Inc. Heat Pump User Manual

ManualsBrandsJohnson Controls ManualsHeat PumpSUNLINE 2000 BQ 036

INSTALLATION

MANUAL

CAUTION: READ ALL SAFETY GUIDES BEFORE YOU

BEGIN TO INSTALL YOUR UNIT.

SAVE THIS MANUAL

ISO 9001

Certified Quality

Management System

SUNLINE 2000™

SINGLE PACKAGE HEAT PUMP

BQ 036, 048 & 060

EXPORT ONLY

364985-XIM-B-0508

CONTENTS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SAFETY CONSIDERATIONS. . . . . . . . . . . . . . . . . 4

INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . 4

APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . . 5

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

START-UP (COOLING) . . . . . . . . . . . . . . . . . . . . 35

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . 35

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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.

Summary of content (40 pages)

PAGE 1
INSTALLATION MANUAL SUNLINE 2000™ SINGLE PACKAGE HEAT PUMP BQ 036, 048 & 060 CONTENTS EXPORT ONLY GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . 4 INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . 4 APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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364985-XIM-B-0508 TABLE OF CONTENTS GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . 4 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 RENEWAL PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . 4 APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PRODUCT NOMENCLATURE . . . . . . . . . . . . . . . .
PAGE 3
64985-XIM-B-0508 LIST OF FIGURES Fig. # Tbl. # Pg. # Pg. # 12 ELECTRICAL DATA - BQ036-060 DIRECT DRIVE W/POWERED CONVENIENCE OUTLET . . . . . . . . . 19 1 RECOMMENDED DRAIN PIPING . . . . . . . . . . . . . . . . 7 2 COMPRESSOR RESTRAINING BRACKET . . . . . . . . 8 3 TYPICAL FIELD POWER & CONTROL WIRING . . . . 9 4 ENTHALPY SETPOINT ADJUSTMENT . . . . . . . . . . 13 5 HONEYWELL ECONOMIZER CONTROL W7212 . . .
PAGE 4
364985-XIM-B-0508 GENERAL YORK Model BQ units are single package heat pumps equipped with optional factory installed electric heaters. These are designed for outdoor installation on a rooftop or slab. The units are completely assembled on rigid, permanently attached base rails. All piping, refrigerant charge, and electrical wiring is factory installed and tested.
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364985-XIM-B-0508 PRODUCT NOMENCLATURE 3-5 Ton Sunline Simplicity Model Number Nomenclature B Q 048 N04 A 2 A AA 1 0 1 2 4 A Product Category Product Style B = HP, Single Pkg., R-22 A = Style A 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. Q = 10.0 SEER HP SS Drain Pan CPC Controller, DFS, APS Johnson Controller, DFS, APS Nominal Cooling Capacity Honeywell Controller, DFS, APS 036 = 3.
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364985-XIM-B-0508 INSTALLATION In Canada: INSTALLATION SAFETY INFORMATION: • Current Canadian Electrical Code C22.1. Read these instructions before continuing this appliance installation. This is an outdoor combination heating 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. • Local plumbing and waste water codes. • Other applicable local codes. 1.
PAGE 7
364985-XIM-B-0508 RIGGING AND HANDLING Exercise care when moving the unit. Do not remove any packaging until the unit is near the place of installation. Rig the unit by attaching chain or cable slings to the lifting holes provided in the base rails. Spreader bars, whose length exceeds the largest dimension across the unit, MUST BE USED. Units may also be moved or lifted with a forklift. Slotted openings in the base rails are provided for this purpose. Fork lengths must be a minimum of 42 inches.
PAGE 8
364985-XIM-B-0508 COMPRESSORS FILTERS Units are shipped with compressor mountings factoryadjusted and ready for operation. One-inch or two-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 shutdown. Minimum filter area and required sizes are shown in Physical Data Table 7.
PAGE 9
364985-XIM-B-0508 TYPICAL POWER WIRING REFER TO THE ELECTRICAL DATA TABLES TO SIZE THE DISCONNECT SWITCH, OVERCURRENT PROTECTION AND WIRING. TYPICAL CONTROL WIRING COOLING / HEATING (24 VOLT THERMOSTAT) THERMOSTAT 1 TERMINALS ADD JUMPER RH UNIT TERMINAL STRIP TB1 RC R Y Y1 24 VOLT TRANSFORMER Y2 W W1 W2 G G C 1 24 VOLT THERMOSTAT 2ET07701024. TO CONTROL THE ECONOMIZER ON THE SECOND STAGE COOLING OR TO HAVE AN ELECTRIC HEAT ACCESSORY WITH TWO STAGES OF HEAT, USE THERMOSTAT 2TH0471024.
PAGE 10
364985-XIM-B-0508 THERMOSTAT 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 the manufacturer's instructions enclosed with the thermostat for general installation procedure. A minimum of seven color-coded insulated wires (#18 AWG) should be used to connect the thermostat to the unit.
PAGE 11
364985-XIM-B-0508 TABLE 3: ELECTRIC HEATER CFM LIMITATIONS MINIMUM SUPPLY AIR CFM UNIT MODEL SIZE NOMINAL TONS 036 (3) 048 (4) 060 (5) VOLTAGE HEATER SIZE NOMINAL KW 5 7 10 15 20 30 208/230-1-60 900 900 900 900 900 - 208/230-3-60 900 900 900 900 900 - 460-3-60 - 900 900 900 900 - 600-3-60 - - 900 900 900 - 208/230-1-60 1200 1200 1200 1200 1200 - 208/230-3-60 1200 1200 1200 1200 1200 - 460-3-60 - 1200 1200 1200 1200 - 600-3-60 - - 1200 1200 1
PAGE 12
364985-XIM-B-0508 MINIMUM POSITION ADJUSTMENT • With thermostat set to indoor fan on position, or terminals “R” to “G” energized, turn the Minimum Position Adjusting screw (located on the damper control module) counterclockwise until the desired minimum damper position has been attained. ENTHALPY SET POINT ADJUSTMENT The enthalpy setpoint may now be set by selecting the desired setpoint shown in the Enthalpy Setpoint Adjustment Figure 4.
PAGE 13
364985-XIM-B-0508 CONTROL CURVE CONTROL POINT APPROX.
PAGE 14
364985-XIM-B-0508 BACK OF UNIT A 447/8 BACK OF UNIT A 447/8 821/4 821/4 D B F X X B APPROXIMATE CENTER OF GRAVITY CONDENSER COIL END OF UNIT C Y FRONT OF UNIT C E APPROXIMATE CENTER OF GRAVITY D Y FRONT OF UNIT CONDENSER COIL END OF UNIT FIGURE 6 - FOUR AND SIX POINT LOADING TABLE 4: CENTER OF GRAVITY (ALL MODELS) DIMENSION 3 - 5 TON X 40-¾” Y 19-¾” TABLE 5: BQ 4 POINT LOADS WEIGHT DISTRIBUTION UNIT TOTAL A B C D BQ036 628 139 137 174 177 BQ048 668 148 146 185 189
PAGE 15
364985-XIM-B-0508 TABLE 7: PHYSICAL DATA BQ MODELS Centrifugal Blower (Dia. x Wd. in.) EVAPORATOR BLOWER 060 12 X 10 12 X 10 12 X 10 1/2 3/4 1 Fan Motor HP (Belt Drive) 1 1/2 1 1/2 1 1/2 Fan Motor HP (Belt Drive High Static) 1 1/2 1 1/2 2 Rows Deep 4 3 3 Fins Per Inch 16 15 15 Face Area (Sq. Ft.) 4.3 5.1 5.1 Propeller Dia. (in.) 22 22 24 Fan Motor Hp 1/3 1/2 1/2 4500 CONDENSER FANS Nom. CFM 4300 4200 Rows Deep 1 1 1 Fins Per Inch 20 20 20 Face Area (Sq. Ft.
PAGE 16
364985-XIM-B-0508 TABLE 9: ELECTRICAL DATA - BQ036-060 DIRECT DRIVE W/O POWERED CONVENIENCE OUTLET Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 11.9 85.0 16.7 1.7 4.4 0.0 230-3-60 11.9 85.0 16.7 1.7 4.4 0.0 460-3-60 5.9 42.0 8.2 1.0 2.2 0.0 575-3-60 4.8 34.0 6.7 1.0 2.2 0.0 208-3-60 14.7 130.0 23.0 2.3 5.0 0.0 230-3-60 14.7 130.0 23.0 2.3 5.0 0.0 460-3-60 7.7 64.0 12.0 1.3 2.2 0.
PAGE 17
364985-XIM-B-0508 TABLE 10: ELECTRICAL DATA - BQ036-060 BELT DRIVE W/O POWERED CONVENIENCE OUTLET Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 11.9 85.0 16.7 1.7 5.2 0.0 230-3-60 11.9 85.0 16.7 1.7 5.2 0.0 460-3-60 5.9 42.0 8.2 1.0 2.6 0.0 575-3-60 4.8 34.0 6.7 1.0 2.0 0.0 208-3-60 14.7 130.0 23.0 2.3 5.2 0.0 230-3-60 14.7 130.0 23.0 2.3 5.2 0.0 460-3-60 7.7 64.0 12.0 1.3 2.6 0.
PAGE 18
364985-XIM-B-0508 TABLE 11: ELECTRICAL DATA - BQ036-060 BELT DRIVE HIGH STATIC W/O POWERED CONVENIENCE OUTLET Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 11.9 85.0 16.7 1.7 5.2 0.0 230-3-60 11.9 85.0 16.7 1.7 5.2 0.0 460-3-60 5.9 42.0 8.2 1.0 2.6 0.0 575-3-60 4.8 34.0 6.7 1.0 2.0 0.0 208-3-60 14.7 130.0 23.0 2.3 5.2 0.0 230-3-60 14.7 130.0 23.0 2.3 5.2 0.0 460-3-60 7.7 64.0 12.0 1.
PAGE 19
364985-XIM-B-0508 TABLE 12: ELECTRICAL DATA - BQ036-060 DIRECT DRIVE W/POWERED CONVENIENCE OUTLET Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 11.9 85.0 16.7 1.7 4.4 10.0 230-3-60 11.9 85.0 16.7 1.7 4.4 10.0 460-3-60 5.9 42.0 8.2 1.0 2.2 5.0 575-3-60 4.8 34.0 6.7 1.0 2.2 4.0 208-3-60 14.7 130.0 23.0 2.3 5.0 10.0 230-3-60 14.7 130.0 23.0 2.3 5.0 10.0 460-3-60 7.7 64.0 12.0 1.3 2.
PAGE 20
364985-XIM-B-0508 TABLE 13: ELECTRICAL DATA - BQ036-060 BELT DRIVE W/POWERED CONVENIENCE OUTLET Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 11.9 85.0 16.7 1.7 5.2 10.0 230-3-60 11.9 85.0 16.7 1.7 5.2 10.0 460-3-60 5.9 42.0 8.2 1.0 2.6 5.0 575-3-60 4.8 34.0 6.7 1.0 2.0 4.0 208-3-60 14.7 130.0 23.0 2.3 5.2 10.0 230-3-60 14.7 130.0 23.0 2.3 5.2 10.0 460-3-60 7.7 64.0 12.0 1.3 2.6 5.
PAGE 21
364985-XIM-B-0508 TABLE 14: ELECTRICAL DATA - BQ036-060 BELT DRIVE HIGH STATIC W/POWERED CONVENIENCE OUTLET Size (Tons) Volt Compressors (each) RLA LRA MCC OD Fan Motors (each) Supply Blower Motor Pwr Conv Outlet FLA FLA FLA 208-3-60 11.9 85.0 16.7 1.7 5.2 10.0 230-3-60 11.9 85.0 16.7 1.7 5.2 10.0 460-3-60 5.9 42.0 8.2 1.0 2.6 5.0 575-3-60 4.8 34.0 6.7 1.0 2.0 4.0 208-3-60 14.7 130.0 23.0 2.3 5.2 10.0 230-3-60 14.7 130.0 23.0 2.3 5.2 10.0 460-3-60 7.7 64.0 12.
PAGE 22
364985-XIM-B-0508 TABLE 15: ELECTRIC HEAT CORRECTION FACTORS NOMINAL VOLTAGE VOLTAGE kW CAP. MULTIPLIER 208 208 0.75 240 230 0.92 480 460 0.92 600 575 0.92 TABLE 16: VOLTAGE LIMITATIONS1 VOLTAGE POWER SUPPLY MIN. MAX. 208/230-3-60 187 253 460-3-60 414 506 575-3-60 518 630 1. Utilization Range “A” in accordance with ARI Standard 110.
PAGE 23
364985-XIM-B-0508 DETAIL “A” FIGURE 8 - UNIT WITH ECONOMIZER RAINHOOD DETAIL “B” FIGURE 9 - UNIT WITH FIXED OUTDOOR AIR/MOTORIZED DAMPER RAINHOOD Johnson Controls Unitary Products 23
PAGE 24
364985-XIM-B-0508 FIGURE 10 - UNIT DIMENSIONS (REAR VIEW) TABLE 18: MINIMUM CLEARANCES Filter Access LOCATION CLEARANCE Front 24” (Cooling/Electric Heat) 32” (Gas Heat) Rear 12” (Less Economizer) 36” (With Economizer or Fixed Air/Motorized Damper) Left Side (Filter Access) 24” (Less Economizer) 36” (With Economizer) Right Side (Cond.
PAGE 25
364985-XIM-B-0508 TABLE 19: SUPPLY AIR BLOWER PERFORMANCE (BQ036 BELT DRIVE) - SIDE DUCT APPLICATION Available External Static Pressure - IWG1 Air 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP 800 1000 1200 1400 1600 1. 2. 3. 4. Field Supplied Drive 678 0.37 761 0.44 699 0.42 782 0.49 727 0.45 810 0.52 759 0.51 842 0.58 795 0.60 878 0.67 840 862 889 922 958 0.52 0.56 0.60 0.65 0.74 Standard Drive Option 917 0.
PAGE 26
364985-XIM-B-0508 TABLE 23: SUPPLY AIR BLOWER PERFORMANCE (BQ060 BELT DRIVE) - SIDE DUCT APPLICATION Available External Static Pressure - IWG1 Air 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 Flow (CFM) RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP RPM BHP Field Supplied Drive Standard Drive Option HIgh Static Drive Option 1200 680 0.47 781 0.52 874 0.58 960 0.65 1041 0.72 1115 0.80 1185 0.88 1251 0.96 1314 1.05 1375 1.14 1400 706 0.56 807 0.61 901 0.
PAGE 27
364985-XIM-B-0508 TABLE 26: SUPPLY AIR BLOWER PERFORMANCE (BQ036, 048 & 060 DIRECT DRIVE) BOTTOM DUCT APPLICATION 0.2 WATTS CFM WATTS CFM WATTS CFM WATTS CFM WATTS CFM WATTS CFM WATTS CFM WATTS 53 1.0 CFM 43 0.9 WATTS HI MED LOW HI MED LOW HI MED LOW 33 AVAILABLE EXTERNAL STATIC PRESSURE - IWG2 0.5 0.6 0.7 0.8 0.4 CFM UNIT MOTOR1 TONNAGE SPEED 0.
PAGE 28
364985-XIM-B-0508 Drive Selection 1. Determine desired airflow. 2. Calculate or measure the amount of external static pressure. 3. Using the operating point determined from steps 1 & 2, locate this point on the appropriate supply air blower performance table. (Linear interpolation may be necessary.) 4. Noting the RPM and BHP from step 3, locate the appropriate model and drive on the RPM selection table. 5. Review the BHP compared to the motor options available. Select the appropriate motor. 6.
PAGE 29
364985-XIM-B-0508 Altitude/Temperature Correction Factors Air Temp. 40 50 60 70 80 90 100 0 1.060 1.039 1.019 1.000 0.982 0.964 0.946 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 Altitude (Ft.) 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.
PAGE 30
364985-XIM-B-0508 PHASING 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 misphased. Change the incoming line connection phasing to obtain proper rotation. (Scroll compressors operate in only one direction. If the scroll is drawing low amperage, has similar suction and discharge pressures, or producing a high noise level, the scroll is misphased).
PAGE 31
364985-XIM-B-0508 under field conditions would be inaccurate. To assure a dry coil, the compressors should be deactivated 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 CFM (Figure 13). Failure to properly adjust the total system air quantity and static pressure can result in extensive system damage.
PAGE 32
364985-XIM-B-0508 ECONOMIZER WITH SINGLE ENTHALPY SENSOR - When the room thermostat calls for cooling, 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 dampers 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” energizes the economizer.
PAGE 33
364985-XIM-B-0508 ing is still present at the conclusion of the ASCD, the UCB will re-energize the compressor. trolled. On any fault, the system will be affected by any safety/preventive action. Should a freezestat open three times within two hours of operation, the UCB will lock-out the compressor and flash a code (see Table 32). The unit control board monitors the temperature limit switch of the electric heat.
PAGE 34
364985-XIM-B-0508 DEFROST MODE SAFETY CONTROLS As mentioned earlier, the defrost control (DC) utilizes a time/temperature defrost scheme. The following two conditions must be met before the DC will enter a defrost mode: The control circuit includes the following safety controls: The defrost thermostat (SD) must be closed. This normally open thermostat is mounted on the liquid line and is set to close at 28 ± 4°F.
PAGE 35
364985-XIM-B-0508 Refer to Table 31 for the required electric heat anticipator setting. POST START CHECK LIST TABLE 31: ELECTRIC HEAT ANTICIPATOR SETPOINTS HEATER KW VOLTAGE 3. Compressor will energize after the built-in time delay (five minutes). 1. Verify proper system pressures. SETTING, AMPS 2. Measure the temperature drop across the evaporator coil. TH1 TH2 5 0.024 0.35 7 0.024 0.35 0.024 0.35 0.024 0.35 20 0.024 0.35 30 0.024 0.35 7 0.024 0.35 10 0.024 0.35 1.
PAGE 36
4985-XIM-B-0508 has energized when the fan switch is in the AUTO position, check the room thermostat for contact between R and G in the AUTO position during calls for cooling. 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 M2, contactor, and that the contactor is pulled in. Check for loose wiring between the contactor and the supply air blower motor. 4.
PAGE 37
364985-XIM-B-0508 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. For units with factory installed economizers, the UCB is programmed to lock out compressor operation when the LAS set point is reached. NOTE: While the above step will reset any lockouts, For units without factory installed or with field installed economizers, the UCB allows compressor operation all the time.
PAGE 38
364985-XIM-B-0508 MAINTENANCE NORMAL MAINTENANCE Prior to any of the following maintenance procedures, shut off all electric power to the unit to prevent personal injury. FILTERS Inspect once a month. Replace disposable or clean permanent type as necessary. DO NOT replace permanent type with disposable. The dimensional size of the replacement filter must be the same as the replaced filter. MOTORS Outdoor fan motors are permanently lubricated and require no maintenance.
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364985-XIM-B-0508 Johnson Controls Unitary Products 39