gas_electric_residential_package

If the total pressure exceeds the designed maximum allowable ESP on the equipment data plate,evaluate the duct system and ensure that it is sized properly. Systems with excessive ESPdisplay increased operational sound and will not provide published performance.Temperature RiseA package unit that is operating properly must have a heating mode temperature rise that is withinthe allowable range listed on the data plate.The temperature rise is measured by subtracting the return air dry bulb temperature from thesupply air dry bulb temperature as seen in the following example. The supply and return airtemperatures should be measured as close to the package unit as possible without being in directview of the heat exchanger. If the readings are taken in direct line of sight to the heat exchanger,the temperature will be of the radiant heat generated rather than the air temperature entering orleaving the unit. Example: Supply air dry bulb 115ºF -70ºF Return air dry bulb = 45ºFΔT – Rise =Temperature RiseTemperature DropA package unit with proper airflow established and the nameplate refrigerant charge will haveapproximately an 18ºF to 20ºF temperature drop across the indoor coil during cooling operation.The temperature drop is measured by subtracting the supply air dry bulb temperature from thereturn air dry bulb temperature as seen in the following example. Example: Return air dry bulb 75ºF Supply air dry bulb -55ºF =Temperature Drop =20ºFΔT - Drop50

Figure 5-4: Leaving Air Temperature ChartDuring certain conditions, the temperature drop may be increased or decreased depending on thereturn air wet bulb temperatures. To increase accuracy when evaluating if the system is absorbingthe proper amount of heat, the technician can use Figure 5-7. This chart can be used to identifyif the air leaving the indoor coil is correct for a system that should be moving a nominal 400 CFMof supply air per ton of cooling. If the technician records the return air wet bulb temperature andthe return air dry bulb temperature and cross references the temperatures on the chart, the chartwill indicate the dry bulb temperature within +/- 3ºF that should be leaving the coil if the system isoperating within design specifications. 51

Airflow Calculation Formula: BTU Output = CFM 1.08 X Temp Rise This formula will provide a means of evaluating the CFM produced during heating. The CFMformula requires the BTU output from the heating unit and a temperature rise measurementacross the heating section.Gas Heat:To evaluate the CFM during emergency heating operation, verify the BTU content of the fuelsupplying the equipment. The BTU content may vary depending on the production of the naturalgas. The BTU content can be verified by contacting the local utility. In this example, the BTUcontent of the fuel is 1030 BTU per cubic foot for natural gas.If the gas heating unit has a BTU input rating of 60,000 BTU/H and has an 80% Annual FuelUtilization Efficiency (AFUE) rating, the unit would have a 48,000 BTU/H output. Formula: 60,000 Input X .80 = 48,000 BTU/H OutputIn this example, if the BTU/H output is 48,000 and the unit has 45ºFΔT (Temperature Rise), theformula would indicate an air flow of 987.65 CFM. 60,000 X .80 = 48,000 BTU/H Output = 987.65 CFM 1.08 X 45ºFΔT = 48.6Calculating Gas Heat Input and Output (Clocking the Meter)When clocking the gas meter: ● All other gas appliances must be in the OFF position to calculate the exact input to the heater. ● The unit must be firing at full capacity (High Fire Emergency Heat) ● Log the cubic feet of gas utilized in 6 minutes of operation. Keep in mind, 6 minutes is 1/10th of one hour. ● Multiply the cubic feet of gas by 10.If the unit uses 5 cubic feet of gas in 1/10th of one hour, the 5 cubic feet is multiplied by 10. Thiswould indicate an input of 50 cubic feet of gas in one hour. 10 x 5 = 50 cubic feet per hour input ● Multiply the BTU content of the fuel by the cubic feet per hour.52

If the BTU content was verified to be 1030 BTU per cubic foot, the 1030 BTU per cubic foot wouldbe multiplied by the 50 cubic feet input per hour. 1030 x 50 = 51,500 BTU/H InputThis would indicate a 51,500 BTU/H input to the unit. ● Multiply the BTU/H input by the AFUE ratingIf this unit had an AFUE rating of 80%, the output will be approximately a 41,200 BTU/H. 51,500 x .80 = 41,200 BTU/H OutputTotal AmperesThe total amperes should be measured and recorded when the unit has been operating in thecooling mode for at least 10 minutes. The total amperes should be measured either at theequipment electrical disconnect or the package unit’s contactor.Once the unit has been operating at full capacity for approximately 10 minutes, the amp draw canbe measured and recorded on the start up sheet. The current for each leg of power should beclose to the run load amps (RLA) or full load amps (FLA) rating on the equipment data plate.If the equipment is operating under light load conditions, the amp draw may be lower than the(RLA) or (FLA).Compressor AmperesThe compressor amperes should be measured at the unit contactor or at the compressor terminalblock.Once the unit has been operating for approximately 10 minutes, the amp draw can be measuredand recorded on the start up sheet. The current for each leg of power should be close to the runload amps (RLA) or full load amps (FLA) rating on the compressor data plate.Gas Pipe Leak TestingWhen the system has been installed to the Installation Manual specifications and all local, city,state and federal codes, the gas piping will be tested for leaks as described in the InstallationManual provided with the equipment.Check all of the pipe joints, gas valve connections and manual valve connections for leakage.Only approved gas leak testing equipment and non-corrosive leak detection solvents shall beused. 53

If a leak is detected, the unit should be locked-out including the electrical power and gas supplyingthe unit and the leak repaired before any further start-up is completed.Gas Line Pressure MeasurementLine pressure is measured on the inlet side of the gas valve. Line pressure to the valve shouldnot exceed the values on the rating plate or the gas valve. Line pressure supplying fuel to the gasvalve should be between 4.5” W.C. and 10.5” W.C. for natural gas and between 11” W.C. and 14”W.C. for propane (LP) gas.When measuring supply line pressure, all other gas appliances in the structure should be turnedon if accessible to ensure that line pressure does not drop to low when the other appliances are inoperation.Turn off the manual shut off valve in the gas line supplying the package unit.After the fitting is removed, insert a barbed fitting into the pressure tap. Connect an inclinemanometer, U-tube manometer, or other approved gas pressure test kit to the barbed fitting.Slowly open the manual shut off valve and observe the line pressure displayed on the testequipment.If the line pressure is not within the required range as indicated in the installation manual, aproblem with the gas supply and/or pipe sizing may be indicated and must be corrected.If the line pressure is within the required pressure range, it is time to verify the gas manifoldpressure.Manifold Pressure Verification and Adjustments Manifold pressure is the outlet pressure of the gas valve and shall be set to 3.5” W.C. for natural gas and 10” W.C. for propane (LP). Power should be disconnected, and the manual shut off valve must be closed prior to installing the pressure testing equipment.Figure 5-5: Gas Valve To adjust the regulator screw, the screw cap must be removed to expose the regulator adjustment screw. Turning the regulator adjustment screw clockwise will increase manifold pressure and counterclockwise will decrease the manifold pressure.An improper flame, including a yellow or lazy flame, must be investigated and correctedimmediately. The inshot burners do not have primary air adjustments.54

Chapter 6 - Sequence of OperationStandby ModeWhen there is no demand from the thermostat for fan operation, the control is considered to be inStandby Mode. In this mode, it will de-energize all outputs until action is initiated by a thermostatcall. In Standby, it will continually monitor all thermostat inputs and the LED will flash a greenheartbeat.Blower Motor ControlThe outputs to the motor will operate as follows. If the thermostat demand changes the modeof operation during a single call for operation, the control will appropriately transition to the newmode. This will ensure that the motor delivers the highest cfm for the calls that are present.Fan Only OperationWhen there is a thermostat demand for Fan Only Operation (G), the control will immediatelysupply 24VAC to the S-ECM motor on the G SPD terminal. If the demand for Furnace Heating issent to the control during continuous fan operation, the control continues to energize the G SPDoutput as long as the G call is present.When the thermostat demand for Fan Only Operation is removed, the control will immediately de-energize the G SPD output.Compressor Only OperationWhen there is a thermostat demand for compressor operation (Y or Y+G without W), after onesecond, the control supplies 24VAC to the Y SPD output.If the control senses a Y call without G it continues to energize the Y SPD output and provide a 4amber flash code.When the thermostat demand for compressor operation is removed, the control continues toenergize the Y SPD output for an Off Delay period of 60 seconds. It will then de-energize the YSPD output.Gas Heating OperationWhen there is a thermostat demand for Furnace Heating operation (W or W+G), the controlenergizes the W SPD output to the S-ECM motor.Blower On Delay - If the control is beginning a new ignition cycle, it will not energize the blowermotor until 30 seconds after the gas valve has opened.If a demand for continuous fan operation (G) is present at the start of the ignition cycle, the controlcontinues to run the blower motor at the established fan speed for the duration of the Blower OnDelay period after which time both calls will be active. 55

At the completion of a heating cycle, the control continues to energize the blower motor for thetime selected by the Furnace Heating Blower Off Delay adjustment jumper. Each jumper labelcorresponds directly to the number of seconds the control continues to energize the blower motorafter the gas valve has been de-energized. In other words, when the Blower Off Delay time hasexpired, the control will de-energize the W SPD output. If a thermostat demand for FurnaceHeating operation arrives during a Blower Off Delay, the control will begin the normal ignitionsequence and continue to operate the Blower Off Delay independently.If a demand for continuous fan operation (G) is present at the end of an ignition cycle, the controlwill transition to the continuous fan speed (G) after the selected Furnace Heating Blower Off Delayis complete. The control energizes the motor speed outputs.Full Heat SequenceA control will consider an active signal on the W thermostat input a call for furnace heatingoperation. The control will then follow the sequence as listed below.1. After one second, the microprocessor will run a self check routine.2. The Fault and Status LEDs will display the appropriate flash code for heat operation.3. The control will set the Pre Purge Timer to 15 seconds.4. The control will check the status of the high limit switch for normally closed contacts.5. The control will verify that the gas valve is closed and check for the presence of voltage at the valve.6. The control will verify that the pressure switch is open.7. The control will begin the pressure Switch Proving Sequence.8. The control energizes the Inducer motor.9. The control will monitor the pressure Switch, checking for it to close.10. If the pressure switch does not close within 5 seconds, the control will display the “3” flash code on the LED and continue to energize the inducer.11. If the pressure switch does not close within 60 seconds, the control will turn off the inducer for a 60 second period (while continuing to flash the “3” flash code).12. After 60 seconds with the inducer off, then control will return to step 2 of the heating sequence of operation.13. Once the pressure switch is detected as closed, the control moves to the Pre-Purge Sequence.14. The control will begin the Pre-Purge sequence. The pre-purge time for this control is 15 seconds. If the thermostat demand for furnace heating is removed during any step of this sequence, the control will immediately de-energize the inducer and return to standby.15. The control continues to energize the Inducer motor and monitor the pressure switch.16. The control will remain in this state for the duration of the Pre-Purge Timer.17. The control will begin a Trial for Ignition. If the thermostat demand for furnace heating is removed during any step of this sequence, the control will immediately de-energize the gas valve and igniter, energize the blower on W SPD, initiate a shut down sequence, and run the heating blower off delay. The control will monitor the High Limit input during this sequence. If the control detects that the pressure switch opens for more than 2 seconds, it will de-energize the igniter and gas valve (if energized), count the open pressure switch cycle, and return to the pressure switch proving sequence to retry ignition. 56

Retrial Sequence• The control energizes the Gas Valve and the Ignitor.• The control will pause for 5 seconds.• The control will de-energize the Igniter.The control will monitor the Flame Sensor for 2 seconds to validate ignition. If the control sensesflame, the control continues on to step 9.5. If the control does not detect that flame has beenestablished after 2 seconds, it will execute the following sequence:• De-energize the Gas Valve• Count the Failed Ignition.If less than 3 failed ignitions, set the Pre-Purge/Inter-Purge Timer to 15, and return to the pressureswitch proving sequence to retry the ignition.Entering LockoutIf the maximum number of failed ignitions has been reached, the control will:• De-energize the gas valve.• If the blower is energized, the control continues energizing the blower motor for the selected heating Blower Off Delay.• Continue energizing the inducer for a 15 second post-purge period, then de-energize the inducer• Enter Soft Lockout.• Display a 7 Red Flash code,• Store the fault code in memory.Sensing FlameIf the control senses flame, It continues to energize the gas valve and inducer, and initiate the heatblower on delay (30 seconds).When the gas valve has been energized for 30 seconds, the control will proceed to Steady Heatstate. (Blower On Delay is taking place in this time period)The control will then enter Steady Heat state.Steady Heat StateThe blower will be energized at W SPD. The control will continuously monitor all thermostat inputs,limit switch inputs, pressure switch, and flame sensor.If the thermostat demand for furnace heating is removed during this state, the control willimmediately de-energize the gas valve and begin the shut down sequence as defined in sectionThe control continues to energize the blower motor for the selected heating Blower Off Delay.The control will monitor the High Limit input during this state. 57

Pressure Switch Open Mid-CycleIf the control detects that the low pressure switch is open for more than 2 seconds, it will executethe following steps.• De-energize the gas valve.• Count the open pressure switch cycle.• Continue energizing the blower motor for the selected heating Blower Off Delay.• Retry ignition from the pressure proving sequence.• If the control detects that the pressure switch is open for less than 2 seconds, it will behave as follows:• The gas valve will be momentarily de-energized (since the signal to the gas valve runs through the pressure switch). This may cause a loss of flame, which would interrupt the heating cycle.Flame Loss Mid-CycleIf the flame is lost, the control will respond to the loss of flame as a pressure switch opening.If the control detects a loss of flame, it will execute the following steps:• De-energizes the gas valve within 2 seconds.• Energizes the Inducer motor.• Set the Pre-Purge Timer to 15 seconds.• Continue energizing the blower motor for the selected heating Blower Off Delay.• When the Pre-Purge/Inter-Purge delay is over, the control will initiate another ignition cycle starting at the Pressure Switch Proving Sequence.• If the control loses flame 5 times during a single call for furnace heating, it will lock out.Shut Down SequenceThe control will execute the Shut Down sequence as listed below any time thermostat demand forFurnace heating is removed, flame is lost, or flame cannot be established.• The control will de-energize the gas valve.• If the blower is energized the control continues energizing the blower motor for the selected heating Blower Off Delay.• The control continues to energize the Inducer motor for 60 seconds.• If the control is executing the shut down sequence due to a fault, it energizes the Inducer.• If the control is executing the shut down sequence due to the removal of thermostat demand, the control continues energizing the inducer for a 15 second post-purge period, then de- energize the inducer.• If the control is executing a shut down sequence due to a fault, it may now retry for ignition or lock out.• If the control is executing a shut down sequence due to the removal of thermostat demand, after the inducer and blower motor have de-energized, the control will return to standby mode. 58

Chapter 7 - TroubleshootingThis section provides unit-specific diagnostics on controls and sequences for gas electricresidential package units. For detail concerning more “generic” troubleshooting, such as relays,capacitors, compressors, please refer to the ProficienTECH Basic Troubleshooting manual.Diagnostic CodesThe control stores fault codes in non-volatile memory for review by the service technician for 30days.The control will store, as a minimum, the five most recent fault codes. These codes are storedwhile power is removed from the control and will remain in memory until the control has beenenergized for 30 consecutive days.Flash DefinitionsThe control flashes status and fault codes using the timings as described below.Heartbeat 2 seconds ON, 2 seconds OFFFlash 1/3 second ON, 1/3 second OFFRapid Flash 1/10 second ON, 1/10 second OFFDisplay of Fault/Status CodeThe control will display the fault code on the LED repeatedly with a 2 second off period betweenrepetitions of the code. If multiple fault codes are present at the same time, the LED willdisplay only the highest priority fault as shown in the table below. The other active error(s)may be accessed via the ERROR BUTTON. The table below shows the flash code definitions,corresponding flash code and priority rank (with 11 being the highest priority). For instance, a flashcode entry of 3 indicates that the control energizes the output for three 1/3 second on, 1/3 secondoff flashes, wait two seconds, then energize the output for three more 1/3 second on, 1/3 secondoff flashes and repeat.Fault/Status Code TableThe control will display the current status/fault as listed in the table below.Description Flash CodeNormal OperationStandby mode Green HeartbeatCall for furnace heat active Amber HeartbeatCall for cool active Green HeartbeatCall for fan active Green HeartbeatControl in Factory Test mode Rapid Green Flash 59

Operational Faults ON (any color) Control failure Rapid Amber Flash Low flame current 1 Red Flash Flame sensed with gas valve off 2 Red Flashes Pressure switch closed with inducer off 3 Red Flashes Pressure switch open with inducer on 4 Red Flashes Limit/Rollout switch open 5 Red Flashes Limit/Rollout switch open >15 minutes 6 Red Flashes Pressure switch cycle lockout 7 Red Flashes Lockout due to failed ignition 8 Red Flashes Lockout due to too many flame dropouts 10 Red Flashes Gas valve fault code 11 Red Flashes Limit/Rollout switch open between 5 and 15 minutes Wiring Related Faults 9 Red Flashes Incorrect line voltage polarity 4 Amber Flashes Y thermostat demand without a G Fault Code HistoryIf the LAST ERROR push button is pressed for longer than 1/5 second but less than 5 seconds,and no thermostat signals are currently active, the control will sequentially flash, on the StatusLED, the series of stored error codes (up to the last 5 active error codes since they were lastcleared or 30 days, whichever is shorter) starting with the most recent. There will be a 2 seconddelay between error codes. The series may be repeated by pressing LAST ERROR push buttonagain. If one of the thermostat signals becomes active while the control is flashing stored errorcodes, the error code flashing mode will immediately terminate and normal operation of thecontrol resumes. The control will ignore the LAST ERROR push button during any mode with theexception of Standby mode. If there are no error codes stored in memory, the LED will give a 2Green Flash code.If the LAST ERROR push button is pressed for longer than 5 seconds, the control will immediatelyclear the stored error code array and flash the green LED 3 times to indicate that the errormemory has been cleared. The control will not wait until the LAST ERROR button is released toexecute this behavior.Fault DescriptionsPressure Switch Closed with Inducer OffThe control will monitor the status of the pressure switch at the beginning of a furnace heatingcycle. If the control detects that the switch is closed for longer than 5 seconds, prior to theenergizing of the Inducer motor, it will indicate a 2 Red Flash fault code, store the fault in memory,and halt the ignition sequence. Once the pressure switch is detected to be open, the control willremove the fault code indication and proceed with a new ignition sequence.60

Pressure Switch Open During Pressure Switch ProvingThe control will monitor the status of the pressure switch at the beginning of a furnace heatingcycle. If the control detects that the pressure switch does not close during the pressure provingsequence, it will display a fault code as described in table 13.4 and store the fault in memory.Pressure Switch Open During Pre-Purge/Inter-PurgeThe control will continuously monitor the status of the pressure switch during the Pre-Purgeand Inter-Purge sequences. If the control detects that a pressure switch is open for more than 2seconds during the Pre-Purge and Inter-Purge sequence as described in section 8.0, it will displaya fault code, store the fault in memory, and return to the Pressure Switch Proving Sequence toretry ignition.Pressure Switch Open During Trial For IgnitionThe control will continuously monitor the status of the pressure switch during the Trial For Ignitionsequence. If the control detects an open pressure switch during the Trial for Ignition sequenceas described in section 9.0, it will display a fault code, store the fault in memory, and return to thePressure Switch Proving Sequence to retry ignition.Pressure Switch Open During Steady HeatThe control will continuously monitor the status of the pressure switch during Steady Heat. Ifthe control detects that a pressure switch is opened during a single call for furnace heating asdescribed in section 10.0, it will display a fault code, store the fault in memory, and return to thePressure Switch Proving Sequence to retry ignition.Multiple Pressure Switch Openings During Single Call for HeatThe control will count the number of pressure switch openings during a single call for furnaceheating. If the control senses five pressure switch openings during a single call for furnaceheating as described in section 10.0, it will display a fault code, store the fault in memory, andenter a Soft Lockout.. If the blower motor is running when this condition occurs, it continuesrunning until the heating call is removed. When the heating call is removed, it continues to run theselected heat blower off delay before de-energizing the blower. 61

High Limit FaultThe control will monitor the status of the High Limit input any time there is a gas heating call (W).If the High Limit input is removed, 24VAC to the Gas Valve will be removed immediately and thecontrol will enter the post-purge period. This operation is micro controlled. The control will performthe following operations when the limit switch opens:• De-energize the Gas Valve• De-energize the Igniter• Energize the Inducer• Energize the blower on W Spd• Display a 4 Red Flash code• Store the Fault Code in memory• Count the Open Limit switch• Operate normally for compressor operationsIf the limit switch closes within 5 minutes, the control will store the fault code in memory andresume normal operation. If the control enters post-purge due to a high limit opening, the inducerwill remain energized for the duration of that post-purge regardless of a high limit closing. That is,a subsequent high limit closing (with W present) will not send the control back to the pre-purgesequence until the post- purge is completed. This function ensures that the inducer will completethe off-delay if the W is removed during the post-purge period.Open High Limit Longer Than 5 MinutesIf the High Limit input has been removed for more than 5 minutes, it is assumed that the mainblower has failed. The control will enter a Hard Lockout. The control will change to an 11 RedFlash code, store the fault in memory, and continue all other previously described behavior.Specifically, the blower will remain energized until either the High Limit switch is closed or the W isremoved. Upon removal, the control will begin the blower off delay timer.Open High Limit Longer Than 15 MinutesIf the High Limit input has been removed for more than 15 minutes, it is assumed that a rolloutswitch has been opened.Multiple High Limit Openings During Single Call for Furnace HeatingIf the control detects that the High Limit input has been removed 5 times during a single call forfurnace heating, it will perform the following additional operations:• Energize the Inducer as long as the limit is open, then perform a post-purge• Energize the Blower as long as the limit is open, then run a Heat Off-Delay• Display a 4 Red Flash code• Store the Fault Code in memory• Enter Soft Lockout 62

Rollout Switch FaultIf the High Limit input has been removed for more than 15 minutes, it is assumed that a rolloutswitch has been opened. Since rollout switches require a manual reset, this is necessarily a hardlockout.The control will perform the following operations when the limit switch has been open for 15minutes:• Continue to energize the blower• Continue normal blower operation for compressor heating and cooling calls• Display a 5 Red Flash code• Store the Fault Code in memoryFlame Faults/WarningsWeak Flame WarningIf the control senses that the flame signal falls below 1.5 µA for more than 4.25 seconds aftera successful trial for ignition, the control will display the Rapid Amber Flash code. The controlcontinues to operate the furnace normally during this time. The flame signal must rise back above1.5 µA for 4.25 seconds before the removing the Rapid Amber Flash code.Runaway FlameIf the control senses that flame is still present 4 seconds after de-energizing the gas valve, thecontrol will consider this Runaway Flame. The control will perform the following operations untilflame is no longer sensed:• Energize the Inducer• Energize the blower on W SPD• Display a 1 Red fault code• Store the Fault Code in memoryWhen the control no longer senses flame:• Inducer motor will shut down after a 15 second delay.• De-energize the blower after the blower off delay• Control will enter a Hard Lockout• Continue to display the 1 Red Flash Fault code. 63

Multiple Failed IgnitionsIf the control fails to sense flame after three trials for ignition, it will:• De-energize the Gas Valve• If the blower is energized, the control continues energizing the blower motor for the selected heating Blower Off Delay• Continue energizing the inducer for a 15 second post-purge period, then de-energize the inducer,• Enter Soft Lockout• Display a 7 Red Flash code• Store the fault code in memoryMultiple Losses of Flame During Single Call for Furnace HeatingIf the control detects that flame has been lost 5 times during a single call for Furnace Heating itwill:• De-energize the Gas Valve.• If the blower is energized the control continues energizing the blower motor for the selected heating Blower Off Delay.• The control continues to energize the Inducer motor for 60 seconds.• If the control is executing the shut down sequence due to a fault, it energizes the Inducer.If the control is executing the shut down sequence due to the removal of thermostat demand, thecontrol continues energizing the inducer for a 15 second post-purge period, then de-energize theinducer. It will then:• Continue energizing the inducer for a 15 second post-purge period, then de-energize the inducer• Enter a Soft Lockout• Display an 8 Red Flash code• Store the fault code in memoryGas Valve FaultThe control will monitor the status of the gas valve at all times. If the control detects that thegas valve is energized when it should not be for more than 1 second it will perform the followingoperations:• De-energize the inducer to force open the pressure switch (if flame is not present)• If the W SPD is energized, it will run the heating blower off delay• If any other blower call is present, it will run normal operation and delays for the given call• Display a 10 Red Flash Code• Store the Fault Code in memory• Enter Soft Lockout 64

If the gas valve was detected as energized when it should not be and the control continues tosense that the gas valve has not de-energized 10 seconds after de-energizing the inducer motoror if flame is detected while the gas valve is energized when it should not be, it will re-energize theinducer to vent the unburned gas, and enter a hard lockout.Wiring FaultsY Present Without a GIf the control detects any Y thermostat call without a G thermostat call, it will• Energize the blower• Display a 4 Amber Flash CodeThe control continues to display the 4 Amber Flash Code until either a G signal is provided by thethermostat or all Y calls are removed.Incorrect Line PolarityThe control will verify that the TR input for 24VAC is in phase with the LINE input of the208/230VAC input within tolerance of transformer phase shifting. The control will verify that theTC input for 24VAC does not show voltage with respect to earth ground. There will be a 12.5(±2.5)second delay to allow sufficient sampling time to confirm a polarity issue. If the control detects afault with the voltage connections, it will display a 9 Red Flash code, store the fault in memory, haltall furnace heating operation.Control FaultIf the control detects a fault on the control board (including a fault within the microprocessor), it willimmediately de-energize all outputs, ignore all inputs, display a Solid Red Fault code and enter a1 hour Hard Lockout. If possible, the control will reset itself after 1 hour in an attempt to clear thefault.Power Up OperationWhen power is first applied to the control, all outputs will be turned off and all timers will be reset.The control will display a Solid Green Status code while it performs an initial self check routine.The Solid Green Status code will be removed upon successful completion of the self checkroutine. The control will check the status of the gas valve circuitry and line polarity before enteringStandby Mode.Lockout ModesSoft LockoutThe control will cause a soft lockout during the following conditions. Detailed descriptions of theconditions required for the control to enter the Soft Lockout mode are contained in other sectionsof this document. 65

1. Pressure Switch opening 5 times during a single call for furnace heating2. Flame not proven after 3 Trials for Ignition3. 5 losses of flame during a single call for heat4. High Limit opening 5 times during a single call for furnace heating5. Gas Valve FaultDuring the Soft Lockout mode, the control will do the following.1. Begin a 1 hour timer2. Continue displaying the fault code which caused the lockout3. Monitor and react to flame, High Limit, and Gas Valve4. Continue operating with normal compressor functionality5. Additional requirements as listed per the fault which caused the lockoutThe control will reset the Soft Lockout condition when any of the following occur following theremoval of the fault condition.1. Power is cycled to the control.2. All thermostat calls are removed from the control.3. The 1 hour timer expiresWhen the Soft Lockout is reset, the control will stop displaying the fault code and status code andwill respond to thermostat inputs normally.Hard LockoutThe control will cause a Hard Lockout during the following conditions. Detailed descriptions of theconditions required for the control to enter the Hard Lockout mode are contained in other sectionsof this document.High Limit Open Longer than 5 MinutesIf the High Limit input has been removed for more than 5 minutes, it is assumed that the mainblower has failed. The control will enter a Hard Lockout as described in section 16.2. The controlwill change to an 11 Red Flash code, store the fault in memory, and continue all other previouslydescribed behavior. Specifically, the blower will remain energized until either the High Limit switchis closed or the W is removed. Upon removal, the control will begin the blower off delay timer.High Limit Open Longer than 15 MinutesIf the High Limit input has been removed for more than 15 minutes, it is assumed that a rolloutswitch has been opened. If the control fails to sense flame after three trials for ignition, it will:de-energize the Gas Valve.If the blower is energized the control continues energizing the blower motor for the selectedheating Blower Off Delay. 66

The control continues to energize the Inducer motor for 60 seconds. If the control is executing theshut down sequence due to a fault, it energizes the Inducer. If the control is executing the shutdown sequence due to the removal of thermostat demand, the control continues energizing theinducer for a 15 second post-purge period, then de-energize the inducer.If the blower is energized the control continues energizing the blower motor for the selectedheating Blower Off Delay then:• Continue energizing the inducer for a 15 second post-purge period, then de-energize the inducer• Enter Soft Lockout• Display a 7 Red Flash code• Store the fault code in memoryRunaway FlameIf the control senses that flame is still present 4 seconds after de-energizing the gas valve, thecontrol will consider this Runaway Flame. The control will perform the following operations untilflame is no longer sensed:• Energize the Inducer• Energize the blower on W SPD• Display a 1 Red fault code• Store the Fault Code in memoryWhen the control no longer senses flame:• Inducer motor will shut down after a 15 second delay.• De-energize the blower after the blower off delay• Control will enter a Hard Lockout• Continue to display the 1 Red Flash Fault codeGas Valve FaultThe control will monitor the status of the gas valve at all times. If the control detects that thegas valve is energized when it should not be for more than 1 second it will perform the followingoperations:• De-energize the inducer to force open the pressure switch (if flame is not present)• If the W SPD is energized, it will run the heating blower off delay• If any other blower call is present, it will run normal operation and delays for the given call• Display a 10 Red Flash Code• Store the Fault Code in memory• Enter Soft LockoutIf the gas valve was detected as energized when it should not be and the control continues tosense that the gas valve has not de-energized 10 seconds after de-energizing the inducer motoror if flame is detected while the gas valve is energized when it should not be, it will re-energize theinducer to vent the unburned gas, and enter a hard lockout. 67

Unless otherwise described elsewhere, during the Hard Lockout mode, the control will:1. Energize the inducer (*, **)2. Continue displaying the fault code which caused the lockout3. Energize the blower for gas heating calls.4. Continue normal blower operation for compressor heating and cooling calls5. Additional requirements as listed per the fault which caused the lockoutA Hard Lockout can only be reset by cycling power to the control. When a Hard Lockout is reset,the control will respond to thermostat inputs normally.*If the Hard Lockout is entered via a High Limit fault, the control will de-energize the inducermotor after 15 seconds. If the control receives thermostat inputs for fan only (G) or compressoroperation (Y1 and/or Y/Y2) the control will run the appropriate airflow, but still continue displayingthe fault code which caused the lockout. If the control later receives another heating demand(W/W1), the hard lockout continues as specified above, where the control will not energize theinducer motor, and continue displaying the fault code which caused the lockout.**If the Hard Lockout is entered via Runaway Flame, when the flame is no longer sensed theinducer motor will shut down after a 15 second delay.Power InterruptionIf power to the control in interrupted for less than 20 milliseconds, the control resumes operationat the same point in the timing cycle that the interruption began, but may not go to any othermode of operation. Power interruptions greater than 100 milliseconds may reset the control as apower up sequence. Power interruptions less than 100 milliseconds will not affect timings. Powerinterruptions of any duration will not directly cause lockout. 68

Chapter 8 - MaintenancePreventative maintenance is crucial to proper system operation and meeting the requiredequipment efficiency standards.Provide the owner with the equipment owner-operators maintenance procedures thataccompanied the equipment.Offer to provide the customer with service contracts to have the system cleaned and serviced on aregular maintenance schedule.General MaintenanceIt is recommended that the heating system is inspected once a year by a qualified service person.For proper and safe operation, the gas heating section needs air for combustion and ventilation.Do not block or obstruct air openings or spacing around the unit.Keep the area around the gas heating system clear and free of combustible materials, gasolineand other flammable vapors and liquids.Snow or debris should not be allowed to accumulate in or around the unit.Do not permit overhanging structures or shrubs to obstruct outdoor air discharge or vent outlet onthe unit.ThermostatsThermostats must be evaluated during an annual maintenance inspection. The thermostatshould be level and tightly secured to the wall. Gently blow out any dust accumulation and checkexposed contacts of snap acting thermostats for deterioration.Return Air FiltersMost single phase equipment is shipped without a return air filter. It is the responsibility of theinstallation technician to provide a return air filter and filter/frame kit for the equipment.Return air filters must always be used and kept clean. Filters should be checked monthly andchanged or cleaned when filters become dirt laden. Dirty filters will reduce system efficiency andincrease energy consumption.Refer to the Installation Manual for filter sizing and proper filter/frame kits to be installed whenapplicable. 69

Indoor CoilThe indoor coil absorbs heat from the conditioned space during cooling operation and rejects heatto the conditioned space during mechanical heating operation. It is essential that the equipmenthave the designed airflow across the coil to maintain comfort within the structure. If this is to beachieved, the coil must be kept clean and free of debris.The indoor coil can be kept clean with regularly changed return air filters. If the coil shouldbecome restricted and must be cleaned, it should only be cleaned using approved methods.They include: ● Coil brushes ● Vacuum cleaner attachments ● Water ● Approved non-acid evaporator coil cleaners If water or evaporator coil cleaners are being used, the unit should have supply voltage removed and proper lock-out tag-out procedures followed to prevent personal injury. The technician should read the Material Safety Data Sheets (MSDS) and wear the proper Personal Protective Devices (PPDs) prior to applying chemical cleaners.Outdoor CoilThe outdoor coil rejects heat from the refrigerant during cooling operation and is used to absorbheat from the outdoor air during mechanical heating operation. It is essential that the equipmenthave the designed airflow across the coil to facilitate rejection of heat. If this is to be achieved, thecoil must be kept clean and free of debris. The coil should be cleaned according to the approvedmethods. Do not use traditional condenser coil cleaner with MicroChannel condenser coils. If water or condenser coil cleaners are being used, the unit should have supply voltage removed and proper lock-out tag-out procedures followed to prevent personal injury. The technician should read the Material Safety Data Sheets (MSDS) and wear the proper Personal Protective Devices (PPD) prior to applying chemical cleaners.Fan MotorsThe induced draft fan motor, outdoor fan motor, and indoor fan motors are permanently lubricatedand require no maintenance.Even with good filters properly in place, blower wheels and motors will become dust covered aftermonths of operation. The entire blower assembly should be inspected annually. If the motor andwheel are heavily coated with dust, they can be brushed and cleaned with a vacuum cleaner. Inextreme conditions a hose can be used after the motor is removed to clean the blower wheel. 70

Caution must be taken to lock-out and tag-out the unit when evaluating the fan motors for cleanliness and for excessive play or wear to the motors shaft assembly.Natural Gas and Propane (LP) Heating SystemsIt is recommended that all heating systems have a maintenance inspection performed annually bya qualified service technician.During the initial inspection, ensure that all supply and return air registers are free of obstructionsand in the open position.The return air filters should be clean and coils must have unrestricted airflow.The combustion air vent should be visually inspected to ensure proper circulation through the heatexchanger. If excessive soot and dirt are present, clean the discharge of the stack assembly andinspect the burner assembly and heat exchanger.BurnersInshot burners do not have adjustable shutters. If it appears that the burners do not have properflame and the manifold gas pressure is correct, the burners should be removed and cleaned.The inshot burners have flame cross-over ports that allow the flame to transfer from one burner tothe next. The cross-over ports must be kept clean to provide proper burner ignition. Cleaning thecross-over ports may be accomplished with a wire brush.Heat ExchangerThe heat exchanger tubes should be visually inspected for possible defects or cracks in the tubingand cleaned if excessive soot, debris or moisture is present.If any cracks or splits are present within the tubing of the heat exchanger, the system must be putout of service until the heat exchanger is replaced.Flame SensorThe flame sensing rod can be cleaned with a fine to medium steel wool. Do not use emerycloth, which may leave residue on the rod. Inspect for pitting, especially on the propane (LP) gasapplications. 71

Cleaning Flue PassagesWith proper combustion adjustment, the heating element of a gas fired unit will seldom needcleaning. If the element should become sooted due to issues with gas supply, it can be cleanedas follows: 1. Remove the burner assembly as outlined in BURNER INSTRUCTIONS for the unit being serviced. 2. Remove the screws securing the restrictor plate to the tube sheet. 3. Using a wire brush on a flexible wand, brush out the inside of each heat exchanger from the burner inlet and flue outlet ends. 4. Brush out the inside of the restrictor plate to the tube sheet. 5. If soot build-up is particularly bad, remove the vent motor and clean the wheel and housing. 6. After brushing is complete, blow all brushed areas with air or nitrogen. Use a vacuum as needed. 7. Replace parts in reverse order from which they were removed in steps 1 through 3. 72

Appendix A - Wiring DiagramsCOOLING UNIT WITH GAS HEAT CAUTION - OPEN ALL DISCONNECTS WITH RECIPROCATING COMPRESSOR BEFORE SERVICING THIS UNIT 208/230-1-60CONNECTION WIRING DIAGRAM POWER SUPPLY 208/230-1-60 USE COPPER CONDUCTORS ONLY GND BLK 6 230V 208V PUR 1 L1 T1 BLK C PRI COM SINGLE POLE S COMPR CONTACTOR BRN CONTACTOR XFMR R COIL 24V SEC L2 T2 RED BLU 43 40 VA DUAL BLU 42 CAPACITOR GRN 44 FAN BLK/WHT 11 HI PRESS RED 45 YEL 18 YEL 16 YEL 46 1 START RELAY HERM C BRN/WHT 13 1 BRN START CAP 25 RED 7 2 BLK RED 8 BRN 15 BLK/WHT 12 3 GRN W 4 RED OD FAN MOTOR Y GRN 10 5 6 O BLOWER RED 9 DELAY LOW R 180 VOLTAGE C 120 BLK 5 BOX C BLU 23 C 90 PUR 2 R RED 22 Y R 60 W YEL 21 O G WHT 20THERMOSTAT GRN 19 Y CONTROL (CONTINUOUS FAN)RED 32 (LOW) 1 W BOARD GAS BLK VALVE G PUR 26 RED 34 RED/GRN 36 (LOW/MED) 2 N1 ROLLOUT LIMIT (HEATING SPEED) (MED) 3 BLOWER G 2 GRN 4 WHT 33 MOTOR 3 21 RED/BLK 35 YEL 38 6 5 4 (COOLING SPEEDY) EL 31(MED/HIGH) 4 L3 SHARED TAP 5 SEE NOTE 7 C 4 GRN 40 987 (HIGH) YEL 38 FLAME ORG 37 IGNITOR SENSOR PRESSURE ORG 39 W SPD SPARK CONTROL BOARD SETTINGS: COMBUSTION BLOWER POST PURGE: 60 SEC G SPD L1 TRANSFORMER INDOOR BLOWER HEAT ON DELAY: 30 SEC Y SPD IND FS INDOOR BLOWER COOL OFF DELAY: 60 SEC INDOOR BLOWER HEAT OFF DELAY: FIELD SELECT 24V COM 1 2 3 ORG RED 28 DRAFT BRN CAP LINE VOLTAGE WHT 27 MOTOR YEL FIELD INSTALLED POWER LOW VOLTAGE FIELD INSTALLED CONTROL BLU 30 NOTES: 1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/OR NATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT. 2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUST BE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLT WIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION. VERIFY PROPER OPERATION AFTER SERVICING. 3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVE BLACK WIRE FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER. 4. MOTORS ARE INHERENTLY PROTECTED. 5. SEE UNIT NAMEPLATE FOR MAXIMUM FUSE AND/OR CIRCUIT BREAKER SIZE AND MINIMUM CIRCUIT AMPACITY. 6. SELECT INDOOR BLOWER SPEED TO REMAIN WITHIN THE TEMPERATURE RISE RANGE ON THE NAMEPLATE IN HEATING AND TO OBTAIN APPROX. 400 CFM/TON IN COOLING. 7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL, BUT MAY VARY BY MODEL AND APPLICATION. 73

COOLING UNIT GROUND WITH GAS HEAT LUG WITH L1 L2RECIPROCATING COMPRESSOR R RED L2 208/230-1-60 L1 T1 BLK C COMPRES LADDER WIRING DIAGRAM S R RED CAUTION OPEN ALL DISCONNECTS BLK/WHT C OD FAN BEFORE SERVICING THIS UNIT BRN MOTOR BLK/WHT S BRN T2 BRN/WHT DUAL CAPACITOR HC F RED 5 21 YEL RED START RELAY START CAP BLK L MBLOOTWOERRN PUR BLK PUR CONTROL G BOARD DRAFT RELAY MOTOR WHT L1 IND CAP BLK 230V 208V COM PUR PRI XFMR RED 24V SEC BLU 40 VA THERMOSTAT YEL C 3A HI PRESS C R FUSE YEL R BLU O CONTACTOR RED Y CONTROL COIL W BOARD Y WHT G BLU W GRN G RED/GRN LIMIT RED ROLLOUT RED/BLK 3 21 YEL 6 5 4 GRN 987 PRESSURE YEL GAS ORG IGNITOR FLAME VALVE ORG SENSOR ORG 43 2 WHT W SPD L1 SPARK RED G SPD 1 TRANSFORMER 51 Y SPD IND FS BLOWER BLU 24V COM MOTOR 23 C YEL RED74

COOLING UNIT WITH GAS HEAT CAUTION - OPEN ALL DISCONNECTS WITH SCROLL COMPRESSOR BEFORE SERVICING THIS UNIT 208/230-1-60 CONNECTION WIRING DIAGRAM POWER SUPPLY 208/230-1-60 USE COPPER CONDUCTORS ONLY GND 230V 208V BLK 6 L1 T1 BLK C PRI PUR 1 SINGLE POLE S COMPR CONTACTOR BRN COM R L2 T2 RED XFMR DUAL CAPACITOR CONTACTOR 24V SEC COIL 40 VA FAN BLU 43BLU 42 GRN 44 HI PRESS RED 45 YEL 18 YEL 16 HERM C BRN/WHT 13 1 BRN RED 7 2 3 BLK BLK/WHT 12 4 5 GRN W GRN 10 6 RED OD FAN Y MOTOR O R BLOWER RED 9 C DELAY LOW BLK 5 VOLTAGE C 180 C BLU 23 R 120 PUR 2 R BOX RED 22 O RED 34 Y 90 (CONTINUOUS FAN)RED 32 (LOW) 1 Y YEL 21 W 60 W WHT 20 G G GRN 19 CONTROLTHERMOSTAT RED/GRN 36 BOARD BLK (LOW/MED) 2 N 1 PUR 26 2 GRN 4 ROLLOUT LIMIT (HEATING SPEED) (MED) 3 BLOWER G 3 WHT 33 MOTOR 4 3 21 RED/BLK 35 YEL 38 6 5 4 (COOLING SPEEDY) EL 31(MED/HIGH) 4 L SHARED TAP 5 SEE NOTE 7 C GRN 40 987 (HIGH) GAS YEL 38 FLAMEVALVE ORG 37 IGNITOR SENSOR PRESSURE ORG 39 W SPD SPARK CONTROL BOARD SETTINGS: G SPD COMBUSTION BLOWER POST PURGE: 60 SEC Y SPD L1 IND TRANSFORMER INDOOR BLOWER HEAT ON DELAY: 30 SEC FS INDOOR BLOWER COOL OFF DELAY: 60 SEC INDOOR BLOWER HEAT OFF DELAY: FIELD SELECT 24V COM 1 2 3 ORG LINE VOLTAGE RED 28 FIELD INSTALLED POWER DRAFT BRN CAP LOW VOLTAGE MOTOR YEL WHT 27 FIELD INSTALLED CONTROL BLU 30 NOTES: 1. ALL FIELD WIRING TO BE ACCOMPLISHED FOLLOWING CITY, LOCAL AND/OR NATIONAL CODES IN EFFECT AT THE TIME OF INSTALLATION OF THE UNIT. 2. CAUTION : LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. IF ANY OF THE WIRING, AS SUPPLIED WITH THE UNIT, MUST BE REMOVED, IT MUST BE REPLACED WITH TYPE 105 C. 600 VOLT WIRE OR EQUIVALENT CLEARLY RENUMBERED FOR IDENTIFICATION. VERIFY PROPER OPERATION AFTER SERVICING. 3. FACTORY WIRED FOR 230 VOLT SUPPLY POWER. FOR 208 VOLT, MOVE BLACK WIRE FROM THE 230 TO THE 208 VOLT TAP ON THE TRANSFORMER. 4. MOTORS ARE INHERENTLY PROTECTED. 5. SEE UNIT NAMEPLATE FOR MAXIMUM FUSE AND/OR CIRCUIT BREAKER SIZE AND MINIMUM CIRCUIT AMPACITY. 6. SELECT INDOOR BLOWER SPEED TO REMAIN WITHIN THE TEMPERATURE RISE RANGE ON THE NAMEPLATE IN HEATING AND TO OBTAIN APPROX. 400 CFM/TON IN COOLING. 7. BLOWER MOTOR SPEED CONNECTIONS SHOWN ARE TYPICAL, BUT MAY VARY BY MODEL AND APPLICATION. 75

COOLING UNIT GROUND WITH GAS HEAT LUG WITH L1 L2 SCROLL COMPRESSOR R RED 208/230-1-60 L1 T1 BLK C COMPRESLADDER WIRING DIAGRAM S R RED BLK/WHT C OD FAN MOTOR BRN S BRN/WHT T2 L2 DUAL CAPACITOR HC F RED CAUTION BLK L MBLOOTWOERRN PUR OPEN ALL DISCONNECTS BLKBEFORE SERVICING THIS UNIT CONTROL G BOARD DRAFT PUR RELAY MOTOR WHT L1 IND CAP BLK 230V 208V COM PUR PRI XFMR RED 24V SEC BLU 40 VA THERMOSTAT YEL C 3A HI PRESS C R FUSE YEL R BLU O CONTACTOR RED Y CONTROL COIL W BOARD Y WHT G BLU W GRN G RED/GRN LIMIT RED ROLLOUT RED/BLK 3 21 YEL 6 5 4 GRN 987 PRESSURE YEL GAS ORG IGNITOR FLAME VALVE ORG SENSOR ORG 43 2 WHT W SPD L1 SPARK RED G SPD 1 TRANSFORMER 51 Y SPD IND FS BLOWER BLU 24V COM MOTOR 23 C YEL RED76

Appendix B: Accessory Installation and PartsThe following instructions and parts information are provided for quick reference. Always consultUPGNet for the most up-to-date accessory instructions and parts lists.INSTALLATION CONMCOEDFNEITELRL#IDC1AICNKUS0RT1A0B8LT/L1REAADKN0S1I0T9IONINSTRUCTIONSThe Concentric Curb Transition is designed to drop into the curb and convert the square duct unit connections toround duct. For use with both 1RC0501 / 1RC0502 / 1RC0503 / 1RC0504 roof curbs. SUPPLY RETURN ROOF CURB JCI MODEL# RRS MODEL# DUCT SIZE 1AK0108 80-490-4916 16\" ROUND 1AK0109 80-490-5018 18\" ROUNDStep 1:Check for correct part number listed above:Step 2:Attach duct to transition duct connections.Step 3:Install transition in supply/return opening in roof curb.JANUARY 21, 2015 1199092-UAI-B-0115 RRS FORM# YKITRN49 77

IINNSSTTRAULLCATTIOIONNS MSOINFDIGEELLLE#DSDIN1R-SY2TEBACUL0LL4EB7D0K0I7T24 General Converting Enthalpy Control to Dry Bulb Control. This kit is used to convert an economizer from enthalpy 1. Remove filter access panel of fresh air hood and filter. control to dry bulb control, or replacing defective dry bulb 2. Locate enthalpy sensor and unplug harness and sensor. Kit Includes remove the two screws securing sensor. 1 ea. - Dry Bulb Sensor 3. Install dry bulb sensor in the same location of the Tools Required enthalpy sensor securing with the screws removed in l 516\" hex nut driver Step 2. l screwdriver, Phillips-head 4 Plug dry bulb sensor into harness. These tools are not supplied with this kit and must be 5. Move plug on the W7220 module from the S-Bus supplied at time of installation. terminal to the OAT terminal Installation 6. Re-install filter and filter access panel that were Replacing Existing Dry Bulb Sensor removed in Step 1. 1. Remove blower access panel. 2. Locate Existing dry bulb and unplug and remove the two screws securing sensor. 3. Place new dry bulb sensor in the same location securing with the screws removed in Step 2. 4 Re-install blower access panel that were removed in Step 1. Subject to change without notice. Published in U.S.A. 1199084-UAI-B-0115 (YKI725001) Copyright © 2015 by Johnson Controls, Inc. All rights reserved. Supersedes: None York International Corp. 5005 York Drive Norman, OK 7306978

INSTALLATION MODFDUIEAELLL#DESNIN1T-SH2TEAACLL0PL4YE7DK00IT624INSTRUCTIONS 3. Locate Existing sensor and unplug and remove theGeneral two screws holding it in place.This kit is used to convert single enthalpy economizer unitsto dual enthalpy economizer units, and replace a single 4. Place with the new sensor in the same locationenthalpy sensor. securing with the screws removed in Step 3.Kit Includes1 ea. - Enthalpy Sensor 5. Plug the new sensor into the same plug location.2 ea. - 6\" Harness w/ Plug 6. Re-install filter and filter access panel that were2 ea. - Self Drilling ScrewsTools Required removed in Step 2. Converting Single Enthalpy to Dual Enthalpy l 516\" hex nut driver 1. Remove filter access panel of economizer hood and l screwdriver, Phillips-headThese tools are not supplied with this kit and must be remove filter.supplied at time of installation. 2. Take one of the 6\" harness and connect to W7220InstallationReplacing Existing Enthalpy Sensor module. (Refer to wiring diagram)1. To replace the 7400S enthalpy sensor that is 3 Take the dry bulb sensor from kit and connect to defective.2. Remove filter access panel of fresh air hood and second 6\" harness and locate sensor in return duct. remove filter. 4. Route field supplied wires to connect to ¼\" male quick connect terminals of 6\" harness. Follow the mixed air sensor green wires from W7220 through economizer and down to return duct.Subject to change without notice. Published in U.S.A. 1199085-UAI-B-0115 (YKI7400S01)Copyright © 2015 by Johnson Controls, Inc. All rights reserved. Supersedes: None York International Corp. 5005 York Drive Norman, OK 73069 79

IINNSSTTRAULLCATTIOIONNS 0-3M5%ODMEOLT#O2FRMIEIDZL0ED4D7IN0OS5U1TT2AS4LI/LD2EEMDADI0R4D70A5M2P24ER The 0-35% manual outside air system is designed to replace the unit duct cover. No drilling on the unit or field assembly is required. A 2-position control motor that opens the intake damper when the blower is energized. The amount of air is controlled by the a slide damper on damper motor. The intake panel is fully insulated. JCI MODEL# RRS MODEL# A/C UNIT 2MD04705124 82-287-49 2MD04705224 82-287-50 SUPPLY DUCT COVER 2-POSITION MOTOR OUTSIDE AIR INTAKE HOOD UNIT FILTER ACCESS RETURN DUCT COVER (REMOVED) ADJUSTABLE SLIDE DAMPERS Figure 1 Step 1: Check for correct number of parts. See list below: 1 ea. - Outside Air Intake damper assembly with hood and slide damper. Step 2: Remove return air duct cover from inside vent, and save the screws. Step 3: Remove unit filter access panel. Route wiring through unit to connect to fan control in return section. Step 4: Install outside air assembly as shown in Figure 1 over duct opening with the screws removed in Step 2. Step 5: Adjust the slide damper to the desired position. NOTE: It will be necessary to remove intake hood, so the second slide damper can be removed, if the full amount of outside air is required. JANUARY 21, 2015 1199089-UAI-B-0115 RRS FORM# YKI35OM4980

HARNESS DETAIL COMPONENT CODE WIRE COLOR CODE Revision Change Date E# = WIRE END DESIGNATION Terminal Strip E2 STUD #6 18 Ga. Wire TS1 Damper Actuator 24V BLK Black BLU Blue E3 Female ¼ Quick Disc. M847A BRN Brown GRN Green E4 Male ¼ Quick Disc. Insul GRY Grey ORG Orange E6 Wire Nut Size 73B PNK Pink RED Red VIO Violet WHT White YEL Yellow Notes: 2FA08700124 1. Unit wiring shown as reference only. Check unit wiring for actual unit wiring. 0-35% Motorized Outside Air Damper81 D*NA/EB/B*HA 018-060 Date: January 19, 2015 Supercedes: Drawn by: MGL Unit #: 80-287-49 Diagram#: 8028749w Approved by:

INSTALLATION ROMUONDDFEIETLOL#D1SAIQNKUS0AT1AR10LE/L1AEADDKA0P1T11OR INSTRUCTIONS The Round to Square Adaptor is designed to fit over horizontal duct opening and convert the square duct connections to the round duct opening. 14\" ROUND JCI MODEL# RRS MODEL# DUCT SIZE 1AK0110 82-490-49 12\" ROUND 1AK0111 82-490-50 14\" ROUND Step 1: Check for correct part number listed above: Step 2: Attach duct adaptor to horizontal duct openings on unit. Step 3: Install supply/return duct work to round connection. JANUARY 21, 2015 1199091-UAI-B-0115 RRS FORM# YKITAK4982

IINNSSTTRAULLCATTIOIONNS 0-3M5%ODMEALN#FUISEA1LL-D1OFINAUS0T5TS0AI1DLE/LSEA1DI-R1FDAA0M50P2ERThe 0-35% manual outside air system is designed to replace the unit duct cover. No drilling on the unit or field assembly isrequired. The amount of outside air is controlled by simply adjusting the slide damper. The panel is fully insulated.JCI MODEL# RRS MODEL# A/C UNITS1-1FA0501 82-285-49S1-1FA0502 82-285-50 SUPPLY DUCT COVER OUTSIDE AIR INTAKE HOOD RETURN DUCT COVER (REMOVED) ADJUSTABLE SLIDE DAMPERS Figure 1Step 1:Check for correct number of parts. See list below: 1 ea. - Outside Air Intake panel assembly with hood and slide damper.Step 2:Remove bottom return air duct cover from inside unit, and save the screws.Step 3:Install outside air assembly as shown in Figure 1 over duct opening with the screws removed in Step 2.Step 4:Adjust the slide damper to the desired position.NOTE: It will be necessary to remove intake hood, so the second slide damper can be removed, if the full amount of outside air is required.Subject to change without notice. Published in U.S.A. 1199090-UAI-A-0115 (YKI35OA49)Copyright © 2015 by Johnson Controls, Inc. All rights reserved. Supersedes: None York International Corp. 5005 York Drive Norman, OK 73069 83

IINNSSTTRAULLCATTIOIONNS M0O-3D5E%LM# OS1T-O2FRMIEIDZL0ED4D7IN0OS5U1TT2AS4LI/LDSEE1DA-2IMRDD0A4M70P5E2R24 The 0-35% motorized outside air system is designed to replace the unit duct cover. No drilling on the unit or field assembly is required. A 2-position control motor that opens the intake damper when the blower is energized. The amount of air is controlled by the a slide damper on damper motor. The intake panel is fully insulated. JCI MODEL# RRS MODEL# A/C UNIT S1-2MD04705124 82-287-49 S1-2MD04705224 82-287-50 SUPPLY DUCT COVER 2-POSITION MOTOR OUTSIDE AIR INTAKE HOOD UNIT FILTER ACCESS RETURN DUCT COVER (REMOVED) ADJUSTABLE SLIDE DAMPERS Figure 1 Step 1: Check for correct number of parts. See list below: 1 ea. - Outside Air Intake damper assembly with hood and slide damper. Step 2: Remove return air duct cover from inside vent, and save the screws. Step 3: Remove unit filter access panel. Route wiring through unit to connect to fan control in return section. Step 4: Install outside air assembly as shown in Figure 1 over duct opening with the screws removed in Step 2. Step 5: Adjust the slide damper to the desired position. NOTE: It will be necessary to remove intake hood, so the second slide damper can be removed, if the full amount of outside air is required. Subject to change without notice. Published in U.S.A. 1199089-UAI-A-0115 (YKI35OM49) Copyright © 2015 by Johnson Controls, Inc. All rights reserved. Supersedes: None York International Corp. 5005 York Drive Norman, OK 7306984

HARNESS DETAIL COMPONENT CODE WIRE COLOR CODE Revision Change Date E# = WIRE END DESIGNATION Terminal Strip E2 STUD #6 18 Ga. Wire TS1 Damper Actuator 24V BLK Black BLU Blue E3 Female ¼ Quick Disc. M847A BRN Brown GRN Green E4 Male ¼ Quick Disc. Insul GRY Grey ORG Orange E6 Wire Nut Size 73B PNK Pink RED Red VIO Violet WHT White YEL Yellow Notes: 1. Unit wiring shown as reference only. Check unit wiring for actual unit wiring.85

1199087-UAI-A-0215 (YKICO206) ACCESSORY KIT INSTALLATION INSTRUCTIONS CO2 SensSo1r -I2nAsQta0ll4a7ti0o0n8I2n4structions WARNING: BEFORE INSTALLING READ ALL OF THE MANUFACTURERS INSTALLATION AND MAINTENANCE INSTRUCTIONSStep 1:Check for the correct number of parts: See list below:1 ea CPCiOOto22t Sensor1 ea Sensor Base1 ea Tube Kit1 ea (tubing to be cut to length for each application)6 ea C8 Ox 2½S\"ePnAsNor/PBHraILckSectrfeowr s3-6 ton2 ea 8 x ¾\" PAN/PHIL Screws1 ea 10' Red Wire1 ea 10' Brown Wire8 ea. Wire Ties2 ea #10-16 x ½ HexTex Screws 3-6 TON BRACKET COA2NSDENBSAOSRE PITOT TUBE KIT Figure 1 Johnson Controls Inc. 186

1199087-UAI-A-0215(YKICO206)1. AaeSbnentettoaeweuccFeghoiehgnmnucoebrlmeetyaai2zrlree.abtrnruacirtcnekmaferuiotrstmfotlobdbweaaamsanetptdapescarihndbeeloadfddtuueoncsatitfo,oltporoecpaanittionliootgcntua(wwbtieoiitt)nhh. CO2 SENOSOR MODULE CLEAR TUBING Figure 4 5. Wire CO2 module. See Figure 5. Figure 22. Atdeucatbtomaencpohienmrptiibzhtoleeatrdtriuesebstuue)s.rnetSodeameairseFstnaitgorluetbratreomac3hka(eUvtesaepsictsoahtuottuwiobnne, iwwnihptheantphiatoontfPITOT TUBE Figure 5 6. dWFiiagirguerraeCm6O.2(SmeeodFuilgeutroe E7c).onToiemdizoewr nCoanntyrowl ipreesr.wiSrieneg Figure 3 Figure 63. SFiegcuurree4C. O2 sensor module to bracket as shown. See Johnson Controls Inc.4. Attach tubing to both legs of pitot tube. See Figure 4.2 87

1199087-UAI-A-0215 (YKICO206) Figure 7 Johnson Controls Inc. 388

This Page Intentionally Left BlankSubject to change without notice. Published in U.S.A. 1199087-UAI-A-0215 (YKICO206)Copyright © 2015 by Johnson Controls, Inc. All rights reserved. Supersedes: None York International Corp. 89 5005 York Drive Norman, OK 73069

1199093-UAI-A-0115 YKICRB49 ACCESSORY KIT INSTALLATION INSTRUCTIONS S1-1R\"CH0in50g1e\"/ RS1o-o1fRCCu0r5b0I2ns/ tSa1ll-a1tRioCn0I5n0s3tr/uSc1ti-o1nRsC0504This Roof Curb is built to NRCA specifications and is constructed of 18 gauge galvanized steel with a full perimeter 1\" x 4\"wood nailer strip. Curb height is determined by the part number as listed below. York Model# Dimensions Height S1-1RC0501 RSI Model# 8 S1-1RC0502 14 S1-1RC0503 80-201-4908 8 S1-1RC0504 80-201-4914 14 80-201-5008 80-201-5014SCtheepck1:for the correct number of parts. See list below.2 ea. Curb Long Sides (A) Figure 12 ea. Curb Short Side (B)2 ea. Vertical Duct Support (C)2 ea. Horizontal Duct Support (D)2 ea. Gasket ¾\" x 1 ¼\" x 14'1 ea. Hardware Package contains: 10 ea. #10 X ½\" Hex Screws 4 ea. \"Hinge\" Pins (B) (C (D) (A) (D) (C (A) (B) Figure 2SLateypou2t:the curb pieces before assembly to insure that all the necessary pieces are included.Johnson Controls Inc. U. S. PATENT 5148647 190

1199093-UAI-A-0115YKICRB49 HINGE PIN TAPERED END HINGE CURB SIDE Figure 3 Figure 4Step 3:Corner Assembly: Align each curb side as shown in Figure 3. Using a hammer, drive the curb \"hinge\" pin down until thetop of the pin is below the top of the curb as shown in Figure 4. Figure 5Step 4:After the four corners are assembled; the curb should be checked to be sure it is in \"square\". Do this by measuringdiagonally from each opposite corner as shown in Figure 5. The two measurements should be the same for each direction. DETAILS1. Brace interlocks 2. Brace interlocks 3. Tab rests on top of curb for with pan or other added support. with curb. brace.Duct Support flange goes in slot on Duct Support flange goes in slot on Duct Support is supported by \"tabs\".curb. Screw Brace to curb. pan or other brace. Screw brace Screw pan to curb.2 together. Johnson Controls Inc. 91

1199093-UAI-A-0115 YKICRB49The Roof Curb can now have the duct supports installed.Step 5:Install horizontal duct supports (D) on the curb as shown with the roof opening over the desired duct location. See Figure 6and DETAILS #1.Step 6:Place the vertical duct supports (C) on the curb and the horizontal duct supports (D), making sure that it is in the rightlocation. See Figure 6 and DETAILS #2.Step 7:If the curb is being assembled and moved to another location, attach the vertical duct supports (C) and horizontal ductsupports (D) to the curb as shown in the \"DETAILS\".Step 8:Place one strip of ¾\" x 1 ¼\" gasket on the top edges of the curb and vertical duct supports (C) and horizontal duct supports.See Figure 6. TOP VIEW F (C) RETURN 2 (D) AC ROOF OPENING DETAILS #2 19\" x 47\" 2 DETAILS #1 (D) E (C) SUPPLY G D B Figure 6 JCI Model# RRS Model# A B C D EF G Return Duct Supply Duct Height S1-1RC0501 80-201-4908 49 132 33 ½ 47 ¼ 33 ¾ 15 15 18 17 ½ x 14 ½ 17 ½ x 14 ½ 8 S1-1RC0502 80-201-4914 14 S1-1RC0503 80-201-5008 48 78 43 38 47 18 41 58 16 316 16 316 18 17 ½ x 15 ¾ 17 ½ x 15 ¾ 8 S1-1RC0504 80-201-5014 14Johnson Controls Inc. 392

ROOFING INSTRUCTIONS WOOD NAILER CURB FRAME COUNTER FLASHING (FIELD SUPPLIED) ROOFING FELT (FIELD SUPPLIED) RIGID INSULATION (FIELD SUPPLIED) CANT STRIP (FIELD SUPPLIED)Subject to change without notice. Published in U.S.A. 1199093-UAI-A-0115 (YKICRB49)Copyright © 2015 by Johnson Controls, Inc. All rights reserved. Supersedes: None York International Corp. 93 5005 York Drive Norman, OK 73069

INSTALLATION MODFDUIEAELLL#DESNIN1T-SH2TEAACLL0PL4YE7DK00IT624 INSTRUCTIONS 3. Locate Existing sensor and unplug and remove the General two screws holding it in place. This kit is used to convert single enthalpy economizer units to dual enthalpy economizer units, and replace a single 4. Place with the new sensor in the same location enthalpy sensor. securing with the screws removed in Step 3. Kit Includes 1 ea. - Enthalpy Sensor 5. Plug the new sensor into the same plug location. 2 ea. - 6\" Harness w/ Plug 6. Re-install filter and filter access panel that were 2 ea. - Self Drilling Screws Tools Required removed in Step 2. Converting Single Enthalpy to Dual Enthalpy l 516\" hex nut driver 1. Remove economizer control access door. l screwdriver, Phillips-head 2. Take one of the 6\" harness and connect to W7220 These tools are not supplied with this kit and must be supplied at time of installation. module. (Refer to wiring diagram) Installation 3 Take the enthalpy sensor from kit and connect to Replacing Existing Enthalpy Sensor 1. To replace the 7400S enthalpy sensor that is second 6\" harness and locate sensor in return duct. defective. 4. Route field supplied wires to connect to ¼\" male quick 2. Remove filter access panel of fresh air hood and remove filter. connect terminals of 6\" harness. Follow the mixed air sensor green wires from W7220 through economizer and down to return duct. Subject to change without notice. Published in U.S.A. 1199085-UAI-A-0115 (YKIDE49) Copyright © 2015 by Johnson Controls, Inc. All rights reserved. Supersedes: None York International Corp. 5005 York Drive Norman, OK 7306994

1199083-UAI-A-0115 YKIGEJ49ACCESSORY KIT INSTALLATION INSTRUCTIONS ESc1o-n2EomE0iz4e7r0I8n4s2t4al/laSt1io-2nEInEs0t4r7u0c8ti5o2n4sGeneral FILTER ACCESS DOORThis instruction provides the necessary information toproperly field-install economizer assembly on 2 tonthrough 5 ton single package rooftop units.The damper accessory provides the return air and outdoorair dampers and actuator for economizer operations.Contained in this kit are all rain hood components.Kit Includes ECONOMIZER ASSEMBLY Figure 2: Filter Access Door 3. Remove screws in immediate area on mid pan. See Figure 3 Figure 1: Kit Components11 -- HE1152caoereednaaawomar---iezeBraTTNAgeioser.smWe1im0nraabxpll½ysBw\"loS/cFkeillwft-editrrhillWingireSHcraerwnesss MID PAN ECONOMIZER TOP PANEL Figure 3: Mid pan6 ft - Gasket 1¾8 X ½ ¼ 4. Remove top plate of economizer assembly. See7 ft - Gasket x1 Figure 4.Tools Requiredl 516\" hex socket driverl screwdriver, Phillips-headl screwdriver, small flat-bladeInstallation1. Disconnect the power supply. ECONOMIZER TOP PANEL2. Removal of filter access door. See Figure 2. Figure 4: Economizer Top PanelJohnson Controls Inc. 1 95

1199083-UAI-A-0115 Figure 7:YKIGEJ245. Before installing economizer into the unit, make sure the duct cover has been removed. See Figure 5. Place the economizer into the unit and support the economizer from underneath until Step 6 is completed. Place gasket as needed. DUCT COVER BOTTOM DUCT OPENING Figure 8: Figure 5: Duct Cover / Opening 7. Replace screws in mid pan to secure economizer to unit.6. Replace top panel of economizer assembly, with front flange under mid pan and place screws back into place. See Figure 6. 6a. Only for 4 & 5 Ton units - Use the side door provided to close gap between economizer and compressor panel. FRONT FLANGE Figure 9: 8. Drill a ½\" hole in compressor barrier as needed to route wiring to main control board and sensors. Tightly seal opening around wires. Figure 6: Front Flange Johnson Controls Inc.296

1199083-UAI-A-0115 YKIGEJ24 10. Route wiring through existing openings to control panel.Figure 10: Figure 14: Figure 11: Figure 15:9. Mixed air temperature sensor should be mounted on the blower wheel wrap. Use only #8 screws shorter than ½\" in length to avoid hitting blower wheel. Figure 12: 3 Figure 13: 97Johnson Controls Inc.

Figure 16: Wiring Connections Subject to change without notice. Published in U.S.A. 1199083-UAI-A-0115 (YKIGEJ49) Copyright © 2015 by Johnson Controls, Inc. All rights reserved. Supersedes: None York International Corp. 5005 York Drive Norman, OK 7306998

1199084-UAI-A-0115 YKIHEJ49 ACCESSORY KIT INSTALLATION INSTRUCTIONS HorizoSn1ta-2l EEEc0o4n7o0m8i6z2e4r /InSs1t-a2llEaEti0o4n7I0n8s7t2ru4ctionsGeneral 1.382 6.840This instruction provides the necessary information to 2.423properly field-install horizontal economizer assembly on 2 0.330ton through 5 ton single package rooftop units.Horizontal Economizers are used with units for automatic 10.764sensor-controlled introduction of outdoor air into thesystem through an electro-mechanically controlleddamper.Kit Includes FRESH AIR INTAKE HOOD ADAPTOR PANEL (MATES TO RETURN OPENING LOGIC MODULE & CONTROLS 0.330 Figure 2: Hole Layout for S1-2EE04708624 CONTROL 2.433 9.874 1.860 2.741 AND FILTER 0.330 ACCESS PANEL RETURN DAMPER SECTION Figure 1: Kit Components 10.764118 --- #WE1ci0roinn-go1m6Diizaxegr1r2aAHmsesSxemtTicebkcleyrScrewsTools Requiredl 516\" hex socket driverl screwdriver, Phillips-head 2.423l screwdriver, small flat-bladeInstallation 0.5921. Disconnect the power supply. Figure 3: Hole Layout for S1-2EE047087242. Remove filter access panels from economizer and RTU.3. To mount economizer, holes will need to be drilled into the RTU. Determine which economizer is being mounted, if S1-2EE04708624 use Figure 2 for S1-2EE04708724 use Figure 3 for hole locations.Johnson Controls Inc. 1 99