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Johnson Controls PD 180 THRU 240 manual

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  • Page 1

    R-410A MODELS: PC090 Thru 240  PD180 Thru 240 7.5 - 20 Ton 60 Hertz 430645-YIM-D-0610 TABLE OF CONTENTS Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Renewal Parts . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 2

    430645-YIM-D-0610 2 Johnson Controls Unitary Products Nomenclature General These condensing u nits are desi gned for outdoor installa tion on a roof or at ground level. Every unit is completely piped an d wired at the factory and is shipped ready for immediate installation. Only the li quid and suction lines to the evaporator coil, the filter drier[...]

  • Page 3

    430645-YIM-D-0610 Johnson Controls Unitary Products 3 Safety Considerations Installer should pay particular attenti on to the words: NOTE , CAUTION , and WARNING . Notes are inten ded to clarify or make the installation easier. Cau tions are given to prevent equipment damage. Warnings are given to aler t instal ler that personal injury and/or equip[...]

  • Page 4

    430645-YIM-D-0610 4 Johnson Controls Unitary Products Physical Data Table 1: PC090 - 240 and PD180 - 240 Physic al Data Component Models PC090 PC120 PC180 PD180 PC240 PD240 Nominal Tonnage 7.5 10 15 15 20 20 REFRIGERANT Refrigerant type R-410A R-410A R-410A R-410A R-410A R-410A Holding charge (lb) 1 1. Holding Charge is the amount in the unit as sh[...]

  • Page 5

    430645-YIM-D-0610 Johnson Controls Unitary Products 5 Installation Limitations These units must be installed in a ccordance with all natio nal and local safety codes. If no local codes apply, installation must conform to the appropriate national codes. Units are designed to meet National Safety Code Standards. If components are to be added to a uni[...]

  • Page 6

    430645-YIM-D-0610 6 Johnson Controls Unitary Products Figure 1: Corner W eights & Center Of Gravity NOTE: Front of unit is considered the side having the control box. Concrete piers can also support gro und level units. These piers should (1) extend below the frost line, (2) be located under each of the section's four corners, and (3) be s[...]

  • Page 7

    430645-YIM-D-0610 Johnson Controls Unitary Products 7 Clearances The unit must be installed with sufficient clearance for air to enter the condenser coils, for ai r di scharge and for servicing access. See Table Table 4 for clearances. NOTE: Additional cl earance is required to remove the compressors out the back of the unit. Rigging Exercise care [...]

  • Page 8

    430645-YIM-D-0610 8 Johnson Controls Unitary Products Power Wiring Check the available power and the unit namepl ate for correct voltage. Run the necessary number of properly sized wires to the unit. Provide a disconnect switch (if not included with the unit) and fusing as required (Factory disconnect is a fu sed disconnect /breaker). Route the con[...]

  • Page 9

    430645-YIM-D-0610 Johnson Controls Unitary Products 9 Electrical Data Table 5: Electrical Data - Outdoor U nit - HP Without Powere d Con venience Outlet Model Compressors Outdoor Fan Motor Pwr Conv Outlet Minimum Circuit Ampacity 1 Maximu m Fuse S ize (A) 2 Power Supply Qty RLA (each) MCC (each) LRA (each) Power Supply HP Qty FLA (each) FLA PC090 2[...]

  • Page 10

    430645-YIM-D-0610 10 Johnson Controls Unitary Products Refrigerant Main s Line Sizing When sizing refrigerant pipe fo r a split-system air conditioner, check the following: 1. Suction line pressure drop due to friction. 2. Liquid line pressure drop due to frictio n. 3. Suction line velocity for oil return. 4. Liquid line pressure drop due to vertic[...]

  • Page 11

    430645-YIM-D-0610 Johnson Controls Unitary Products 11 Always punch a small hole in se aling disks before unbrazing to prevent the pressure in the line from blowing th em off. Do not use a drill as copper s havings can enter system. NOTE: Solenoid and hot gas bypass valves (if used) should be opened manual ly or electric ally duri ng brazing or eva[...]

  • Page 12

    430645-YIM-D-0610 12 Johnson Controls Unitary Products Figure 3: Typical Fi el d Wiring Diagram - NC0 90 Air Han dling Unit With PC090 Heat Pump R C Y1 G W1 W2 THERMOSTAT SINGLE STAGE COOLING TWO STAGE HEATING NOTE: Do not use a heat pump thermostat. NOTE: Liquid line solenoid is not included or required on 7.5 T on Single Stage Units.[...]

  • Page 13

    430645-YIM-D-0610 Johnson Controls Unitary Products 13 Figure 4: Typical Fi el d Wiring Diagram - NC120 thr u 240 Evaporator Unit with PC120 thru 240 Heat Pump Figure 5: NC120 - 240 Liqui d Li ne Solenoid Wiring R C Y1 G W1 W2 Y2 THERMOSTAT TWO STAGE COOLING TWO STAGE HEATING NOTE: Do not use a heat pump thermostat. NOTE: Liquid line solenoid is on[...]

  • Page 14

    430645-YIM-D-0610 14 Johnson Controls Unitary Products Figure 6: Typical Fi el d Wiring Diagram - ND180 thr u 240 Evaporator Unit with PD180 thru 240 Heat Pump R C Y1 G W1 W2 Y2 THERMOSTAT TWO STAGE COOLING TWO STAGE HEATING NOTE: Do not use a heat pump thermostat. NOTE: Liquid line solenoid is not included or required on any 4 pipe units.[...]

  • Page 15

    430645-YIM-D-0610 Johnson Controls Unitary Products 15 Figure 7: PC090, PC120 Unit Dimensio ns NOTE: Use System 1 piping di mensions when applying a PC090/120 model system. Table 7: PC090, PC120 Unit Height Dimension s MODEL A PC090 44.5 PC120 50.0 LEFT REAR RIGHT FRONT RIGHT 2X (Ø 0.875) KNOCKOUT 30.994 2X (Ø 1.375) KNOCKOUT CONVENIENCE OUTLET 7[...]

  • Page 16

    430645-YIM-D-0610 16 Johnson Controls Unitary Products Figure 8: PC/PD180 & PC/PD240 Unit Dimensions and Pipin g & Ele ctrical Dimensions NOTE: Use System 1 piping dimensions wh en applying a PC180/240 model system. Table 8: PC/PD180 & PC/PD2 40 Unit Height Dimensions MODEL A PC180 44.5 PD180 44.5 PC240 50.0 PD240 50.0 LEFT RIGHT FRONT [...]

  • Page 17

    430645-YIM-D-0610 Johnson Controls Unitary Products 17 Piping And Electrical Connections Piping connections are made from the re ar of 7.5 thru 12.5 Ton units and from the front of 15 th ru 20 Ton units. Stub outs are provided on the suction and liquid line service valves. Pi pin g can be routed to the unit from the left or right side. Electrical c[...]

  • Page 18

    430645-YIM-D-0610 18 Johnson Controls Unitary Products Operation Unit Control Overview This series of heat pumps come factory equipped with Simplicity ™ controls to monitor all uni t function ality and safety controls. Safety Controls The Simplicity ™ control board incorporates featur es to monitor safety circuits as well as minimize compressor[...]

  • Page 19

    430645-YIM-D-0610 Johnson Controls Unitary Products 19 M1 while sending a signal to one of the "CFAN" te rminals on DC. • Relay RY1 controls the cran kcase heater (CCH1). The normally closed contacts allow CCH1 to operate durin g unit shutdown. • Contactor M1 controls compressor COMPR1. The output signal from the re maining "CFAN[...]

  • Page 20

    430645-YIM-D-0610 20 Johnson Controls Unitary Products • Contactor M4 controls outdoor fans ODFAN3 & 4. If the initial call for cooling r equ ires both stages (Y1 and Y2), the UCB will delay the second stage by 30 seco nds to avoid an excessive power inrush. When the call for cooling (Y2) is satisfied, th e UCB disables the signal to RY2 and [...]

  • Page 21

    430645-YIM-D-0610 Johnson Controls Unitary Products 21 Defrost Operation The defrost control board (DC) utilizes a time/temperature defrost scheme. The DC repeats normal heating run cycles, which must be completed, until one of the followi ng conditions is met and the DC enters defrost mode: 1. The DC satisfie s its accumulate d minimum run time. T[...]

  • Page 22

    430645-YIM-D-0610 22 Johnson Controls Unitary Products Figure 10: Uni t Control Board Table 11: PD180 thru 240 Unit Control Board Flas h Cod es FLASH CODE DESCRIPTION GREEN LED 16 RED LED 8 RED LED 4 RED LED 2 RED LED 1 On S teady This is a Control Failure ----- 1 Flash Not Applicable ----- 2 Flashes Control waiting ASCD 1 1. Non-alarm condition. F[...]

  • Page 23

    430645-YIM-D-0610 Johnson Controls Unitary Products 23 Flash Codes Various flash codes are utilized by the unit control board (UCB) to aid in troubleshooting. Fla sh co des are distinguished by the short on and off cycle used (approximately 200ms on and 200ms off). To show normal operation, the co ntro l board flashes a 1 second on, 1 second off &q[...]

  • Page 24

    430645-YIM-D-0610 24 Johnson Controls Unitary Products Cooling Trou bleshooting Guid e On calls for coolin g, if the co mpressors are op e ra ti n g bu t th e supply air blower motor does not energize after a short delay (the room thermostat fa n sw itch is in the “AUTO” positio n): 1. Turn the thermostat fan switch to the ON position. If the s[...]

  • Page 25

    430645-YIM-D-0610 Johnson Controls Unitary Products 25 “OUT” terminal to the Mate-N-L ock plug, the jumper in the Mate-N-Lock plug, and in the wiring from the Ma te -N-Lock plug to the Y1 “ECON” terminal.) 12. If non e of the above corrected th e er ror, test th e integri ty of the UCB. Disconnect the C1 te rmin al wire and jumper it to the[...]

  • Page 26

    430645-YIM-D-0610 26 Johnson Controls Unitary Products HPS1 and LPS1 terminals of the UCB. If a switch has opened, there should be a vo ltag e potential between the UCB terminals, e.g. if LPS1 has ope ned, there will be a 24- volt potential between the LPS1 terminals. 9. If 24 volts is present at t he UCB Y1 terminal and none of the protection swit[...]

  • Page 27

    430645-YIM-D-0610 Johnson Controls Unitary Products 27 Figure 11: P C090 Charging Chart Figure 12: P C120 Charging Chart Cooling Charging Curves PC090 200 300 400 500 600 120 130 140 150 160 170 180 Suction Pressure (psi) Discharge Pressure (psi) 65° 1. Make sure that both condenser fans are running when charging. 2. This chart is applicable to un[...]

  • Page 28

    430645-YIM-D-0610 28 Johnson Controls Unitary Products Figure 13: P C180 Charging Chart Figure 14: P D180 Charging Chart Cooling Charging Curves PC180 200 300 400 500 600 120 130 140 150 160 170 180 Suction Pressure (psi) Discharge Pressure (psi) 1. Make sure that all condenser fans are running when charging. 2. This chart is applicable to unit wit[...]

  • Page 29

    430645-YIM-D-0610 Johnson Controls Unitary Products 29 Figure 15: P C240 Charging Chart Figure 16: P D240 Charging Chart Cooling Charging Curves PC240 200 300 400 500 600 120 130 140 150 160 170 180 Suction Pressure (psi) Discharge Pressure (psi) Outdoor Air Entering Condenser (F) 1. Make sure that all condenser fans are running when charging. 2. T[...]

  • Page 30

    430645-YIM-D-0610 30 Johnson Controls Unitary Products Typical Wiring Diagrams Figure 17: Typical PC090 Heat Pump Wiring Diag ram[...]

  • Page 31

    430645-YIM-D-0610 Johnson Controls Unitary Products 31 Figure 18: Typical PC120 Heat Pump Wiring Diag ram[...]

  • Page 32

    430645-YIM-D-0610 32 Johnson Controls Unitary Products Figure 19: Typical PC180 - 240 Heat Pump Wiring Diagram[...]

  • Page 33

    Subject to change without notice. Pr inted in U.S.A. 430645-YIM-D-0610 Copyright © 2010 b y Johnson Controls, Inc. All rights rese rved. Supersedes: 430645-YIM-C-0310 Johnson Contro ls Unitary Products 5005 York Drive Norman, OK 73069 Figure 20: Typical PD180 - 240 Heat Pump Wiring Diagram[...]