(Each)
(Each)
1
6,000
2
8,000
2
7,200
3
CONDENSER
COIL
FINS PER INCH
FACE AREA (Sq. Ft.)
13
36
1
20
15
43.3
~
43.3
~
5 TON HERMETIC (RECIP.)
10 TON TANDEM (RECIP.)
1*
~
~
COMPRESSOR
(Qty. Per Unit)
10 TON SCROLL
~
2
~
12.5 TON
~
~
2
QUANTITY PER UNIT (12" X 24" X 2" or 4”)
QUANTITY PER UNIT (16" X 20" X 2" or 4”)
QUANTITY PER UNIT (16" X 25" X 2" or 4”)
QUANTITY PER UNIT (18" X 24" X 2" or 4”)
TOTAL FACE AREA (Sq. Ft.)
~
~
12
~
4
~
FILTERS
CHARGE
~
4
~
5
~
~
15
16
7/8
1900
2100
2140
20
24
SYSTEM No.1
SYSTEM No. 2
COOLING ONLY
19/0
16/4
2100
2300
2340
160
25/8
24/8
2709
2909
2971
REFRIGERANT
22 (Lb./Oz.)
BASIC UNIT
N24
N32
GAS / ELECTRIC
ECONOMIZER
ECONOMIZER WITH
POWER EXHAUST
245
MOTORIZED DAMPER
150
25
18 KW
36 KW
54 KW
72 KW
OPERATING
WEIGHTS
(LBS.)
30
ELECTRIC HEATER
35
40
ROOF CURB
175
200
185
45
185
220
BAROMETRIC DAMPER
ECONOMIZER / MOTORIZED
DAMPER RAIN HOOD
55
ECONOMIZER / POWER
EXHAUST RAIN HOOD
90
WOOD SKID
220
* NOTE: This compressor will be energized first.
20
Johnson Controls Unitary Products
356214-XIM-A-0108
TABLE 8: DM ELECTRICAL DATA -WITHOUT POWERED CONVENIENCE OUTLET
COMPRESSORS
HEATER OPTION
MAX.
FUSE/
BRKR1
SIZE
ID
MIN.
OD FAN
MOTORS
FLA EACH
CONV
OUTLET
AMPS
MODEL
TONNAGE
BLOWER
MOTOR
FLA
CIRCUIT
AMPACITY
(AMPS)
VOLTAGE
RLA
LRA
MODEL KW STAGES AMPS
EACH EACH
(AMPS)
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
0.0
-
-
46.0
46.0
53.3
74.6
96.0
46.0
46.0
57.2
80.6
85.2
62.5
62.5
62.5
80.6
100.3
62.5
62.5
62.3
84.6
89.2
74.7
76.0
76.0
87.9
109.4
74.7
76.0
76.0
94.0
98.6
50
50
11.3
22.6
33.8
45.1
0.0
1
2
2
2
-
17.1
34.3
51.4
68.6
-
380
9.6
9.6
62
62
2.1
2.1
2.1
2.1
2.1
2.1
8.3
8.3
11.7
11.5
19
0.0
0.0
0.0
0.0
0.0
0.0
60
80
100
50
15
20
25
13.5
26.9
40.4
53.8
0.0
1
2
2
2
-
18.7
37.4
56.2
74.9
-
50
415
380
415
380
415
60
90
100
80
11.3
22.6
33.8
45.1
0.0
1
2
2
2
-
17.1
34.3
51.4
68.6
-
80
20.7
20.7
22.9
22.9
130
130
145
145
80
90
110
80
13.5
26.9
40.4
53.8
0.0
1
2
2
2
-
18.7
37.4
56.2
74.9
-
80
80
90
100
90
11.3
22.6
33.8
45.1
0.0
1
2
2
2
-
17.1
34.3
51.4
68.6
-
90
90
90
110
90
13.5
26.9
40.4
53.8
1
2
2
2
18.7
37.4
56.2
74.9
90
19
90
100
110
Note 1: HACR Type per NEC.
Johnson Controls Unitary Products
21
356214-XIM-A-0108
TABLE 9: DM ELECTRICAL DATA -WITH POWERED CONVENIENCE OUTLET
COMPRESSORS
HEATER OPTION
MAX.
FUSE/
BRKR1
SIZE
ID
MIN.
CIRCUIT
AMPACITY
(AMPS)
OD FAN
MOTORS
FLA EACH
CONV
OUTLET
AMPS
MODEL
TONNAGE
BLOWER
MOTOR
FLA
VOLTAGE
RLA
LRA
MODEL KW STAGES AMPS
EACH EACH
(AMPS)
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
None
E18
E36
E54
E72
0.0
-
-
52.3
52.3
61.2
82.4
103.9
52.3
52.3
65.0
88.5
93.1
68.8
68.8
68.8
86.7
108.2
68.8
68.8
69.0
92.5
97.1
82.3
82.3
82.3
95.8
117.3
82.3
82.3
82.3
101.9
106.5
50
60
11.3
22.6
33.8
45.1
0.0
1
2
2
2
-
17.1
34.3
51.4
68.6
-
380
9.6
9.6
62
62
2.1
2.1
2.1
2.1
2.1
2.1
8.3
8.3
11.7
11.5
19
6.3
6.3
6.3
6.3
6.3
6.3
70
90
110
50
15
20
25
13.5
26.9
40.4
53.8
0.0
1
2
2
2
-
18.7
37.4
56.2
74.9
-
60
415
380
415
380
415
70
90
100
80
11.3
22.6
33.8
45.1
0.0
1
2
2
2
-
17.1
34.3
51.4
68.6
-
80
20.7
20.7
22.9
22.9
130
130
145
145
80
90
110
80
13.5
26.9
40.4
53.8
0.0
1
2
2
2
-
18.7
37.4
56.2
74.9
-
80
80
100
100
100
100
100
100
125
100
100
100
110
110
11.3
22.6
33.8
45.1
0.0
1
2
2
2
-
17.1
34.3
51.4
68.6
-
13.5
26.9
40.4
53.8
1
2
2
2
18.7
37.4
56.2
74.9
19
Note 1: HACR Type per NEC.
22
Johnson Controls Unitary Products
356214-XIM-A-0108
ECONOMIZER / MOTORIZED DAMPER,
FIXED OUTDOOR INTAKE AIR AND
POWER EXHAUST RAIN HOODS
(See detail "Y")
BLOWER
ACCESS
BLOWER MOTOR
ACCESS
FIELD-SUPPLIED
DISCONNECT SWITCH
LOCATION
COMPRESSOR
ACCESS
BLOWER
COMPARTMENT
ACCESS
COIL
GUARD
(Auxiliary)
DOT PLUG
(For pressure
Drop Reading)
48-5/8"(15 TON)
52-5/8" (20, 25 TON)
ELECTRIC/
GAS HEAT
ACCESS
CONDENSER
COILS
VENT AIR
OUTLET
HOODS
21"
5"
7-1/8"
COMBUSTION
AIR INLET
HOOD
6-3/8"
9-3/4"
5-7/8"
92"
)
(C)
(A)
GAS SUPPLY
ENTRY
CONTROL WIRING
ENTRY
46-5/8"
CONTROL BOX
ACCESS
11-1/2"
(B)
35"
POWER WIRING
ENTRY
BOTTOM SUPPLY
AND RETURN
AIR OPENINGS
(See Note)
FRONT
VIEW
RETURN
AIR
3-3/4"
33"
SUPPLY
AIR
2-3/4" 21-1/2"
11-1/8"
All dimensions are in inches. They are
subject to change without notice. Certified
dimensions will be provided upon request.
UNIT BASE WITH RAILS
(B)
(D)
Shown separately to illustrate
Bottom Duct openings, Power
and Gas Piping Connection
locations
POWER WIRING
ENTRY
GAS SUPPLY
ENTRY
(A)
CONTROL WIRING
ENTRY
8-1/8"
NOTE:
46-5/8"
For curb mounted units, refer to the curb hanger
dimensions of the curb for the proper size of the
supply and return air duct connections.
9-1/4"
12-1/2"
9-3/4"
UTILITIES ENTRY DATA
HOLE
A
OPENING SIZE (DIA.)
USED FOR
29 / 1-1/8” KO
Side
Control Wiring
Power Wiring
19 / 3/4” NPS (Fem.)
92 / 3-5/8” KO
Bottom
Side
Bottom
1
B
76 / 3” NPS (Fem.)
60 / 2-3/8” KO
C
D
Gas Piping (Front)
2
43 / 1-11/16” Hole
Gas Piping (Bottom)
1.
2.
One-inch gas piping NPT required.
Opening in the bottom of the unit can be located by the slice in the
insulation.
NOTE: All entry holes should be field sealed to prevent rain
water entry into the building.
FIGURE 13 - FRONT VIEW DIMENSIONS (15, 20 & 25 TON)
Johnson Controls Unitary Products
23
356214-XIM-A-0108
EVAPORATOR
SECTION
DOT PLUG
(For pressure
drop reading)
40-3/8"
FILTER
ACCESS
SUPPLY
AIR
RETURN
AIR
COMPRESSOR
ACCESS
OUTDOOR
AIR
40-1/2"
SUPPLY AIR
ACCESS
18-5/8"
1" NPT FEMALE
COND. DRAIN
CONNECTION
27-3/4"
Dimensions listed are for side
5-1/8"
RETURN AIR
ACCESS
duct flange openings; see
Field Accessories for Side
Duct Flange Kit.
OUTDOOR AIR
COMPARTMENT
ACCESS
28-5/8” (15 TON)
39-5/8" (20, 25 TON)
REAR
VIEW
FIGURE 14 - REAR VIEW DIMENSIONS
NOTE: Units are shipped with the bottom duct open-
ings covered. An accessory flange kit is avail-
able for connecting side ducts.
For bottom duct applications:
For side duct applications:
1. Remove the side panels from the supply and return air
compartments to gain access to the bottom supply and
return air duct covers.
1. Replace the side panels on the supply and return air
compartments with the side duct flange accessory kit
panels.
2. Remove and discard the bottom duct covers. Duct
openings are closed with sheet metal covers except
when the unit includes a power exhaust option. The
covering consists of a heavy black paper composition.
2. Connect ductwork to the flanges on those panels.
3. Replace the side supply and return air compartment
panels.
24
Johnson Controls Unitary Products
356214-XIM-A-0108
NOTE: ELEC / ELEC Models: Units and ductwork are
approved for zero clearance to combustible material
when equipped with electric heaters.
CLEARANCES
LOCATION
Front
CLEARANCE
914 / 36”
610 / 24” (Less Economizer)
1245 / 49” (With Economizer)
Rear
GAS / ELEC Models: A 25mm/1” clearance must be
provided between any combustible material and the
supply air ductwork for a distance of .9 meter/3 feet
from the unit.
610 / 24” (Less Economizer)
1372 / 54” (With Economizer)
Left Side (Filter Access)
Right Side (Cond. Coil)
3
914 / 36”
0 / 0”
1
Below Unit
The products of combustion must not be allowed to
accumulate within a confined space and recirculate.
1829 / 72” With 914 / 36”
Maximum Horizontal Overhang
(For Condenser Air Discharge)
2
Above Unit
Locate unit so that the vent air outlet hood is at
least:
1.
Units may be installed on combustible floors made from wood
or class A, B, or C roof covering material.
2.
Units must be installed outdoors. Overhanging structures or
shrubs should not obstruct condenser air discharge outlet.
3. If economizer is factory installed, the unassembled rain hood
must be removed from its ride along position in front of evapo-
rator coil, or in the outdoor air compartment, prior to final instal-
lation.
•
•
•
9 meters/3 feet above any force air inlet located
within 3.0 meters/10 horizontal feet (excluding
those integral to the unit).
1.2 meters/4 feet below, four horizontal feet
from, or one foot above any door or gravity air
inlet into the building.
1.2 meters/4 feet from electric and gas meters,
regulators and relief equipment.
ECONOMIZER
MOTORIZED
DAMPER
POWER EXHAUST
RAIN HOOD
(on Return Air Compartment)
SUPPLY AIR
RAIN HOOD
(on Outdoor Air Compartment)
COMPARTMENT
ECONOMIZER / MOTORIZED DAMPER
AND POWER EXHAUST RAIN HOODS
FIXED
OUTDOOR AIR
INTAKE HOOD
(located on
Return Air
Compartment)
930
(36-5/8”)
25 (1“) CONDENSATE
DRAIN
(Must be trapped)
410
(16-1/8”)
127 (5”)
716
(28-3/16”)
2337
(92”)
REAR VIEW
LH VIEW
DETAIL “Y”
FIGURE 15 - UNIT CLEARANCES AND RAIN HOOD DIMENSIONS (15, 20 & 25 TON)
Johnson Controls Unitary Products
25
356214-XIM-A-0108
order to use the indoor blower tables for high altitude applica-
tions, certain corrections are necessary.
CFM, STATIC PRESSURE, AND POWER -
ALTITUDE AND TEMPERATURE CORRECTIONS
A centrifugal fan is a "constant volume" device. This means
that, if the rpm remains constant, the CFM delivered is the
same regardless of the density of the air. However, since the
air at high altitude is less dense, less static pressure will be
generated and less power will be required than a similar
application at sea level. Air density correction factors are
The information below should be used to assist in application
of product when being applied at altitudes at or exceeding
1000 feet above sea level.
The air flow rates listed in the standard blower performance
tables are based on standard air at sea level. As the altitude
or temperature increases, the density of air decreases. In
TABLE 10: ALTITUDE CORRECTION FACTORS
ALTITUDE (METER)
AIR TEMP
°C
0
305
610
914
1219
0.916
0.898
0.880
0.864
0.848
0.833
0.817
1524
0.882
0.864
0.848
0.832
0.817
0.802
0.787
1829
0.849
0.832
0.816
0.801
0.787
0.772
0.758
2134
0.818
0.802
0.787
0.772
0.758
0.744
0.730
2438
0.788
0.772
0.757
0.743
0.730
0.716
0.703
2743
0.758
0.743
0.729
0.715
0.702
0.689
0.676
3048
0.729
0.715
0.701
0.688
0.676
0.663
0.651
4.4
10
1.060
1.039
1.019
1.000
0.982
0.964
0.946
1.022
1.002
0.982
0.964
0.947
0.929
0.912
0.986
0.966
0.948
0.930
0.913
0.897
0.880
0.950
0.931
0.913
0.896
0.880
0.864
0.848
15.5
21
26.6
32
38
ALTITUDE (FEET)
AIR TEMP
°F
0
1000
1.022
1.002
0.982
0.964
0.947
0.929
0.912
2000
0.986
0.966
0.948
0.930
0.913
0.897
0.880
3000
0.950
0.931
0.913
0.896
0.880
0.864
0.848
4000
0.916
0.898
0.880
0.864
0.848
0.833
0.817
5000
0.882
0.864
0.848
0.832
0.817
0.802
0.787
6000
0.849
0.832
0.816
0.801
0.787
0.772
0.758
7000
0.818
0.802
0.787
0.772
0.758
0.744
0.730
8000
0.788
0.772
0.757
0.743
0.730
0.716
0.703
9000
0.758
0.743
0.729
0.715
0.702
0.689
0.676
10000
0.729
0.715
0.701
0.688
0.676
0.663
0.651
40
50
1.060
1.039
1.019
1.000
0.982
0.964
0.946
60
70
80
90
100
The examples below will assist in determining the airflow per-
formance of the product at altitude.
blower tables to select the blower speed and the BHP
requirement.
Example 1: What are the corrected CFM, static pressure,
and BHP at an elevation of 5,000 ft. if the blower performance
data is 6,000 CFM, 1.5 IWC and 4.0 BHP?
Solution: As in the example above, no temperature informa-
tion is given so 70°F is assumed.
The 1.5" static pressure given is at an elevation of 5,000 ft.
The first step is to convert this static pressure to equivalent
sea level conditions.
Solution: At an elevation of 5,000 ft the indoor blower will still
deliver 6,000 CFM if the rpm is unchanged. However, Table
Since no temperature data is given, we will assume an air
be 0.832.
Sea level static pressure = 1.5 / .832 = 1.80"
Enter the blower table at 6000 sCFM and static pressure of
1.8". The rpm listed will be the same rpm needed at 5,000 ft.
Corrected static pressure = 1.5 x 0.832 = 1.248 IWC
Corrected BHP = 4.0 x 0.832 = 3.328
Suppose that the corresponding BHP listed in the table is 3.2.
This value must be corrected for elevation.
Example 2: A system, located at 5,000 feet of elevation, is to
BHP at 5,000 ft = 3.2 x .832 = 2.66
deliver 6,000 CFM at a static pressure of 1.5". Use the unit
26
Johnson Controls Unitary Products
356214-XIM-A-0108
TABLE 11: SUPPLY AIR BLOWER PERFORMANCE (15 TON) - COOLING ONLY
180 MBH - BOTTOM DUCT CONNECTIONS
AIRFLOW
MOTOR
BLOWER
SPEED,
(RPM)
3
3
3
3
3
PULLEY
(TURNS
OPEN)*
2.10 m /s
2.45 m /s
2.80 m /s
3.10 m /s
3.40 m /s
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
3
HIGH STATIC DRIVE (m /s)
1030
1070
1115
1155
1200
1240
6.0
5.0
4.0
3.0
2.0
1.0
357
405
461
514
577
636
2.4
2.5
2.7
2.9
3.1
3.3
2.8
3.0
3.2
3.4
3.7
3.9
316
362
416
468
529
587
2.8
3.0
3.2
3.4
3.6
3.8
3.4
3.6
3.8
4.0
4.3
4.5
253
298
351
401
461
-
3.3
3.5
3.7
3.9
4.1
-
3.9
4.2
4.4
4.7
5.0
-
183
3.7
3.9
4.2
-
4.5
4.7
5.0
-
97
-
4.2
5.0
226
-
-
-
-
-
-
-
-
-
-
278
-
-
-
-
-
-
-
-
-
-
-
AIRFLOW
5930 CFM
MOTOR
PULLEY
(TURNS
OPEN)*
BLOWER
SPEED,
(RPM)
4450 CFM
5190 CFM
6565 CFM
7200 CFM
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
(kW)
(kW)
(kW)
(kW)
(kW)
HIGH STATIC DRIVE (CFM)
1030
1070
1115
1155
1200
1240
6.0
5.0
4.0
3.0
2.0
1.0
1.4
1.6
1.9
2.1
2.3
2.6
3.2
3.4
3.6
3.9
4.1
4.4
2.8
3.0
3.2
3.4
3.7
3.9
1.3
1.5
1.7
1.9
2.1
2.4
3.8
4.0
4.3
4.5
4.8
5.1
3.4
3.6
3.8
4.0
4.3
4.5
1.0
1.2
1.4
1.6
1.8
-
4.4
4.7
5.0
5.2
5.5
-
3.9
4.2
4.4
4.7
5.0
-
0.7
0.9
1.1
-
5.0
5.3
5.6
-
4.5
4.7
5.0
-
0.4
5.6
5.0
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
NOTES: 1.Blower performance includes fixed outdoor air, 2” T/A filters, a dry evaporator coil and no electric heat.
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total
static pressure of the blower.
* Do NOT close the pulley below 1 turn open.
** Factory setting.
28
Johnson Controls Unitary Products
356214-XIM-A-0108
TABLE 12: SUPPLY AIR BLOWER PERFORMANCE (20 TON) - COOLING ONLY
240 MBH - BOTTOM DUCT CONNECTIONS
AIRFLOW
MOTOR
BLOWER
SPEED,
(RPM)
3
3
3
3
3
PULLEY
(TURNS
OPEN)*
2.80 m /s
3.30 m /s
3.80 m /s
4.10 m /s
4.40 m /s
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
3
HIGH STATIC DRIVE (m /s)
895
930
6.0
5.0
4.0
3.0
2.0
1.0
312
362
421
473
535
590
3.5
3.7
4.0
4.2
4.4
4.6
4.0
4.3
4.5
4.8
5.0
5.3
268
318
377
429
491
546
3.7
4.0
4.2
4.5
4.8
5.0
4.3
4.5
4.9
5.1
5.5
5.8
198
248
306
359
420
475
4.2
4.5
4.8
5.1
5.4
5.7
4.8
5.1
5.5
5.8
6.2
6.5
143
193
252
304
365
420
4.6
4.9
5.2
5.6
5.9
6.2
5.2
5.6
6.0
6.4
6.8
7.1
79
129
187
240
-
5.1
5.4
5.8
6.1
-
5.8
6.2
6.6
7.0
-
970
1005
1045
1080
-
-
-
AIRFLOW
8050 CFM
MOTOR
PULLEY
(TURNS
OPEN)*
BLOWER
SPEED,
(RPM)
5930 CFM
6990 CFM
8685 CFM
9320 CFM
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
(kW)
(kW)
(kW)
(kW)
(kW)
HIGH STATIC DRIVE (CFM)
895
930
6.0
5.0
4.0
3.0
2.0
1.0
1.3
1.5
1.7
1.9
2.1
2.4
4.7
5.0
5.3
5.6
5.9
6.2
4.0
4.3
4.5
4.8
5.0
5.3
1.1
1.3
1.5
1.7
2.0
2.2
5.0
5.3
5.7
6.0
6.4
6.8
4.3
4.5
4.9
5.1
5.5
5.8
0.8
1.0
1.2
1.4
1.7
1.9
5.6
6.0
6.4
6.8
7.3
7.7
4.8
5.1
5.5
5.8
6.2
6.5
0.6
0.8
1.0
1.2
1.5
1.7
6.1
6.6
7.0
7.4
7.9
8.4
5.2
5.6
6.0
6.4
6.8
7.1
0.3
0.5
0.8
1.0
-
6.8
7.2
7.8
8.2
-
5.8
6.2
6.6
7.0
-
970
1005
1045
1080
-
-
-
NOTES: 1.Blower performance includes fixed outdoor air, 2” T/A filters, a dry evaporator coil and no electric heat.
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total
static pressure of the blower.
* Do NOT close the pulley below 1 turn open.
** Factory setting.
Johnson Controls Unitary Products
29
356214-XIM-A-0108
TABLE 13: SUPPLY AIR BLOWER PERFORMANCE (15 TON) - GAS HEAT
180 MBH - BOTTOM DUCT CONNECTIONS
AIRFLOW
MOTOR
BLOWER
SPEED,
(RPM)
3
3
3
3
3
PULLEY
(TURNS
OPEN)*
2.10 m /s
2.45 m /s
2.80 m /s
3.10 m /s
3.40 m /s
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
3
HIGH STATIC DRIVE (m /s)
1030
1070
1115
1155
1200
1240
6.0
5.0
4.0
3.0
2.0
1.0
378
417
461
502
548
590
2.3
2.4
2.6
2.8
3.0
3.2
2.7
2.9
3.1
3.3
3.6
3.8
321
361
407
448
495
538
2.7
2.9
3.1
3.3
3.6
3.8
3.2
3.4
3.7
4.0
4.3
4.6
258
299
345
387
435
-
3.2
3.4
3.7
3.9
4.2
-
3.8
4.1
4.4
4.7
5.0
-
199
3.6
3.9
4.2
-
4.4
4.7
5.0
-
134
4.2
5.0
240
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
286
-
-
-
-
-
-
-
AIRFLOW
5930 CFM
MOTOR
PULLEY
(TURNS
OPEN)*
BLOWER
SPEED,
(RPM)
4450 CFM
5190 CFM
6565 CFM
7200 CFM
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
(kW)
(kW)
(kW)
(kW)
(kW)
HIGH STATIC DRIVE (CFM)
1030
1070
1115
1155
1200
1240
6.0
5.0
4.0
3.0
2.0
1.0
1.5
1.7
1.9
2.0
2.2
2.4
3.1
3.3
3.5
3.7
4.0
4.3
2.7
2.9
3.1
3.3
3.6
3.8
1.3
1.4
1.6
1.8
2.0
2.2
3.6
3.8
4.1
4.4
4.8
5.1
3.2
3.4
3.7
4.0
4.3
4.6
1.0
1.2
1.4
1.6
1.7
-
4.3
4.5
4.9
5.2
5.6
-
3.8
4.1
4.4
4.7
5.0
-
0.8
1.0
1.2
-
4.9
5.2
5.6
-
4.4
4.7
5.0
-
0.5
5.6
5.0
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
NOTES: 1.Blower performance includes a gas-fired heat exchanger, fixed outdoor air, two-inch T/A filters and a dry evaporator coil.
2.Refer to the additional Static Resistances table.
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total
static pressure of the blower.
* Do NOT close the pulley below 1 turn open.
** Factory setting.
30
Johnson Controls Unitary Products
356214-XIM-A-0108
TABLE 14: SUPPLY AIR BLOWER PERFORMANCE (20 TON) - GAS HEAT
240 MBH - BOTTOM DUCT CONNECTIONS
AIRFLOW
MOTOR
BLOWER
SPEED,
(RPM)
3
3
3
3
3
PULLEY
(TURNS
OPEN)*
2.80 m /s
3.30 m /s
3.80 m /s
4.10 m /s
4.40 m /s
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
ESP
(Pa)
Output Input
(kW)
(kW)
(kW)
(kW)
(kW)
(kW)
3
HIGH STATIC DRIVE (m /s)
895
925
6.0
5.0
4.0
3.0
2.0
1.0
0.0
361
400
439
486
527
569
612
2.8
2.9
3.1
3.3
3.5
3.7
3.9
3.2
3.4
3.6
3.8
4.0
4.2
4.4
249
290
332
381
425
469
514
3.5
3.7
3.9
4.1
4.3
4.6
4.8
4.0
4.2
4.4
4.7
5.0
5.2
5.5
114
157
201
254
299
346
393
4.3
4.5
4.7
5.0
5.2
5.5
5.8
4.9
5.1
5.4
5.7
6.0
6.3
6.6
22
4.7
5.0
5.2
5.5
5.8
6.1
6.4
5.4
5.7
6.0
6.3
6.7
7.0
7.3
-
-
-
-
-
-
66
955
112
166
213
261
310
15
70
119
-
5.8
6.1
6.4
-
6.6
7.0
7.3
-
990
1020
1050
1080
-
-
-
AIRFLOW
8050 CFM
MOTOR
PULLEY
(TURNS
OPEN)*
BLOWER
SPEED,
(RPM)
5930 CFM
6990 CFM
8685 CFM
9320 CFM
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
ESP
(iwg)
Output Input
(bhp)
(kW)
(kW)
(kW)
(kW)
(kW)
HIGH STATIC DRIVE (CFM)
895
925
6.0
5.0
4.0
3.0
2.0
1.0
0.0
1.5
1.6
1.8
2.0
2.1
2.3
2.5
3.7
3.9
4.2
4.4
4.7
4.9
5.2
3.2
3.4
3.6
3.8
4.0
4.2
4.4
1.0
1.2
1.3
1.5
1.7
1.9
2.1
4.7
4.9
5.2
5.5
5.8
6.1
6.4
4.0
4.2
4.4
4.7
5.0
5.2
5.5
0.5
0.6
0.8
1.0
1.2
1.4
1.6
5.7
6.0
6.3
6.7
7.0
7.4
7.7
4.9
5.1
5.4
5.7
6.0
6.3
6.6
0.1
0.3
0.4
0.7
0.9
1.0
1.2
6.3
6.7
7.0
7.4
7.8
8.2
8.5
5.4
5.7
6.0
6.3
6.7
7.0
7.3
-
-
-
-
-
-
955
0.1
0.3
0.5
-
7.8
8.2
8.6
-
6.6
7.0
7.3
-
990
1020
1050
1080
NOTES: 1.Blower performance includes a gas-fired heat exchanger, fixed outdoor air, two-inch T/A filters and a dry evaporator coil.
2.Refer to the additional Static Resistances table.
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total
static pressure of the blower.
* Do NOT close the pulley below 1 turn open.
** Factory setting.
Johnson Controls Unitary Products
31
356214-XIM-A-0108
TABLE 15: SUPPLY AIR BLOWER PERFORMANCE (25 TON) - COOLING APPLICATIONS
300 MBH - BOTTOM DUCT CONNECTIONS
DM300 UNIT - DOWNFLOW DUCT CONNECTIONS (CFM)
7500 CFM
8750 CFM
10000 CFM
INPUT
BLOWER
SPEED (rpm) TURNS OPEN
PULLEY
INPUT
(kW)
ESP (iwg) OUTPUT (bhp) INPUT (kW) ESP (iwg) OUTPUT (bhp)
ESP (iwg) OUTPUT (bhp)
(kW)
6.9
7.2
7.6
8.0
8.3
8.7
9.0
945
975
6.0
5.0
4.0
3.0
2.0
1.0
0.0
1.2
1.4
1.6
1.8
2.0
2.1
2.3
5.6
5.9
6.2
6.6
6.9
7.3
7.6
4.6
4.9
5.1
5.4
5.7
6.0
6.2
0.8
1.0
1.2
1.4
1.6
1.8
2.0
7.0
7.3
7.7
8.1
8.5
8.9
9.3
5.7
6.0
6.3
6.7
7.0
7.3
7.6
0.3
0.5
0.7
0.9
1.1
1.3
1.5
8.4
8.8
1005
1040
1070
1100
1130
9.2
9.7
10.2
10.6
11.0
3
DM300 UNIT - DOWNFLOW DUCT CONNECTIONS (m /s)
3
3
3
3.53 m /Sec.
4.13 m /Sec.
4.72 m /Sec.
BLOWER
SPEED (rpm) TURNS OPEN
PULLEY
INPUT
(kW)
INPUT
(kW)
ESP (Pa) OUTPUT(bhp) INPUT (kW) ESP (Pa) OUTPUT (bhp)
ESP (Pa) OUTPUT(bhp)
945
975
6.0
5.0
4.0
3.0
2.0
1.0
0.0
303
347
391
443
489
536
583
5.6
5.9
6.2
6.6
6.9
7.3
7.6
4.6
4.9
5.1
5.4
5.7
6.0
6.2
198
244
291
347
396
445
495
7.0
7.3
7.7
8.1
8.5
8.9
9.3
5.7
6.0
6.3
6.7
7.0
7.3
7.6
71
8.4
8.8
6.9
7.2
7.6
8.0
8.3
8.7
9.0
120
169
228
280
332
385
1005
1040
1070
1100
1130
9.2
9.7
10.2
10.6
11.0
DM300 UNIT - DOWNFLOW DUCT CONNECTIONS - GAS HEAT MODELS (CFM)
7500 CFM
8750 CFM
10000 CFM
BLOWER
SPEED (rpm) TURNS OPEN
PULLEY
INPUT
(kW)
INPUT
(kW)
ESP (iwg) OUTPUT (bhp) INPUT (kW) ESP (iwg) OUTPUT (bhp)
ESP (iwg) OUTPUT (bhp)
945
975
6.0
5.0
4.0
3.0
2.0
1.0
0.0
1.0
1.2
1.4
1.6
1.8
2.0
2.2
5.6
5.9
6.2
6.6
6.9
7.3
7.6
4.6
4.9
5.1
5.4
5.7
6.0
6.2
0.3
0.5
0.7
0.9
1.1
1.3
1.5
7.0
7.3
7.7
8.1
8.5
8.9
9.3
5.7
6.0
6.3
6.7
7.0
7.3
7.6
-
-
-
-
-
-
1005
1040
1070
1100
1130
-
-
-
0.2
0.4
0.6
0.8
9.7
10.2
10.6
11.0
8.0
8.3
8.7
9.0
3
DM300 UNIT - DOWNFLOW DUCT CONNECTIONS - GAS HEAT MODELS (m /s)
3
3
3
3.53 m /sec.
4.13 m /sec.
4.72 m /sec.
BLOWER
SPEED (rpm) TURNS OPEN
PULLEY
INPUT
(kW)
INPUT
(kW)
ESP (Pa) OUTPUT (bhp) INPUT (kW) ESP (Pa) OUTPUT (bhp)
ESP (Pa) OUTPUT (bhp)
945
975
6.0
5.0
4.0
3.0
2.0
1.0
0.0
258
301
345
398
444
490
537
5.6
5.9
6.2
6.6
6.9
7.3
7.6
4.6
4.9
5.1
5.4
5.7
6.0
6.2
87
7.0
7.3
7.7
8.1
8.5
8.9
9.3
5.7
6.0
6.3
6.7
7.0
7.3
7.6
-
-
-
-
133
180
236
285
334
384
-
-
1005
1040
1070
1100
1130
-
-
-
43
94
146
199
9.7
10.2
10.6
11.0
8.0
8.3
8.7
9.0
NOTES: 1.Blower performance includes a gas-fired heat exchanger, fixed outdoor air, two-inch T/A filters and a dry evaporator coil.
2.Refer to the additional Static Resistances table.
ESP = External Static Pressure available for the supply and return air duct system. All internal unit resistances have been deducted from the total
static pressure of the blower.
* Do NOT close the pulley below 1 turn open.
** Factory setting.
32
Johnson Controls Unitary Products
356214-XIM-A-0108
1
TABLE 16: STATIC RESISTANCES
RESISTANCE, Pa/IWG
3
m /s/CFM
DESCRIPTION
MODEL 180
MODEL 240
MODEL 300
2.1/4500 2.8/6000 3.4/7200 2.8/6000 3.8/8000 4.4/9400 3.78/8000
4.25/9000 4.72/10000
WET COIL
GAS HEAT
24.8/0.1
24.8/0.1
24.8/0.1
24.8/0.1
50.0/0.2
50.0/0.2
24.8/0.1
50.0/0.2
24.8/0.1
24.8/0.1
24.8/0.1
50.0/0.2
74.4/0.3
24.8/0.1
24.8/0.1
24.8/0.1
74.4/0.3
99.2/0.4
24.8/0.1
24.8/0.1
24.8/0.1
24.8/0.1
50.0/0.2
24.8/0.1
24.8/0.1
24.8/0.1
50.0/0.2
74.4/0.3
24.8/0.1
24.8/0.1
24.8/0.1
74.4/0.3
99.2/0.4
25/0.1
25/0.1
25/0.1
25/0.1
50/0.2
50/0.2
25/0.1
50/0.2
25/0.1
25/0.1
25/0.1
50/0.2
75/0.3
100/0.4
25/0.1
75/0.3
25/0.1
25/0.1
25/0.1
75/0.3
100/0.4
150/0.6
25/0.1
125/0.5
18 KW
36 KW
54 KW
72 KW
ELECTRIC HEAT OPTIONS
ECONOMIZER OPTION
99.2/0.4 149.0/0.6 50.0/0.2
24.8/0.1 24.8/0.1 24.8/0.1
74.4/0.3 124.0/0.5 50.0/0.2
99.2/0.4 149.0/0.6
24.8/0.1 24.8/0.1
74.4/0.3 124.0/0.5
HORIZONTAL DUCT CONNECTIONS
1.
Deduct these resistance values from the available external static pressures shown in the respective Blower Performance Table except for Horizontal
Duct Connections.
Add these values due to less airflow resistance.
TABLE 17: POWER EXHAUST PERFORMANCE
STATIC RESISTANCE OF RETURN DUCTWORK, IWG
MOTOR
SPEED
0.2
0.3
0.4
0.5
0.6
CFM
5250
4900
4400
KW
0.83
0.77
0.72
CFM
4500
3900
3700
KW
0.85
0.79
0.74
CFM
4200
3500
3000
KW
0.88
0.82
0.78
CFM
3750
2900
-
KW
0.93
0.85
-
CFM
KW
HIGH*
MEDIUM
LOW
3000
0.99
-
-
-
-
* Factory Setting
Power Exhaust motor is a 3/4 HP, PSC type with sleeve bearings, a 48 frame and inherent protection.
TABLE 18: BLOWER MOTOR AND DRIVE DATA
BELT
(NOTCHED)
2
3
FIXED BLOWER PULLEY
PITCH
MOTOR
ADJUSTABLE MOTOR PULLEY
BLOWER
RANGE
(RPM)
MODEL
SIZE
1
DRIVE
PITCH
PITCH
LENGTH QTY.
(mm/IN.)
EFF.
(%)
DESIG-
NATION
BORE
DESIG-
BORE
DESIG-
kW/HP FRAME
DIA.
DIA.
(mm/IN.) NATION
(mm/IN.) NATION
(mm/IN.)
(mm/IN.)
High
Static
109-135
4.3-5.3
180
240
300
1030/1240 3.7/5.0
895-1080 5.6/7.5
950/1130 7.5/10
184 T
213 T
254 T
83
87
89
1VP62
1VP75
29/1-1/8
BK75
175/6.9
239/9.4
25/1
BX68
BX81
1773/69.8
1
1
1
High
Static
140-165
5.5-6.5
4
35/1-3/8
A2
BK100
2103/82.8
2134/84
30/1-3/16
High
Static
1LVP58
B70A
157-188
(6.2-7.4) Bushing
B
1B5V94 241 (9.5)
5VX840
Bushing
1.
2.
All 50 Hz DM180-300 models come standard with factory filtered High Static Drive.
All motors have a nominal speed of 1450 RPM, a 1.15 service factor and a solid base. They can operate to the limit of their service factor because
they are located in the moving air, upstream of any heating device.
3.
4.
Do NOT close this pulley below 1 turn open.
Requires bushing (included in kit).
Johnson Controls Unitary Products
33
356214-XIM-A-0108
PHASING
YORK MODEL DM, units are properly phased at the
factory. Check for proper compressor rotation. If the
blower or compressors rotate in the wrong direction at
start-up, the electrical connection to the unit is mis-
phased. Change the incoming line connection phasing
to obtain proper rotation. (Scroll compressors operate
in only one direction. If the scroll is drawing low amper-
age, has similar suction and discharge pressures, or
producing a high noise level, the scroll is misphased).
Scroll compressors require proper rotation to
operate correctly. Units are properly phased at
the factory. Do not change the internal wiring to
make the blower, condenser fans, or compres-
sor rotate correctly.
CHECKING AIR SUPPLY CFM
The RPM of the supply air blower will depend on the
required CFM, the unit accessories or options and the
static resistances of both the supply and the return air
duct systems. With this information, the RPM for the
supply air blower and the motor pulley adjustment
(turns open) can be determined from the Blower Per-
formance Data Tables.
FIGURE 17 - BELT ADJUSTMENT
Note the following:
1. The supply air CFM must be within the limitations
2. Pulleys can be adjusted in half turn increments.
3. The tension on the belt should be adjusted as
shown in the Belt Adjustment Figure 17.
34
Johnson Controls Unitary Products
356214-XIM-A-0108
Start the supply air blower motor. Adjust the resis-
tances in both the supply and the return air duct sys-
tems to balance the air distribution throughout the
conditioned space. The job specifications may require
that this balancing be done by someone other than the
equipment installer.
measuring the pressure drop across a wet coil
under field conditions would be inaccurate. To
assure a dry coil, the compressors should be deac-
tivated while the test is being run.
4. Knowing the pressure drop across a dry coil, the
actual CFM through the unit can be determined
from the curve in Pressure Drop vs. Supply Air
To check the supply air CFM after the initial balancing
has been completed:
1. Remove the two 5/16" dot plugs from the blower
motor and the filter access panels shown in the
Failure to properly adjust the total system air
quantity can result in extensive blower dam-
age.
2. Insert at least 8" of 1/4 inch tubing into each of
these holes for sufficient penetration into the air
flow on both sides of the indoor coil.
After readings have been obtained, remove the tubes
and reinstall the two 5/16" dot plugs that were removed
in Step 1.
NOTE: The tubes must be inserted and held in a posi-
tion perpendicular to the air flow so that veloc-
ity pressure will not affect the static pressure
readings.
NOTE: DE-ENERGIZE
THE
COMPRESSORS
BEFORE TAKING ANY TEST MEASURE-
MENTS TO ASSURE A DRY INDOOR COIL.
3. Using an inclined manometer, determine the pres-
sure drop across a dry evaporator coil. Since the
moisture on an evaporator coil may vary greatly,
0.65
0.6
0.55
0.5
240 MBH
300 MBH
180 MBH
0.45
0.4
0.35
0.3
0.25
4
5
6
7
8
9
10
11
12
13
NOMINAL CFM (THOUSANDS) SUPPLY AIR
FIGURE 18 - PRESSURE DROP ACROSS A DRY INDOOR COIL VS SUPPLY AIR CFM FOR ALL UNIT
TONNAGES
Johnson Controls Unitary Products
35
356214-XIM-A-0108
condenser fan motor #1, and condenser fan motor #2
for 15 and 20T only (if the ambient temperature is
above 60°F), are energized. After completing the spec-
ified fan on delay for cooling, the UCB will energize the
blower motor.
OPERATION
SEQUENCE OF OPERATIONS OVERVIEW
For these units, the thermostat makes a circuit
between "R" and "Y1" for the first stage of cooling.
When the thermostat calls for the second stage of cool-
ing, the low-voltage control circuit from "R" to "Y2" is
completed. Compressor #2, and condenser fan motor
#2, 25T only (if the ambient temperature is above
60°F), is energized, provided it has not been locked-
out.
The call is passed to the unit control board (UCB),
which then determines whether the requested opera-
tion is available and, if so, which components to ener-
gize.
For gas heating, the UCB monitors the "W1" call but
does not handle the operation of the gas furnace. An
ignition control board controls the gas heater operation.
If there is an initial call for both stages of cooling, the
UCB will delay energizing compressor #2 by 30 sec-
onds in order to avoid a power in rush.
For electric heat units, the UCB passes the call to the
electric heater.
Once the thermostat has been satisfied, it will de-ener-
gize Y1 and Y2. If the compressors have satisfied their
minimum run times, the compressors and condenser
fans are de-energized. Otherwise, the unit operates
each cooling system until the minimum run times for
the compressors have been completed. Upon the final
compressor de-energizing, the blower is stopped fol-
lowing the elapse of the fan off delay for cooling.
In both cases, when the "W1" call is sensed, the indoor
air blower is energized following a specified heating
delay.
If at any time a call for both heating and cooling are
present, the heating operation will be performed. If
operating, the cooling system is halted as with a com-
pletion of a call for cooling. Heating always takes prior-
ity.
To be available, a compressor must not be locked-out
due to a high or low-pressure switch or freezestat trip
and the anti-short cycle delay (ASCD) must have
elapsed.
COOLING SEQUENCE OF OPERATION
CONTINUOUS BLOWER
ECONOMIZER WITH SINGLE ENTHALPY SENSOR -
When the room thermostat calls for "first-stage" cool-
ing, the low voltage control circuit from "R" to "G" and
"Y1" is completed. The UCB energizes the blower
motor (if the fan switch on the room thermostat is set in
the "AUTO" position) and drives the economizer damp-
ers from fully closed to their minimum position. If the
enthalpy of the outdoor air is below the setpoint of the
enthalpy controller (previously determined), "Y1" ener-
gizes the economizer. The dampers will modulate to
maintain a constant supply air temperature as moni-
tored by the discharge air sensor. If the outdoor air
enthalpy is above the setpoint, "Y1" energizes com-
pressor #1, condenser fan motor #1, and condenser
fan motor #2, 15 and 20T only (if the ambient tempera-
ture is above 60°F).
By setting the room thermostat fan switch to "ON," the
supply air blower will operate continuously.
INTERMITTENT BLOWER
With the room thermostat fan switch set to "AUTO" and
the system switch set to either the "AUTO" or "HEAT"
settings, the blower is energized whenever a cooling or
heating operation is requested. The blower is ener-
gized after any specified delay associated with the
operation.
When energized, the indoor blower has a minimum run
time of 30 seconds. Additionally, the indoor blower has
a delay of 10 seconds between operations.
When the thermostat calls for "second-stage" cooling,
the low voltage control circuit from "R" to "Y2" is
completed. The UCB energizes the first available
compressor If the enthalpy of the outdoor air is below
the setpoint of the enthalpy controller (i.e. first stage
NO OUTDOOR AIR OPTIONS
When the thermostat calls for the first stage of cooling,
the low-voltage control circuit from "R" to "Y1" and "G"
is completed. For first stage cooling, compressor #1,
36
Johnson Controls Unitary Products
356214-XIM-A-0108
HIGH-PRESSURE LIMIT SWITCH
has energized the economizer), "Y2" will energize
compressor #1. If the outdoor air is above the setpoint,
"Y2" will energize compressor #2.
During cooling operation, if a high-pressure limit switch
opens, the UCB will de-energize the associated com-
pressor, initiate the ASCD (Anti-short cycle delay), and,
if the other compressor is idle, stop the condenser
fans. If the call for cooling is still present at the conclu-
sion of the ASCD, the UCB will re-energize the halted
compressor.
Once the thermostat has been satisfied, it will de-ener-
gize Y1 and Y2. If the compressors have satisfied their
minimum run times, the compressors and condenser
fans are de-energized. Otherwise, the unit operates
each cooling system until the minimum run times for
the compressors have been completed. Upon the final
compressor de-energizing, the blower is stopped fol-
lowing the elapse of the fan off delay for cooling, and
the economizer damper goes to the closed position. If
the unit is in continues fan operation the economizer
damper goes to the min. position.
Should a high-pressure switch open three times within
two hours of operation, the UCB will lock-out the asso-
ciated compressor and flash a code (see Table 24). If
the other compressor is inactive, the condenser fans
will be de-energized.
LOW-PRESSURE LIMIT SWITCH
ECONOMIZER WITH DUAL ENTHALPY SENSORS -
The low-pressure limit switch is not monitored during
the initial 30 seconds of a cooling system's operation.
For the following 30 seconds, the UCB will monitor the
low-pressure switch to ensure it closes. If the low-pres-
sure switch fails to close after the 30-second monitor-
ing phase, the UCB will de-energize the associated
compressor, initiate the ASCD, and, if the other com-
pressor is idle, stop the condenser fans.
The operation with the dual enthalpy sensors is identi-
cal to the single sensor except that a second enthalpy
sensor is mounted in the return air. This return air sen-
sor allows the economizer to choose between outdoor
air and return air, whichever has the lowest enthalpy
value, to provide maximum operating efficiency.
ECONOMIZER (SINGLE OR DUAL ENTHALPY) WITH
POWER EXHAUST -
Once the low-pressure switch has been proven (closed
during the 30-second monitor period described above),
the UCB will monitor the low-pressure limit switch for
any openings. If the low-pressure switch opens for
greater than 5 seconds, the UCB will de-energize the
associated compressor, initiate the ASCD, and, if the
other compressor is idle, stop the condenser fans.
This system operates as specified above with one
addition. The power exhaust motor is energized 45
seconds after the actuator position exceeds the
exhaust fan setpoint on the economizer control. When
the power exhaust is operating, the second stage of
mechanical cooling will not operate. As always, the "R"
to "G" connection provides minimum position but does
not provide power exhaust operation.
If the call for cooling is still present at the conclusion of
the ASCD, the UCB will re-energize the halted com-
pressor.
MOTORIZED OUTDOOR AIR DAMPERS -
This system operation is the same as the units with no
outdoor air options with one exception. When the "R" to
"G" circuit is complete, the motorized damper drives
open to a position set by the thumbwheel on the
damper motor. When the "R" to "G" circuit is opened,
the damper spring returns fully closed.
Should a low-pressure switch open three times within
one hour of operation, the UCB will lock-out the associ-
other compressor is inactive, the condenser fans will
be de-energized.
FREEZESTAT
COOLING OPERATION ERRORS
During cooling operation, if a freezestat opens, the
UCB will de-energize the associated compressor, initi-
ate the ASCD, and, if the other compressor is idle, stop
the condenser fans. If the call for cooling is still present
at the conclusion of the ASCD, the UCB will re-ener-
gize the halted compressor.
Each cooling system is monitored for operation outside
of the intended parameters. Errors are handled as
described below. All system errors override minimum
run times for compressors.
Johnson Controls Unitary Products
37
356214-XIM-A-0108
Should a freezestat open three times within two hours
of operation, the UCB will lock-out the associated com-
pressor is inactive, the condenser fans will be de-
energized.
The other refrigerant system will continue in operation
unless it is affected by the fault as well.
The unit control board monitors the temperature limit
switch of electric heat units and the temperature limit
switch and the gas valve of gas furnace units.
LOW AMBIENT COOLING
COMPRESSOR PROTECTION
To determine when to operate in low ambient mode,
the UCB has a pair of terminals connected to a temper-
ature-activated switch set at 30ºF. When the low ambi-
ent switch is closed and the thermostat is calling for
cooling, the UCB will operate in the low ambient mode.
The compressors also have inherent (internal) protec-
tion. If there is an abnormal temperature rise in a com-
pressor, the protector will open to shut down the
compressor. The UCB incorporates features to mini-
mize compressor wear and damage. An anti-short
cycle delay (ASCD) is utilized to prevent operation of a
compressor too soon after its previous run. Addition-
ally, a minimum run time is imposed any time a com-
pressor is energized.
Low ambient mode operates the compressors in this
manner: 10 minutes on, 5 minutes off. The indoor
blower is operated throughout the cycle. The 5-minute
off period is necessary to defrost the indoor coil.
Low ambient mode always begins with compressor
operation. Compressor minimum run time may extend
the minutes of compressor operation. The defrost cycle
will begin immediately following the elapse of the mini-
mum run time.
The ASCD is initiated on unit start-up and on any com-
pressor reset or lock-out.
FLASH CODES
The UCB will initiate a flash code associated with
errors within the system. Refer to UNIT CONTROL
BOARD FLASH CODES Table 24.
When operating in low ambient mode, the UCB will not
lockout the compressors due to a freezestat trip. How-
ever, a freezestat trip will de-energize the associated
compressor. If the call for cooling is still present at the
end of the ASCD and the freezestat has closed, the
unit will resume operation.
RESET
Remove the call for cooling, by raising thermostat set-
ting higher than the conditioned space temperature.
This resets any pressure or freezestat flash codes.
SAFETY CONTROLS
The unit control board monitors the following inputs for
each cooling system:
ELECTRIC HEATING SEQUENCE OF OPERATIONS
The following sequence describes the operation of the
electric heat section.
1. A suction line freezestat to protect against low
evaporator temperatures due to a low airflow or a
low return air temperature, (opens at 26 ± 5 °F and
resets at 38 ± 5°F).
Single-stage heating (applies only to 18 KW heater, all
other heaters MUST use a two-stage thermostat):
2. A high-pressure switch to protect against exces-
sive discharge pressures due to a blocked con-
denser coil or a condenser motor failure, (opens at
380 ± 10 psig and resets at 300 ± 10 psig).
a. Upon a call for heat by the thermostat, the heater
contactor (6M) will be energized. After completing
the specified fan on delay for heating, the UCB will
energize the blower motor.
b. The thermostat will cycle the electric heat to satisfy
the heating requirements of the conditioned space.
3. A low-pressure switch to protect against loss of
refrigerant charge, (opens at 22 ± 5 psig and resets
at 45 ± 5 psig).
Two-stage heating (applies to all heaters except 18
KW):
The above pressure switches are hard-soldered to the
unit. The refrigeration systems are independently mon-
itored and controlled. On any fault, only the associated
system will be affected by any safety/preventive action.
a. Upon a call for first-stage heat by the thermostat, the
heater contactor (6M) (6M & 7M on 72 KW, 240V)
will be energized. After completing the specified fan
38
Johnson Controls Unitary Products
356214-XIM-A-0108
on delay for heating, the UCB will energize the
blower motor.
manual reset limit. These limit switches will de-
energize the heaters should the primary limit fail to
open or the contactors fail to open in a failure
mode.
If the second stage of heat is required, heater con-
tactor (7M) will be energized. Note that on the 54
KW, 240V heater, heater contactors (7M & 8M) will
be energized and on the 72 KW, 240V heater,
heater contactors (8M & 9M) will be energized. After
completing the specified fan on delay for heating,
the UCB will energize the blower motor.
TABLE 19: LIMIT CONTROL SETTING
TEMPERATURE LIMIT
SWITCH 1, 2
TEMPERATURE
LIMIT SWITCH 3, 4, 5,
6 OPENS, ºF
UNIT
(Tons)
HEATER
kW
VOLTAGE
415
OPENS, ºF
b. The thermostat will cycle the electric heat to satisfy
the heating requirements of the conditioned space.
18
36
54
72
120
120
120
120
170
170
170
170
15, 20,
25
NOTE: All 50 Hz heaters are provided with manual
reset backup protection limits. These will de-
energize the heaters should the primary limit
fail to open or the contactors fail to open in a
failure mode.
FLASH CODES
The UCB will initiate a flash code associated with
errors within the system. Refer to UNIT CONTROL
BOARD FLASH CODES Table 24.
HEATING OPERATION ERRORS
TEMPERATURE LIMIT
RESET
If the UCB senses zero volts from the high temperature
limit, the indoor blower motor is immediately energized.
Remove the call for heating by lowering the thermostat
setting lower than the conditioned space temperature.
This resets any flash codes.
This limit is monitored regardless of unit operation sta-
tus, i.e. the limit is monitored at all times.
HEAT ANTICIPATOR SETPOINTS
If the temperature limit opens three times within one
hour, it will lock-on the indoor blower motor and a flash
It is important that the anticipator setpoint be correct.
Too high of a setting will result in longer heat cycles
and a greater temperature swing in the conditioned
space. Reducing the value below the correct setpoint
will give shorter "ON" cycles and may result in the low-
ering of the temperature within the conditioned space.
ting.
SAFETY CONTROLS
The unit control board monitors the temperature limit
switch of electric heat units.
The control circuit includes the following safety con-
trols:
TABLE 20: ELECTRIC HEAT ANTICIPATOR
SETPOINTS
1. Temperature Limit Switch (TLS 1, 2).
SETTING, AMPS
HEATER
KW
VOLTAGE
TH1
TH2
-
This control is located inside the heater compart-
ment and is set to open at the temperature indi-
automatically. The limit switch operates when a
high temperature condition, caused by inadequate
supply air flow occurs, thus shutting down the
heater and energizing the blower.
18
36
54
72
0.29
0.29
0.29
0.29
0.29
0.29
0.29
380/415-3-50
GAS HEATING SEQUENCE OF OPERATIONS
2. Temperature Limit Switch (TLS 3, 4, 5 and 6).
The following sequence describes the operation of the
gas heat section.
This control is located inside the heater compart-
ment and is set to open at the temperature indi-
Johnson Controls Unitary Products
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356214-XIM-A-0108
When the thermostat calls for the first stage of heating,
the low-voltage control circuit from "R" to "W1" and "G"
is completed, thru the UCB. The heat relay "RW1" is
energized. The "RW1-2" contacts close energizing the
draft motor control. The draft motor control contacts
close and start the draft motor. As the speed of the
draft motor reaches approximately 2500 RPM, the cen-
trifugal switch contact, located on the end of the draft
motor shaft, closes to power the first stage ignition
module "IC1", thru the "RW1-1 contacts.
24V power is removed from the module either at the
unit or by resetting the room thermostat.
NOTE: That the second stage furnace can operate
even if first stage has locked out.
When the thermostat satisfies de-energizing the
"RW2"and "RW1", thus opening all gas valves. The
blower motor will continue to run after the furnace is
shut down until the specified fan off delay for heating
has been satisfied. The UCB will de-energize the
blower motor.
Ignition module "IC1" will immediately start the first
stage igniter sparking and will open the redundant
valve located inside the first stage main gas valve
"GV1" to allow a flow of gas to only the first stage carry-
over tube. Only after the pilot flame has been ignited
and the presence of pilot flame detected at the "IC1" by
a signal sent back through the flame sensor is sparking
terminated and the first stage main gas valve opened.
REDUNDANT
VALVE
MAIN VALVE
GAS MAIN
Gas flows into each of the main burners and is ignited
from the carryover tube flame.
GAS
VALVE
TO MAIN
BURNER
TO PILOT BURNER
After completing the specified fan on delay for heating,
the UCB will energize the blower motor.
FIGURE 19 - GAS VALVE PIPING
When the thermostat calls for the first stage of heating,
the low-voltage control circuit from "R" to "W1" is com-
pleted. A call for heat passes through the UCB to the
ignition control board (ICB). The UCB monitors the
"W1" call and acts upon any call for heat. Once voltage
has been sensed at “W1”, the UCB will initiate the fan
on delay for heating, energizing the indoor blower after
the specified delay has elapsed.
If "IC1" fails to detect a pilot flame, it will continue to try
for a maximum of 85 seconds to ignite the pilot tube. If
the pilot flame is not detected, then "IC1" will lock out
first stage furnace operation for five minutes or until
24V power is removed from the module either at the
unit or by resetting the room thermostat.
When the thermostat calls for the second stage of
heating, the low-voltage control circuit from "R" to "W2"
is completed, thru the UCB. Heat relay "RW2" is ener-
gized. The "RW2-1" contact is closed energizing the
second stage ignition module "IC2". "IC2" will immedi-
ately start the second stage igniter sparking and will
open the redundant valve located inside the second
stage main gas valve "GV2" to allow a flow of gas to
the second stage carryover tube. Only after the pilot
flame has been ignited and the presence of pilot flame
detected at "IC2" by a signal sent back through the
flame sensor is sparking terminated and the main gas
valve opened.
When the thermostat has been satisfied, heating calls
are ceased. The GV is immediately de-energized. The
blower is de-energized after the fan off delay for heat-
ing has elapsed. The draft motor performs a 25-second
post purge.
GAS HEATING OPERATION ERRORS
TEMPERATURE LIMIT
If the UCB senses zero volts from the high temperature
limit, the indoor blower motor is immediately energized.
When the UCB again senses 24 volts from the temper-
ature limit, the draft motor will perform a 25-second
post-purge and the indoor blower will be de-energized
following the elapse of the fan off delay for heating.
Gas flows into each of the second stage main burners
and is ignited from the carryover tube flame.
If "IC2" fails to detect a pilot flame, it will continue to try
for a maximum of 85 seconds to ignite the pilot tube. If
the pilot flame is not detected, then "IC2" will lock out
first stage furnace operation for five minutes or until
This limit is monitored regardless of unit operation sta-
tus, i.e. the limit is monitored at all times.
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Johnson Controls Unitary Products
356214-XIM-A-0108
If the temperature limit opens three times within one
hour, it will lock-on the indoor blower motor and a flash
code is initiated (See Table 24).
The redundant valves are located upstream of the
main gas valves. Should either or both of the main
gas valves fail in the open position the redundant
valves serve as back-ups and shut off the flow of
gas.
GAS VALVE
The UCB continuously monitors the GV. Any time the
UCB senses voltage at the GV without a call for heat
for a continuous five-minute period, the UCB will lock-
on the indoor blower and a flash code is initiated
GV, the UCB will de-energize the indoor blower follow-
ing the elapse of the fan off delay for heating.
4. Flame Sensor Rod / 100% Ignition Control Lock-
Out.
The flame rods and controls are located per Proper
fails to detect a signal from the flame sensor indi-
cating the pilot flame is properly ignited, then the
main gas valve will not open. It will continue to try
and ignite the pilot for a maximum of 85 seconds,
then if the pilot flame is not detected, the ignition
control will lock out furnace operation until 24V
power is removed from the module either at the
unit or by resetting the room thermostat.
If voltage has been sensed at the GV for at least 15
seconds during the fan on delay for heating and GV
voltage or "W1" is lost, the indoor blower is forced on
for the length of the fan off delay for heating.
SAFETY CONTROLS
5. Rollout Switch.
The unit control board monitors the temperature limit
switch and the gas valve of gas furnace units.
This switch is located above the main burners in
the control compartment, which in the event of a
sustained main burner rollout shuts off and locks
out both ignition controls closing both gas valves.
The ignition controls lock out furnace operation
until 24V power is removed from the controls either
at the unit or by resetting the room thermostat.
The control circuit includes the following safety con-
trols:
1. Limit Control (LS).
This control is located inside the heat exchanger
compartment and is set to open at the temperature
resets automatically. The limit switch operates
when a high temperature condition, caused by
inadequate supply air flow occurs, thus shutting
down the ignition control and closing the main gas
valves and energizing the blower.
NOTE: The auto reset rollout switch must reset before
allowing furnace operation.
6. Auxiliary limit switch (AUX) -
This control is located inside the heat exchanger
compartment and is set to open at 190°F. It is a
manual reset switch. If AUX trips, then the primary
limit has not functioned correctly. Replace the pri-
mary limit.
2. Centrifugal Switch (CS).
If the draft motor should fail, the centrifugal switch
attached to the shaft of the motor prevents the igni-
tion controls and gas valves from being energized.
TABLE 21: LIMIT CONTROL SETTING
Capacity, MBH
Units
Limit Control
Opens, ºF
(Tons)
3. Redundant Gas Valve.
Input
300
Output
240
15, 20 & 25
15, 20 & 25
195
195
There are two separate gas valves in the furnace.
Each valve contains a main and a redundant valve.
350
280
Johnson Controls Unitary Products
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356214-XIM-A-0108
START-UP (COOLING)
PRESTART CHECK LIST
I
G
N
.
C
O
N
T
R
O
L
#
2
After installation has been completed:
I
G
N
.
C
O
N
T
R
O
L
#
1
1. Check the electrical supply voltage being supplied.
Be sure that it is the same as listed on the unit
nameplate.
R
O
L
L
O
U
T
S
W
.
G
V
1
S
E
N
S
O
R
#
1
2. Set the room thermostat to the off position.
3. Turn unit electrical power on.
G
A
L
S
V
A
V
E
G
V
2
I
G
N
I
T
O
R
#
1
G
A
L
S
V
A
V
E
4. Set the room thermostat fan switch to on.
5. Check indoor blower rotation.
S
E
N
S
O
R
#
2
I
G
N
I
T
O
R
#
2
• If blower rotation is in the wrong direction. Refer to
Phasing Section in general information section.
B
U
R
N
E
R
C
O
M
P
A
R
T
M
E
N
T
FIGURE 20 - GAS VALVE AND CONTROLS
• Check blower drive belt tension.
FLASH CODES
6. Check the unit supply air (CFM). See "CHECKING
SUPPLY AIR CFM" on page 34.
The UCB will initiate a flash code associated with
errors within the system. Refer to UNIT CONTROL
BOARD FLASH CODES Table 24.
7. Measure evaporator fan motor's amp draw.
8. Set the room thermostat fan switch to off.
RESETS
9. Turn unit electrical power off.
OPERATING INSTRUCTIONS
1. Turn unit electrical power on.
Remove the call for heating by lowering the thermostat
setting lower than the conditioned space temperature.
This resets any flash codes.
HEAT ANTICIPATOR SETPOINTS
2. Set the room thermostat setting to lower than the
room temperature.
It is important that the anticipator setpoint be correct.
Too high of a setting will result in longer heat cycles
and a greater temperature swing in the conditioned
space. Reducing the value below the correct setpoint
will give shorter "ON" cycles and may result in the low-
ering of the temperature within the conditioned space.
3. First stage compressors will energize after the
built-in time delay (five minutes).
4. The second stage of the thermostat will energize
second stage compressor if needed.
POST START CHECK LIST
TABLE 22: GAS HEAT ANTICIPATOR SETPOINTS
Anticipator Setpoint
Gas Valve
1. Verify proper system pressures for both circuits.
1st Stage
2nd Stage
Honeywell VR8440
2. Measure the temperature drop across the evapora-
tor coil.
0.30 amp
0.11 amp
White-Rodgers 36C68
42
Johnson Controls Unitary Products
356214-XIM-A-0108
3. Measure the system Amperage draw across all
legs of 3 phase power wires.
POST-START CHECK LIST (GAS)
After the entire control circuit has been energized and
the heating section is operating, make the following
checks:
4. Measure the condenser fan amp draw.
SHUT DOWN
1. Check for gas leaks in the unit piping as well as the
supply piping.
1. Set the thermostat to highest temperature setting.
2. Turn off the electrical power to the unit.
START-UP (GAS HEAT)
FIRE OR EXPLOSION HAZARD
PRE-START CHECK LIST
FAILURE TO FOLLOW THE SAFETY WARN-
ING EXACTLY COULD RESULT IN SERIOUS
INJURY, DEATH OR PROPERTY DAMAGE.
Complete the following checks before starting the unit.
NEVER TEST FOR GAS LEAKS WITH AN
OPEN FLAME. USE A COMMERICALLY
AVAILABLE SOAP SOLUTION MADE SPE-
CIFICALLY FOR THE DETECTION OF
LEAKS TO CHECK ALL CONNECTIONS. A
FIRE OR EXPLOSION MAY RESULT CAUS-
ING PROPERTY DAMAGE, PERSONAL
INJURY OR LOSS OF LIFE.
1. Check the type of gas being supplied. Be sure that
it is the same as listed on the unit nameplate.
2. Make sure that the vent and combustion air hoods
have been properly installed.
OPERATING INSTRUCTIONS
2. Check for correct manifold gas pressures. See
This furnace is equipped with an intermittent
pilot and automatic re-ignition system. DO
NOT attempt to manually light the pilot.
3. Check the supply gas pressure. It must be within
the limits shown on rating nameplate. Supply pres-
sure should be checked with all gas appliances in
the building at full fire. At no time should the
standby gas line pressure exceed 13", nor the
operating pressure drop below 5.0" for natural gas
units. If gas pressure is outside these limits, con-
tact the local gas utility for corrective action.
TO LIGHT PILOT AND MAIN BURNERS:
1. Turn “off” electric power to unit.
2. Turn room thermostat to lowest setting.
3. Turn gas valve knob or switch to “on” position.
4. Turn “on” electric power to unit.
5. Set room thermostat to desired temperature.
(If thermostat “set” temperature is above room tem-
perature, pilot burner ignition will occur and, after
an interval to prove pilot flame, main burners will
ignite).
TO SHUT DOWN:
1. Turn “off” electric power to unit.
FIGURE 21 - TYPICAL GAS VALVES
2. Depress knob of gas valve while turning to “off”
position or turn gas valve switch to “off” position.
Johnson Controls Unitary Products
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356214-XIM-A-0108
MANIFOLD GAS PRESSURE ADJUSTMENT
1. Remove the screws holding either end of the mani-
fold to the burner supports.
Small adjustments to the high-fire gas flow may be
made by turning the pressure regulator adjusting screw
on the automatic gas valve.
2. Open the union fitting in the gas supply line just
upstream of the unit gas valve and downstream
from the main manual shut-off valve.
Adjust as follows:
3. Remove the gas piping closure panel.
1. Remove the cap on the regulator. It's located next
to the push-on electrical terminals.
4. Disconnect wiring to the gas valves and spark ignit-
ors. Remove the manifold-burner gas valve
assembly by lifting up and pulling back.
2. To decrease the gas pressure, turn the adjusting
screw counterclockwise.
3. To increase the gas pressure, turn the adjusting
screw clockwise.
NOTE: The correct manifold pressure for these fur-
naces is 3.65 IWG ±0.3.
B
U
R
N
E
R
A
S
S
E
M
B
L
Y
B
R
A
C
K
E
T
FIGURE 23 - TYPICAL FLAME APPEARANCE
Burners are now accessible for service.
F
L
A
M
E
S
E
N
S
O
R
B
U
L
B
Reverse the above procedure to replace the assem-
blies. Make sure that burners are level and seat at the
rear of the heat exchanger.
1
T
/
8
"
G
A
P
B
E
T
W
E
E
N
C
A
R
R
Y
-
O
V
E
R
BURNER AIR SHUTTER ADJUSTMENT
U
B
E
A
N
D
F
L
A
M
E
S
E
N
S
O
R
B
U
L
B
Adjust burner shutters so no yellow flame is observed
in the heat exchanger tubes.
C
A
R
R
Y
-
O
V
E
R
T
U
B
E
FIGURE 22 - PROPER FLAME ADJUSTMENT
PILOT CHECKOUT
CHECKING GAS INPUT
NATURAL GAS
The pilot flame should envelope the end of the flame
sensor. To adjust pilot flame, (1) remove pilot adjust-
ment cover screw, (2) increase or decrease the clear-
ance for air to the desired level, (3) be sure to replace
cover screw after adjustment to prevent possible gas
leakage.
1. Turn off all other gas appliances connected to the
gas meter.
2. With the furnace turned on, measure the time
needed for one revolution of the hand on the small-
est dial on the meter. A typical gas meter usually
has a 1/2 or a 1 cubic foot test dial.
Put the system into operation and observe through
complete cycle to be sure all controls function properly.
3. Using the number of seconds for each revolution
and the size of the test dial increment, find the
cubic feet of gas consumed per hour from the Gas
BURNER INSTRUCTIONS
To check or change burners, pilot or orifices, CLOSE
MAIN MANUAL SHUT-OFF VALVE AND SHUT OFF
ALL ELECTRIC POWER TO THE UNIT.
If the actual input is not within 5% of the furnace rating
(with allowance being made for the permissible range
44
Johnson Controls Unitary Products
356214-XIM-A-0108
of the regulator setting), replace the orifice spuds with
spuds of the proper size.
BELT DRIVE BLOWER
All units have belt drive single-speed blower motors.
The variable pitch pulley on the blower motor can be
adjusted to obtain the desired supply air CFM.
NOTE: To find the Btu input, multiply the number of
cubic feet of gas consumed per hour by the
Btu content of the gas in your particular locality
(contact your gas company for this information
- it varies widely from city to city.)
TROUBLESHOOTING
COOLING TROUBLESHOOTING GUIDE
TABLE 23: GAS RATE - CUBIC FEET PER HOUR
Seconds
for One
Rev.
Size of Test Dial
1/2 cu. ft.
1 cu. ft.
4
6
8
450
300
228
180
900
600
450
360
Troubleshooting of components may require
opening the electrical control box with the
power connected to the unit. Use extreme
care when working with live circuits! Check
the unit nameplate for the correct line voltage
and set the voltmeter to the correct range
before making any connections with line termi-
nals.
10
12
14
16
18
20
150
129
113
100
90
300
257
225
200
180
When not necessary, shut off all electric power
to the unit prior to any of the following mainte-
nance procedures so as to prevent personal
injury.
22
24
26
28
82
75
69
64
164
150
138
129
Example: By actual measurement, it takes 13 seconds for the hand on the 1-
cubic foot dial to make a revolution with just a 300,000 Btuh furnace running.
Read across to the column in the table above, headed “1 Cubic Foot”, where
you will see that 278 cubic feet of gas per hour are consumed by the furnace at
that rate. Multiply 278 x 1050 (the Btu rating of the gas obtained from the local
gas company). The result is 292,425 Btuh, which is close to the 300,000 Btuh
rating of the furnace.
Label all wires prior to disconnection when ser-
vicing controls. Wiring errors can cause
improper and dangerous operation, which
could cause injury to person and/or damage
unit components. Verify proper operation after
servicing.
ADJUSTMENT OF TEMPERATURE RISE
The temperature rise (or temperature difference
between the return air and the heated air from the fur-
nace) must lie within the range shown on the rating
On calls for cooling, if the compressors are operating
but the supply air blower motor does not energize after
a short delay (the room thermostat fan switch is in the
“AUTO” position).
Btuh Input x 0.8
CFM =
1.08 x oF Temp. Rise
1. Turn the thermostat fan switch to the ON position.
If the supply air blower motor does not energize, go
to Step 3.
After the temperature rise has been determined, the
cfm can be calculated as follows:
After about 20 minutes of operation, determine the fur-
nace temperature rise. Take readings of both the return
air and the heated air in the ducts (about six feet from
the furnace) where they will not be affected by radiant
heat. Increase the blower cfm to decrease the temper-
ature rise; decrease the blower cfm to increase the
rise. Refer to the Blower Motor and Drive Data
2. If the blower motor runs with the fan switch in the
ON position but will not run after the first compres-
sor has energized when the fan switch is in the
AUTO position, check the room thermostat for con-
tact between R and G in the AUTO position during
calls for cooling.
Johnson Controls Unitary Products
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356214-XIM-A-0108
3. If the supply air blower motor does not energize
when the fan switch is set to ON, check that line
voltage is being supplied to the contacts of the M3,
contactor, and that the contactor is pulled in. Check
for loose wiring between the contactor and the sup-
ply air blower motor.
providing free cooling and the compressors will not
immediately operate. If both stages of cooling are
requested simultaneously and the economizer pro-
vides free cooling, following a short delay compres-
sor #1 will be energized unless it is locked out. If
compressor #1 is locked out, compressor #2 is
energized. Compressor #2 is always energized in
place of compressor #1 when compressor #1 is
requested but locked out.
4. If M3 is pulled in and voltage is supplied to M3,
lightly touch the supply air blower motor housing. If
it is hot, the motor may be off on internal protec-
tion. Cancel any thermostat calls and set the fan
switch to AUTO. Wait for the internal overload to
reset. Test again when cool.
2. If no economizer is installed or the economizer is
not opening to provide free cooling and compres-
sor #1 does not energize on a call for cooling,
check for line voltage at the compressor contactor,
M1, and that the contactor is pulled in. Check for
loose wiring between the contactor and the com-
pressor.
5. If M3 is not pulled in, check for 24 volts at the M3
coil. If 24 volts are present at M3 but M3 is not
pulled in, replace the contactor.
3. If M1 is pulled in and voltage is supplied at M1,
lightly touch the compressor housing. If it is hot, the
compressor may be off on inherent protection.
Cancel any calls for cooling and wait for the inter-
nal overload to reset. Test again when cool.
6. Failing the above, if there is line voltage supplied at
M3, M3 is pulled in, and the supply air blower
motor still does not operate, replace the motor.
7. If 24 volts is not present at M3, check that 24 volts
is present at the UCB supply air blower motor ter-
minal, “FAN”. If 24 volts is present at the FAN,
check for loose wiring between the UCB and M3.
4. If M1 is not pulled in, check for 24 volts at the M1
coil. If 24 volts are present and M1 is not pulled in,
replace the contactor.
8. If 24 volts is not present at the “FAN” terminal,
check for 24 volts from the room thermostat. If 24
volts are not present from the room thermostat,
check for the following:
5. Failing the above, if voltage is supplied at M1, M1
is pulled in, and the compressor still does not oper-
ate, replace the compressor.
6. If 24 volts is not present at M1, check for 24 volts at
the UCB terminal, C1. If 24 volts is present, check
for loose wiring between C1 and the compressor
contactor.
a. proper operation of the room thermostat (contact
between R and G with the fan switch in the ON posi-
tion and in the AUTO position during operation
calls), b. proper wiring between the room thermostat
and the UCB, and c. loose wiring from the room
thermostat to the UCB.
7. If 24 volts is not present at the C1 terminal, check
for 24 volts from the room thermostat at the UCB
Y1 terminal. If 24 volts is not present from the room
thermostat, check for the following:
9. If 24 volts is present at the room thermostat but not
at the UCB, check for proper wiring between the
thermostat and the UCB, i.e. that the thermostat G
terminal is connected to the G terminal of the UCB,
and for loose wiring.
a. 24 volts at the thermostat Y1 terminal
b. Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2
c. Loose wiring from the room thermostat to the UCB.
10. If the thermostat and UCB are properly wired,
replace the UCB.
8. If 24 volts is present at the UCB Y1 terminal, the
compressor may be out due to an open high-pres-
sure switch, low-pressure switch, or freezestat.
Check for 24 volts at the HPS1, LPS1, and FS1
terminals of the UCB. If a switch has opened, there
should be a voltage potential between the UCB ter-
minals, e.g. if LPS1 has opened, there will be a 24-
volt potential between the LPS1 terminals.
On calls for cooling, the supply air blower motor is
operating but compressor #1 is not (the room thermo-
stat fan switch is in the “AUTO” position).
1. If installed, check the position of the economizer
blades. If the blades are open, the economizer is
46
Johnson Controls Unitary Products
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9. If 24 volts is present at the UCB Y1 terminal and
none of the protection switches have opened, the
UCB may have locked out the compressor for
repeat trips. The UCB should be flashing an alarm
code. If not, press and release the ALARMS button
on the UCB. The UCB will flash the last five alarms
on the LED. If the compressor is locked out, cancel
any call for cooling. This will reset any compressor
lock outs.
nect the Mate-N-Locks and jumper between the
WHITE and YELLOW wires of the UCB's Mate-
NLock plug. If compressor #1 energizes, there is a
fault in the economizer wiring or economizer con-
trol.
14. The UCB can be programmed to lock out compres-
sor operation during free cooling and in low ambi-
ent conditions. These options are not enabled by
default. Local distributors can test the UCB for this
programming.
NOTE: While the above step will reset any lockouts,
compressor #1 may be held off for the ASCD.
See the next step.
For units with factory installed economizers, the
UCB is programmed to lock out compressor opera-
tion when the LAS set point is reached.
10. If 24 volts is present at the UCB Y1 terminal and
none of the switches are open and the compressor
is not locked out, the UCB may have the compres-
sor in an ASCD. Check the LED for an indication of
an ASCD cycle. The ASCD should time out within
5 minutes. Press and release the TEST button to
reset all ASCDs.
For units without factory installed or with field
installed economizers, the UCB allows compressor
operation all the time. This programming can be
checked or changed by the local distributor.
15. If none of the above corrected the error, test the
integrity of the UCB. Disconnect the C1 terminal
wire and jumper it to the Y1 terminal. DO NOT
jump the Y1 to C1 terminals. If the compressor
engages, the UCB has faulted.
11. If 24 volts is present at the UCB Y1 terminal and
the compressor is not out due to a protective
switch trip, repeat trip lock out, or ASCD, the econ-
omizer terminals of the UCB may be improperly
wired. Check for 24 volts at the Y1 “OUT” terminal
of the UCB. If 24 volts is present, trace the wiring
from Y1 “OUT” for incorrect wiring. If 24 volts is not
present at the Y1 “OUT” terminal, the UCB must be
replaced.
16. If none of the above correct the error, replace the
UCB.
On calls for the second stage of cooling, the supply air
blower motor and compressor #1 are operating but
compressor #2 is not (the room thermostat fan switch
is in the “AUTO” position).
12. For units without economizers:If 24 volts is present
at the Y1 OUT terminal, check for 24 volts at the
Y1 “ECON” terminal. If 24 volts is not present,
check for loose wiring from the Y1 “OUT” terminal
to the Mate-N-Lock plug, the jumper in the Mate-N-
Lock plug, and in the wiring from the Mate-N-Lock
plug to the Y1 “ECON” terminal.
1. If installed, check the position of the economizer
blades. If the blades are open, the economizer is
providing free cooling. If the second stage of
cooling is requested, following a short delay,
compressor #1 will be energized unless it is locked
out. Typically, compressor #2 is energized only
during free cooling if the call for the second stage
of cooling persists for 20 minutes.
13. For units with economizers: If 24 volts is present at
the Y1 "OUT" terminal, check for 24 volts at the Y1
"ECON" terminal. If 24 volts is not present, check
for loose wiring from the Y1 "OUT" terminal to the
Mate-N-Lock plug, a poor connection between the
UCB and economizer dMate-N-Lock plugs, loose
wiring from the Mate-N-Lock plug to the econo-
mizer, back to the Mate-N-Lock plug, and from the
Mate-N-Lock plug to the Y1 "ECON" terminal. If
nothing is found, the economizer control may have
faulted and is failing to return the 24-volt "call" to
the Y1 "ECON" terminal even though the econo-
mizer is not providing free cooling. To test, discon-
2. Compressor #2 will not energize simultaneously
with compressor #1 if a call for both stages of cool-
ing is received. The UCB delays compressor #2 by
30 seconds to prevent a power surge. If after the
delay compressor #2 does not energize on a sec-
ond stage call for cooling, check for line voltage at
the compressor contactor, M2, and that the contac-
tor is pulled in. Check for loose wiring between the
contactor and the compressor.
Johnson Controls Unitary Products
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356214-XIM-A-0108
3. If M2 is pulled in and voltage is supplied at M2,
lightly touch the compressor housing. If it is hot, the
compressor may be off on inherent protection.
Cancel any calls for cooling and wait for the inter-
nal overload to reset. Test again when cool.
10. If 24 volts is present at the UCB Y2 terminal and
none of the switches are open and the compressor
is not locked out, the UCB may have the compres-
sor in an ASCD. Check the LED for an indication of
an ASCD cycle. The ASCD should time out within
5 minutes. Press and release the TEST button to
reset all ASCDs.
4. If M2 is not pulled in, check for 24 volts at the M2
coil. If 24 volts is present and M2 is not pulled in,
replace the contactor.
11. The UCB can be programmed to lock out compres-
sor operation during free cooling and in low ambi-
ent conditions. These options are not enabled by
default. Local distributors can test the UCB for this
programming.
5. Failing the above, if voltage is supplied at M2, M2
is pulled in, and the compressor still does not oper-
ate, replace the compressor.
6. If 24 volts is not present at M2, check for 24 volts at
the UCB terminal, C2. If 24 volts are present,
check for loose wiring between C2 and the com-
pressor contactor.
For units with factory installed economizers, the
UCB is programmed to lock out compressor opera-
tion when the LAS set point is reached.
For units without factory installed or with field
installed economizers, the UCB allows compressor
operation all the time. This programming can be
checked or changed by the local distributor.
7. If 24 volts is not present at the C2 terminal, check
for 24 volts from the room thermostat at the UCB
Y2 terminal. If 24 volts is not present from the room
thermostat, check for the following:
12. If none of the above corrected the error, test the
integrity of the UGB. Disconnect the C2 terminal
wire and jumper it to the Y2 terminal. DO NOT
jump the Y2 to C2 terminals. If the compressor
engages, the UCB has faulted.
a. 24 volts at the thermostat Y2 terminal
b. Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2
c. Loose wiring from the room thermostat to the UCB.
13. If none of the above correct the error, replace the
UCB.
8. If 24 volts is present at the UCB Y2 terminal, the
compressor may be out due to an open high-pres-
sure switch, low-pressure switch, or freezestat.
Check for 24 volts at the HPS2, LPS2, and FS2
terminals of the UCB. If a switch has opened, there
should be a voltage potential between the UCB ter-
minals, e.g. if LPS2 has opened, there will be 24
volts of potential between the LPS2 terminals.
On a call for cooling, the supply air blower motor and
compressor #2 are operating but compressor #1 is not
(the room thermostat fan switch is in the “AUTO” posi-
tion).
1. Compressor #2 is energized in place of compres-
sor #1 when compressor #1 is unavailable for cool-
ing calls. Check the UCB for alarms indicating that
compressor #1 is locked out. Press and release
the ALARMS button if the LED is not flashing an
alarm.
9. If 24 volts is present at the UCB Y2 terminal and
none of the protection switches have opened, the
UCB may have locked out the compressor for
repeat trips. The UCB should be flashing a code. If
not, press and release the ALARMS button on the
UCB. The UCB will flash the last five alarms on the
LED. If the compressor is locked out, remove any
call for cooling at the thermostat or by disconnect-
ing the thermostat wiring at the Y2 UCB terminal.
This will reset any compressor lock outs.
2. Check for line voltage at the compressor contactor,
M1, and that the contactor is pulled in. Check for
loose wiring between the contactor and the com-
pressor.
3. If M1 is pulled in and voltage is supplied at M1,
lightly touch the compressor housing. If it is hot, the
compressor may be off on inherent protection.
Cancel any calls for cooling and wait for the inter-
nal overload to reset. Test again when cool.
NOTE: While the above step will reset any lock outs,
compressor #1 will be held off for the ASCD,
and compressor #2 may be held off for a por-
tion of the ASCD. See the next step.
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356214-XIM-A-0108
4. If M1 is not pulled in, check for 24 volts at the M1
coil. If 24 volts is present and M1 is not pulled in,
replace the contactor.
11. If 24 volts is present at the UCB Y1 terminal and
the compressor is not out due to a protective
switch trip, repeat trip lock out, or ASCD, the econ-
omizer terminals of the UCB may be improperly
wired. Check for 24 volts at the Y1 “OUT” terminal
of the UCB. If 24 volts is present, trace the wiring
from Y1 “OUT” for incorrect wiring. If 24 volts is not
present at the Y1 “OUT” terminal, the UCB must be
replaced.
5. Failing the above, if voltage is supplied at M1, M1
is pulled in, and the compressor still does not oper-
ate, replace the compressor.
6. If 24 volts is not present at M1, check for 24 volts at
the UCB terminal, C1. If 24 volts is present, check
for loose wiring between C1 and the compressor
contactor.
12. For units without economizers: If 24 volts is present
at the Y1 “OUT” terminal, check for 24 volts at the
Y1 “ECON” terminal. If 24 volts is not present,
check for loose wiring from the Y1 “OUT” terminal
to the Mate-N-Lock plug, the jumper in the Mate-N-
Lock plug, and in the wiring from the Mate-N-Lock
plug to the Y1 “ECON” terminal.
7. If 24 volts is not present at the C1 terminal, check
for 24 volts from the room thermostat at the UCB
Y1 terminal. If 24 volts are not present at the UCB
Y1 terminal, the UCB may have faulted. Check for
24 volts at the Y1 ECON terminal. If 24 volts is not
present at Y1 “ECON”, the UCB has faulted. The
UCB should de-energize all compressors on a loss
of call for the first stage of cooling, i.e. a loss if 24
volts at the Y1 terminal.
For units with economizers: If 24 volts is present at
the Y1 "OUT" terminal, check for 24 volts at the Y1
"ECON" terminal. If 24 volts is not present, check
for loose wiring from the Y1 "OUT" terminal to the
Mate-N-Lock plug, a poor connection between the
UCB and economizer Mate-N-Lock plugs, loose
wiring from the Mate-N-Lock plug to the
economizer, back to the Mate-N-Lock plug, and
from the Mate-N-Lock plug to the Y1 "ECON"
terminal. The economizer control may have faulted
and is not returning the 24 volts to the Y1 "ECON"
terminal even though the economizer is not
providing free cooling. To test the economizer
control, disconnect the Mate-N-Locks and jumper
between the WHITE and YELLOW wires of the
UCB's Mate-N-Lock plug.
8. If 24 volts are present at the UCB Y1 terminal, the
compressor may be out due to an open high-pres-
sure switch, low-pressure switch, or freezestat.
Check for 24 volts at the HPS1, LPS1, and FS1
terminals of the UCB. If a switch has opened, there
should be a voltage potential between the UCB ter-
minals, e.g. if LPS1 has opened, there will be a 24-
volt potential between the LPS1 terminals.
9. If 24 volts is present at the UCB Y1 terminal and
none of the protection switches have opened, the
UCB may have locked out the compressor for
repeat trips. The UCB should be flashing a code. If
not, press and release the ALARMS button on the
UCB. The UCB will flash the last five alarms on the
LED. If the compressor is locked out, remove any
call for cooling. This will reset any compressor lock
outs.
13. The UCB can be programmed to lock out compres-
sor operation during free cooling and in low ambi-
ent conditions. These options are not enabled by
default. They can be checked by local distributors.
For units with factory installed economizers, the
UCB is programmed to lock out compressor opera-
tion when the LAS set point is reached.
NOTE: While the above step will reset any lock outs,
compressor #2 will be held off for the ASCD,
and compressor #1 may be held off for a por-
tion of the ASCD. See the next step.
For units without factory installed or with field
installed economizers, the UCB allows compressor
operation all the time. This programming can be
checked or changed by the local distributor.
10. If 24 volts is present at the UCB Y1 terminal and
none of the switches are open and the compressor
is not locked out, the UCB may have the compres-
sor in an ASCD. Check the LED for an indication of
an ASCD cycle. The ASCD should time out within
5 minutes. Press and release the TEST button to
reset all ASCDs.
14. If none of the above corrected the error, test the
integrity of the UCB. Disconnect the C1 terminal
wire and jumper it to the Y1 terminal. DO NOT
jump the Y1 to C1 terminals. If the compressor
engages, the UCB has faulted.
Johnson Controls Unitary Products
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356214-XIM-A-0108
15. If none of the above correct the error, replace the
UCB.
1. Place the thermostat fan switch in the “ON” posi-
tion. If the supply air blower motor energizes, go to
Step 10.
GAS HEAT TROUBLESHOOTING GUIDE
2. If the supply air blower motor does not energize
when the fan switch is set to “ON,” check that line
voltage is being supplied to the contacts of the M3
contactor, and that the contactor is pulled in. Check
for loose wiring between the contactor and the sup-
ply air blower motor.
Troubleshooting of components may require
opening the electrical control box with the
power connected to the unit. Use extreme
care when working with live circuits! Check
the unit nameplate for the correct line voltage
and set the voltmeter to the correct range
before making any connections with line termi-
nals.
3. If M3 is pulled in and voltage is supplied at M3,
lightly touch the supply air blower motor housing. If
it is hot, the motor may be off on inherent protec-
tion. Cancel any thermostat calls and set the fan
switch to “AUTO”, wait for the internal overload to
reset. Test again when cool.
When not necessary, shut off all electric power
to the unit prior to any of the following mainte-
nance procedures so as to prevent personal
injury.
4. If M3 is not pulled in, check for 24 volts at the M3
coil. If 24 volts is present at M3 but M3 is not pulled
in, replace the contactor.
5. Failing the above, if there is line voltage supplied at
M3, M3 is pulled in, and the supply air blower
motor still does not operate, replace the motor.
Label all wires prior to disconnection when ser-
vicing controls. Wiring errors can cause
improper and dangerous operation, which
could cause injury to person and/or damage
unit components. Verify proper operation after
servicing.
6. If 24 volts is not present at M3, check that 24 volts
is present at the supply air blower motor terminal
on the UCB. If 24 volts is present at the UCB termi-
nal, check for loose wiring between the UCB and
M3.
7. If 24 volts is not present at the UCB supply air
blower motor terminal, check for 24 volts from the
room thermostat. If 24 volts is not present from the
room thermostat, check for the following:
NOTE: To find the Btu input, multiply the number of
cubic feet of gas consumed per hour by the
Btu content of the gas in your particular locality
(contact your gas company for this information
- it varies widely from city to city.).
a. Proper operation of the room thermostat (contact
between R and G with the fan switch in the “ON”
position and in the “AUTO” position during operation
calls).
b. Proper wiring between the room thermostat and the
UCB.
The furnace may shut down on a high temper-
ature condition during the procedure. If this
occurs, the UCB energize the supply air blower
motor until the high temperature limit has reset.
Caution should be used at all times as the sup-
ply air blower may energize regardless of the
room thermostat fan switch position.
c. Loose wiring from the room thermostat to the UCB.
8. If 24 volts is present at the room thermostat but not
at the UCB, check for proper wiring between the
thermostat and the UCB, i.e. that the thermostat G
terminal is connected to the G terminal of the UCB,
and for loose wiring.
On calls for heating, the draft motor operates and the
furnace lights but the supply air blower motor does not
energize after a short delay (the room thermostat fan
switch is in “AUTO” position).
9. If the thermostat and UCB are properly wired,
replace the UCB.
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Johnson Controls Unitary Products
356214-XIM-A-0108
10. If the blower motor runs with the fan switch in the
“ON” position but does not run shortly after the fur-
nace has ignited when the fan switch is in the
“AUTO” position, check the room thermostat for
contact between R and G during “W1” calls.
4. If the furnace is cold, check for 24 volts at wire 241
attached to the electrical time delay (ETD) located
in the main control box. If 24 volts is not found,
replace the ETD.
5. 24 volts is found at wire 241, remove the wires
attached to the (TDR) and with a VOM, check for
continuity across contacts 1 and 2. If none is found,
the (TDR) is open and must be replaced. If there is
continuity, re-attach the wires.With the draft motor
running, check for 24 volts at terminal 4 of (RW1-2)
and (RW2-1). If 24 volts is not present, the centrifu-
gal switch (CS) has not closed or has gone bad.
Check the line voltage to the unit - if it is correct,
replace the draft motor. If line voltage is low, call
the power company.
On calls for heating, the supply air blower operates but
the draft motor does not (the room thermostat fan
switch is in the “AUTO” position).
1. The draft motor has inherent protection. If the
motor shell is hot to the touch, wait for the internal
overload to reset.
2. If the motor shell is cold with the room thermostat
calling for heat, check for line voltage at the
motor's Mate-N-Lok connector attached to the
evaporator partition. If line voltage is present,
replace the draft motor.
6. Check for 24V at terminal 2 of (RW1-2 and RW2-
1). If 24V is not present, check for 24V at (RW1
and RW2) relay coils. If these relays are pulled in,
then check for a loose connection at terminal 2 and
terminal 4 of each relay. If no problem is found,
then replace (RW1 and/or RW2) as required.
3. If line voltage is not present, check for line voltage
at the heat relay (RW1) contacts in the main con-
trol box and check to see if the (RW1) is pulled in.
4. If the (RW1) relay is pulled in, check for a loose line
voltage connection.
7. If 24 volts is present at the ignitor controls, check
all control wiring at the ignitor controls and the high
tension wire to the ignitors. Check that the ground
wires from the ignitor controls, the gas valves and
pilot burners are all intact and making good electri-
cal connection. Check to make sure that the
ceramic insulator on the pilot ignitors or sensors is
not broken or cracked, if all are intact, replace the
ignition control IC1 or IC2.
5. If the (RW1) relay is not pulled in, check for 24 volts
at the (RW1) coil. If 24 volts is present, replace the
(RW1) relay. If 24 volts is not present, check for a
loose 24 volt connection back to the relay board
and check the connections from the room thermo-
stat to the relay board. If all connections are cor-
rect, replace the relay board.
The draft motor runs and the ignitor sparks at the pilot
burner but the pilot does not ignite and a gas odor is
not detected at the draft motor outlet.
The draft motor runs but the furnace does not light and
the sparker does not spark.
1. The ignition control (IC1, IC2) may be locked out
due to either a flame roll out or 100% shut off.
These safety features are described above. If lock-
out has occurred, 24V must be removed from the
ignition controls. This is done at the unit or by
resetting the room thermostat. After resetting 24V,
check for proper furnace operation. If lock-out con-
tinues to occur, locate the source of the problem
and correct.
1. Check to make sure gas is being supplied to the
unit. Make sure that the gas pressure to the unit is
within the proper limits as described in the “POST
adjust screw is allowing some flow of gas as
described in “PILOT CHECKOUT” page 44.
2. Check all wiring between the ignitor control and the
gas valve. Check to make sure the ground connec-
tions are intact.
2. Check all 24 volt connections from the relay board
to and in the gas heat section. Check low voltage
connections to the (ETD) located in the control
box.
3. If the wiring is intact, check for 24 volts across ter-
minals “PV” and “COMMON” on the ignitor control.
If 24 volts is not present, replace the ignitor control.
3. If the furnace is hot, it may be out on an over-tem-
perature condition, wait for limit reset.
Johnson Controls Unitary Products
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356214-XIM-A-0108
4. If 24 volts is present, remove the pilot burner and
remove the pilot orifice from the pilot burner. The
orifice is removed in the direction opposite the flow
of gas. Inspect the orifice for obstruction. If it is
clear, replace the main gas valve.
1. Make sure that the pilot burner is aligned properly
with the carryover as described in “PILOT CHECK-
2. Make sure that the carryovers on adjoining burners
are screwed fast and are level with respect to one
another.
The ignitor sparks at the pilot burner but the pilot does
not ignite and a gas odor is detected at the draft motor
outlet.
Main burners light but exhibit erratic flame characteris-
tics.
1. Adjust the pilot adjust screw on the gas valve as
described in “PILOT CHECKOUT” page 44.
1. Adjust air shutters as described in “BURNER AIR
SHUTTER ADJUSTMENT” page 44.
2. Check the main burner orifices for obstruction and
alignment. Removal procedure is described in
replace burner orifices and burners as needed.
2. Check the supply pressure as described in “POST
as necessary.
3. Check the pilot orifice for obstruction as described
in paragraph above. Clean as needed but the prob-
lem should not be the gas valve.
UNIT FLASH CODES
Various flash codes are utilized by the unit control
board (UCB) to aid in troubleshooting. Flash codes are
distinguished by the short on and off cycle used
(approximately 200ms on and 200ms off). To show
normal operation, the control board flashes a 1 second
on, 1 second off "heartbeat" during normal operation.
This is to verify that the UCB is functioning correctly.
Do not confuse this with an error flash code. To prevent
confusion, a 1-flash, flash code is not used.
The pilot burner ignites but the ignitor continues to
spark and the main burners do not ignite.
1. Make the same checks and adjustment as
described in “PILOT CHECKOUT” page 44.
2. Check the supply pressure as described in “POST
as necessary.
Alarm condition codes are flashed on the UCB lower
being flashed, it will also be shown by the other LEDs:
lit continuously while the alarm is being flashed. The
total of the continuously lit LEDs equates to the number
of flashes, and is shown in the table. Pressing and
releasing the LAST ERROR button on the UCB can
check the alarm history. The UCB will cycle through the
last five (5) alarms, most recent to oldest, separating
each alarm flash code by approximately 2 seconds. In
all cases, a flashing Green LED will be used to indicate
non-alarm condition.
3. Make sure that the pilot burner is not bent or dam-
aged.
4. Make sure that the ground connections at the pilot
burner, gas valve and ignitor control are intact.
Check the high tension wire for good electrical con-
nection. If all are intact, replace the ignitor module.
The pilot burner lights and the spark stops but the main
burners do not light.
1. Check electrical connections between the ignitor
control and the gas valve. If intact, check for 24
volts across terminals “MV” and “COMMON” termi-
nals. If no voltage detected, replace ignitor control.
If voltage is present, replace gas valve.
In some cases, it may be necessary to "zero" the
ASCD for the compressors in order to perform trouble-
shooting. To reset all ASCDs for one cycle, press and
release the UCB TEST/ RESET button once.
Furnace lights with roll-out or one burner has delayed
ignition.
Flash codes that do and do not represent alarms are
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356214-XIM-A-0108
TABLE 24: UNIT CONTROL BOARD FLASH CODES
GREEN
LED
16
RED
LED
8
RED
LED
4
RED
LED
2
RED
LED
1
FLASH CODE
DESCRIPTION
On Steady
1 Flash
This is a Control Failure
Not Applicable
-
-
-
-
-
-
-
-
-
-
Control waiting ASCD1
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
9 Flashes
10 Flashes
Flashing
Off
Off
Off
Off
Off
Off
Off
On
On
On
Off
Off
On
On
On
On
Off
Off
Off
On
On
Off
Off
On
On
Off
Off
On
Off
On
Off
On
Off
On
Off
On
Off
HPS1 Compressor Lockout
HPS2 Compressor Lockout
Off
LPS1 Compressor Lockout
Off
LPS2 Compressor Lockout
Off
FS1 Compressor Lockout
Off
FS2 Compressor Lockout
Off
Ignition Control Locked Out / Ignition Control Failure
Off
Compressors Locked Out on Low Outdoor Air Temperature1
Compressors locked out because the Economizer is using free
Cooling1
Flashing
11 Flashes
Flashing
On
Off
On
On
12 Flashes
13 Flashes
Unit Locked Out due to Fan Overload Switch Failure
Off
Flashing
Off
On
On
On
Off
On
On
On
Off
Off
Off
On
Off
Off
On
Off
Off
Compressor Held Off due to Low Voltage1
EEPROM Storage Failure
14 Flashes
OFF
No Power or Control Failure
Off
1.
Non-alarm condition.
Check
Alarm
History
Reset All
ASCDs for
One Cycle
Non Alarm
Condition Green
LED Flashing
Current Alarm
Flashed
Red LED
FIGURE 24 - UNIT CONTROL BOARD
Johnson Controls Unitary Products
53
356214-XIM-A-0108
• The 8, 4, 2 and 1 LEDs will then show the status of the
button to change the LED status to correspond to the
desired Heat Delay Value.
UNIT CONTROL BOARD OPTION SETUP
OPTION BYTE SETUP
• Enter the Option Setup mode by pushing the OPTION
SETUP / STORE button, and holding it for at least 2
seconds.
• To save the current displayed value, push the OPTION
SETUP / STORE button and hold it for at least 2
seconds. When the value is saved, the red LED will
flash a few times and then normal display will resume.
• The green status LED (Option Byte) will be turned on
and the red status LED (Heat Delay) is turned off.
NOTE: While in either Setup mode, if no buttons are
pushed for 60 seconds, the display will revert
to its normal display, exiting the Option Setup
mode. When saving, the control board only
saves the parameters for the currently dis-
played mode (Option Byte or Heat Delay).
• The 8, 4, 2 and 1 LEDs will then show the status of the
4 labeled options ((8) Fan Off at Heat Start, (4) Low
Ambient Lockout, (2) Free Cooling Lockout, and (1)
Lead / Lag).
• Press the UP or Down button to change the LED status
to correspond to the desired Option Setup.
• To save the current displayed value, push the OPTION
SETUP / STORE button and hold it for at least 2
seconds. When the value is saved, the green LED will
flash a few times and then normal display will resume.
TABLE 25: HEAT DELAY
Heat
Fan On
Delay
60
Heat
Fan Off
Delay
180
90
Red
LED 8
Red
Red
Red
LED 4
LED 2
LED 1
On
On
On
On
On
On
On
On
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
On
On
Off
Off
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
On
Off
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
On
Off
NOTE: While in either Setup mode, if no buttons are
pushed for 60 seconds, the display will revert
to its normal display, exiting the Option Setup
mode. When saving, the control board only
saves the parameters for the currently dis-
played mode (Option Byte or Heat Delay).
60
60
60
60
30
45
180
90
45
45
60
45
30
HEAT DELAY SETUP
30
180
90
30
•Enter the Option Setup mode by pushing the OPTION
SETUP / STORE button, and holding it for at least 2
seconds.
30
60
30
30
0
60
0
30
•The green status LED (Option Byte) will be turned on
and the red status LED (Heat Delay) is turned off.
0
10
Non-std
Non-std
•Press the COMM SETUP / SELECT button to toggle into
the Heat Delay Setup, the green LED will turn off and
the red LED for Heat Delay will turn on.
54
Johnson Controls Unitary Products
356214-XIM-A-0108
Johnson Controls Unitary Products
55
Subject to change without notice. Printed in U.S.A.
356214-XIM-A-0108
Copyright © 2008 by Johnson Controls, Inc. All rights reserved.
Supersedes: 175240-XIM-B-0707
Johnson Controls Unitary Products
5005 York Drive
Norman, OK 73069
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