Johnson Controls DNQ024, Installation Manual

Page 1: ...ical Field Control Wiring Diagram Single Stage Thermostat Single Stage Gas Heat 11 8 Typical Field Control Wiring Diagram Single Stage Thermostat Two Stage Gas Heat 11 9 Typical Field Control Wiring Diagram Two Stage Thermostat Two Stage Gas Heat 12 10 Typical Field Power Wiring Diagram 12 11 External Supply Connection External Shut Off 15 12 Flue Vent Outlet Air Hood 16 13 Control Board Speed Tap...

Page 2: ... and mechanical codes Before performing service or maintenance operations on unit turn off main power switch to unit Electrical shock could cause personal injury Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier This sys...

Page 3: ...FPA No 70 Latest Edition 2 National Fuel Gas Code ANSI Z223 1 Latest Edition 3 Gas Fired Central Furnace Standard ANSI Z21 47a Latest Edition 4 Local building codes and 5 Local gas utility requirements This product must be installed in strict compliance with the enclosed installation instructions and any applicable local state and national codes including but not limited to building electrical and...

Page 4: ...Aluminum Fin OR Micro Channel Aluminum Tube Aluminum Fin Condenser Decorative Louvered Coil Guard Except 5 Ton which ships with a Wire Form Coil Guard High Efficiency Compressor Rigidly Mounted Pilot Assembly High Grade Aluminized In Shot Burners Low Voltage Terminal Block Self Diagnostic Controls Automatic Gas Valve 1 2 NPTF High Voltage Terminal Block Power Draft Motor Direct Drive Blower Motor ...

Page 5: ...ing and proper unit operation 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 across the top of the unit Units may be moved or lifted...

Page 6: ...r of Gravity 4 Point Load Location lbs Shipping Operating X Y A B C D 024 2 0 395 390 20 24 5 113 81 82 114 030 2 5 430 425 20 24 25 122 88 90 125 036 3 0 435 430 20 24 25 123 89 91 127 042 3 5 490 485 20 24 138 99 104 144 048 4 0 495 490 20 24 139 100 105 146 060 5 0 535 530 20 24 150 108 114 158 Table 3 Unit Accessory Weights Unit Accessory Model Weight lbs Shipping Operating Add Economizer All ...

Page 7: ...ACCESS COMPARTMENT PANEL 1 1 2 2 5 8 3 1 3 12 3 4 11 5 3 8 49 1 8 47 1 4 Table 4 Unit Dimensions Front Unit Size Dimensions A B 024 030 036 33 1 2 18 1 4 042 048 060 41 1 2 23 1 8 Table 5 Unit Clearances1 2 1 A 1 clearance must be provided between any combustible material and the supply air duct work 2 The products of combustion must not be allowed to accumulate within a confined space and recircu...

Page 8: ... SUPPLY 1 5 8 DIA KNOCKOUT 1 2 NPTF CONNECTION LOW VOLTAGE CONN 7 8 DIA KNOCKOUT 4 5 8 26 3 4 CONDENSATE DRAIN 3 4 NPTF HIGH VOLTAGE CONN 1 3 32 DIA KNOCKOUT 4 14 1 2 28 3 8 14 1 2 BACK 3 3 8 SIDE RETURN AIR OPENING 14 1 2 4 1 4 3 1 2 15 1 3 4 1 3 4 BOTTOM RETURN AIR OPENING 15 28 9 16 15 1 3 4 BOTTOM SUPPLY AIR OPENING CONDENSER COIL SIDE SUPPLY AIR OPENING ...

Page 9: ...to note supply and return openings Refer to Figures 4 and 5 for information concerning rear and bottom supply and return air duct openings Roof Curb On applications when a roof curb is used the unit must be positioned on the curb so the front of the unit is tight against the curb Filters Single phase units are shipped without a filter or filter racks It is the responsibility of the installer to se...

Page 10: ...cal ordinances The unit must be electrically grounded in accordance with local codes or in their absence with the N E C C E C Voltage tolerances which must be maintained at the compressor terminals during starting and running conditions are indicated on the unit Rating Plate and Table 6 The wiring entering the cabinet must be provided with mechanical strain relief A fused disconnect switch should ...

Page 11: ...G wire should be used for all field installed 24 volt wire PROGRAMMABLE THERMOSTAT ONLY THERMOSTAT UNIT CONTROL BOARD TERMINAL STRIP 24 VOLT TRANSFORMER NOTE HEAT ANTICIPATOR SHOULD BE SET AT 0 35 AMPS FOR ALL MODELS R G W R G C Y Y W2 C W1 Minimum wire size of 18 AWG wire should be used for all field installed 24 volt wire PROGRAMMABLE THERMOSTAT ONLY THERMOSTAT UNIT CONTROL BOARD TERMINAL STRIP ...

Page 12: ... Amps 2 Maximum Over Current Protection per standard UL 1995 3 Fuse or HACR circuit breaker size installed at factory or field installed RLA LRA MCC FLA FLA 024 2 0 208 230 1 60 8 3 43 13 1 4 4 3 16 1 20 030 2 5 208 230 1 60 14 1 73 22 1 4 6 8 25 8 35 208 230 3 60 8 9 58 14 1 4 6 8 19 3 25 460 3 60 4 2 28 7 0 8 3 4 9 5 15 036 3 0 208 230 1 60 14 1 77 22 1 4 6 8 25 8 35 208 230 3 60 9 0 71 14 1 4 6...

Page 13: ... 1 2 DIMENSIONS inches Length 49 1 8 49 1 8 49 1 8 49 1 8 49 1 8 49 1 8 Width 47 1 4 47 1 4 47 1 4 47 1 4 47 1 4 47 1 4 Height 33 1 2 33 1 2 33 1 2 41 1 2 41 1 2 41 1 2 OPERATING WT lbs 390 425 430 485 490 530 COMPRESSORS Type Recip 1 spd Scroll 1 spd Scroll 1 spd Scroll 1 spd Scroll 1 spd Scroll 1 spd Quantity 1 1 1 1 1 1 CONDENSER COIL DATA Face area Sq Ft 7 9 11 9 11 9 15 15 15 Rows 1 1 1 1 1 1...

Page 14: ...8 49 1 8 49 1 8 Width 47 1 4 47 1 4 47 1 4 47 1 4 47 1 4 47 1 4 Height 33 1 2 33 1 2 33 1 2 41 1 2 41 1 2 41 1 2 OPERATING WT lbs 390 425 430 485 490 530 COMPRESSORS Type Recip 1 spd Scroll 1 spd Scroll 1 spd Scroll 1 spd Scroll 1 spd Scroll 1 spd Quantity 1 1 1 1 1 1 CONDENSER COIL DATA Face area Sq Ft 7 9 11 9 11 9 15 15 15 Rows 1 1 1 1 1 1 Fins per inch 23 23 23 23 23 23 Tube diameter in 0 71 1...

Page 15: ...in all cases unless superseded by local codes or gas company requirements Refer to Tables 9 and 10 The heating value of the gas may differ with locality The value should be checked with the local gas utility NOTE There may be a local gas utility requirement specifying a minimum diameter for gas piping All units require a 1 2 inch pipe connection at the gas valve Gas Connection The gas supply line ...

Page 16: ... 180 370 80 43 90 170 350 90 40 84 160 320 100 38 79 150 305 Table 10 Propane LP Gas Pipe Sizing Chart1 1 Maximum capacity of pipe in thousands of BTU per hour based upon a pressure drop of 0 5 inch water column Length In Feet Nominal Inches Iron Pipe Size 1 2 3 4 1 1 1 4 10 275 567 1 071 2 205 20 189 393 732 1 496 30 152 315 590 1 212 40 129 267 504 1 039 50 114 237 448 913 60 103 217 409 834 70 ...

Page 17: ...Propane Conversion Accessory Model 1NP0807 for 2 and 3 Ton units with 33 1 2 tall cabinets and Model 1NP0808 for 4 and 5 Ton units with 41 1 2 tall cabinets Available On Models Input Capacity Mbh 2 2 Heating capacity valid for elevations up to 2 000 feet above sea level For elevations above 2 000 feet rated capacity should be reduced by 4 for each 1 000 feet above sea level Output Capacity Mbh Gas...

Page 18: ...0 130 155 180 206 233 W1 HEAT C 710 138 163 189 215 242 W1 HEAT D 750 155 181 207 235 262 W1 W2 HEAT A 940 253 281 312 344 378 W1 W2 HEAT B 970 271 300 331 364 400 W1 W2 HEAT C 1000 290 319 351 385 422 W1 W2 HEAT D 1050 324 353 386 422 461 030 2 5 Cool High Y1 COOL A 900 222 254 291 323 340 381 431 462 516 Y1 COOL B 1000 271 306 360 397 433 469 508 554 571 Y1 COOL C 1125 367 411 445 500 533 588 62...

Page 19: ...20 252 296 341 385 W1 HEAT D 975 282 328 374 421 W1 W2 HEAT A 1200 439 489 541 595 W1 W2 HEAT B 1300 528 578 631 687 W1 W2 HEAT C 1400 628 677 731 789 W1 W2 HEAT D 1480 716 764 818 877 042 3 5 Cool High Y1 COOL A 1400 466 513 561 611 663 715 770 826 882 Y1 COOL B 1350 430 476 523 571 621 672 718 766 815 Y1 COOL C 1500 544 596 648 702 758 815 867 921 975 Y1 COOL D 1600 630 687 745 804 864 926 988 1...

Page 20: ...OL A 1550 438 480 522 609 696 736 803 866 930 Y1 COOL B 1650 510 554 598 690 782 826 896 963 1031 Y1 COOL C 1750 589 635 682 778 873 924 995 1066 1137 Y1 COOL D 2000 822 875 927 1027 1128 1198 Heat N065 W1 HEAT A 1200 251 285 319 382 445 475 W1 HEAT B 1300 295 331 367 438 509 541 W1 HEAT C 1400 346 385 423 501 579 613 W1 HEAT D 1500 405 446 487 572 656 693 N090 W1 HEAT A 1325 307 344 381 453 526 5...

Page 21: ... 180 206 233 W1 HEAT C 710 138 163 189 215 242 W1 HEAT D 750 155 181 207 235 262 W1 W2 HEAT A 940 253 281 312 344 378 W1 W2 HEAT B 970 271 300 331 364 400 W1 W2 HEAT C 1000 290 319 351 385 422 W1 W2 HEAT D 1050 324 353 386 422 461 030 2 5 Cool High Y1 COOL A 900 222 254 291 323 340 381 431 462 516 Y1 COOL B 1000 271 306 360 397 433 469 508 554 571 Y1 COOL C 1125 367 411 445 500 533 588 625 647 665...

Page 22: ...0 252 296 341 385 W1 HEAT D 975 282 328 374 421 W1 W2 HEAT A 1200 439 489 541 595 W1 W2 HEAT B 1300 528 578 631 687 W1 W2 HEAT C 1400 628 677 731 789 W1 W2 HEAT D 1480 716 764 818 877 042 3 5 Cool High Y1 COOL A 1400 466 513 561 611 663 715 770 826 882 Y1 COOL B 1350 430 476 523 571 621 672 718 766 815 Y1 COOL C 1500 544 596 648 702 758 815 867 921 975 Y1 COOL D 1600 630 687 745 804 864 926 988 10...

Page 23: ...L A 1550 438 480 522 609 696 736 803 866 930 Y1 COOL B 1650 510 554 598 690 782 826 896 963 1031 Y1 COOL C 1750 589 635 682 778 873 924 995 1066 1137 Y1 COOL D 2000 822 875 927 1027 1128 1198 Heat N065 W1 HEAT A 1200 251 285 319 382 445 475 W1 HEAT B 1300 295 331 367 438 509 541 W1 HEAT C 1400 346 385 423 501 579 613 W1 HEAT D 1500 405 446 487 572 656 693 N090 W1 HEAT A 1325 307 344 381 453 526 55...

Page 24: ... 0 05 0 01 0 13 1200 0 06 0 02 0 16 1300 0 07 0 03 0 17 036 3 0 700 0 01 0 00 0 04 800 0 02 0 01 0 06 900 0 03 0 01 0 08 1000 0 04 0 01 0 10 1100 0 05 0 01 0 13 1200 0 06 0 02 0 16 1300 0 07 0 03 0 17 1400 0 08 0 04 0 18 042 3 5 1100 0 02 0 02 0 04 1200 0 03 0 02 0 04 1300 0 04 0 02 0 05 1400 0 05 0 03 0 05 1500 0 06 0 04 0 06 1600 0 07 0 04 0 07 1700 0 07 0 04 0 08 1800 0 08 0 04 0 09 1900 0 09 0...

Page 25: ...an Only CFM When the connection is made from R to G the fan only mode is activated In this mode the blower will deliver 75 of the cooling system CFM This connection is factory set from the manufacturer but can be field adjusted Figure 13 Control Board Speed Tap Location Operation The unit is controlled by a conventional heating cooling thermostat common to this class of equipment Heating Sequence ...

Page 26: ...end of this 60 second period the control de energizes the high gas output and steps the inducer to low speed If W2 is energized the control remains on high heat There is no high heat warm up on single stage models Low Heat The control board keeps the pilot gas valve main gas valve and induced draft motor energized while continuously monitoring the call for heat low pressure switch and flame status...

Page 27: ... a hard lockout and not respond to any thermostat demands The only way to recover from a hard lockout is to remove and then reapply 24VAC power to the control board Flame Sense Circuit Failure If the control detects an internal hardware failure in the flame sense circuit it shuts off all outputs and enters a hard lockout flashing 10 on the LED The control will not respond to thermostat demands dur...

Page 28: ...ance is equipped with an ignition device which automatically lights the burners 5 Remove the access panel 6 Turn the gas valve switch to the OFF position 7 Wait five 5 minutes to clear out any gas If you then smell gas STOP Follow B in the information on the unit safety label If you don t smell gas go to the next step 8 Turn the gas valve switch to the ON position 9 Replace the control access pane...

Page 29: ...s CLOSE THE MAIN MANUAL SHUT OFF VALVE AND SHUT OFF ALL POWER TO THE UNIT 1 Remove the two 2 8 screws holding each burner in place 2 Remove the burner assembly from the manifold assembly by moving the burner assembly forward turn at an angle and pull back 3 Burners are now accessible for service Pilot Instruction To adjust the pilot flame Figure 18 Proper Flame Adjustment Manual Gas Switch Pilot A...

Page 30: ...and on the smallest dial on the meter A typical gas meter usually has a 1 2 or a 1 cubic foot test dial 3 Using the number of seconds for each revolution and the size of the test dial increment find the cubic feet of gas consumed per hour from Table 21 If the actual input is not within 5 of the furnace rating with allowance being made for the permissible range of the regulator setting replace the ...

Page 31: ...437758 YIM A 0409 Johnson Controls Unitary Products 31 Typical Wiring Diagrams Typical DNQ024 048 Cooling Unit with Single Stage Gas Heat 208 230 1 60 volt Wiring Diagram ...

Page 32: ...437758 YIM A 0409 32 Johnson Controls Unitary Products Typical DNQ024 048 Cooling Unit with Two Stage Gas Heat 208 230 1 60 volt Wiring Diagram ...

Page 33: ...437758 YIM A 0409 Johnson Controls Unitary Products 33 Typical DNQ060 Cooling Unit with Single Stage Gas Heat 208 230 1 60 volt Wiring Diagram ...

Page 34: ...437758 YIM A 0409 34 Johnson Controls Unitary Products Typical DNQ060 Cooling Unit with Two Stage Gas Heat 208 230 1 60 volt Wiring Diagram ...

Page 35: ...437758 YIM A 0409 Johnson Controls Unitary Products 35 Typical DNQ036 048 Cooling Unit with Single Stage Gas Heat 208 230 3 60 volt Wiring Diagram ...

Page 36: ...437758 YIM A 0409 36 Johnson Controls Unitary Products Typical DNQ036 048 Cooling Unit with Two Stage Gas Heat 208 230 3 60 volt Wiring Diagram ...

Page 37: ...437758 YIM A 0409 Johnson Controls Unitary Products 37 Typical DNQ060 Cooling Unit with Single Stage Gas Heat 208 230 3 60 volt Wiring Diagram ...

Page 38: ...437758 YIM A 0409 38 Johnson Controls Unitary Products Typical DNQ060 Cooling Unit with Two Stage Gas Heat 208 230 3 60 volt Wiring Diagram ...

Page 39: ...437758 YIM A 0409 Johnson Controls Unitary Products 39 Typical DNQ036 048 Cooling Unit with Single Stage Gas Heat 460 3 60 volt Wiring Diagram ...

Page 40: ...437758 YIM A 0409 40 Johnson Controls Unitary Products Typical DNQ036 048 Cooling Unit with Two Stage Gas Heat 460 3 60 volt Wiring Diagram ...

Page 41: ...437758 YIM A 0409 Johnson Controls Unitary Products 41 Typical DNQ060 Cooling Unit with Single Stage Gas Heat 460 3 60 volt Wiring Diagram ...

Page 42: ...437758 YIM A 0409 42 Johnson Controls Unitary Products Typical DNQ060 Cooling Unit with Two Stage Gas Heat 460 3 60 volt Wiring Diagram ...

Page 43: ...s only Manifold sets must be at least 700 psig high side and 180 psig low side with 550 psig retard All hoses must have a service pressure rating of 800 psig Leak detectors must be designed to detect HFC refrigerants Systems must be charged with liquid refrigerant Use a commercial type metering device in the manifold hose R 410A can only be used with POE type oils POE type oils rapidly absorb mois...

Page 44: ...ct to change without notice Printed in U S A 437758 YIM A 0409 Copyright 2009 by Johnson Controls Inc All rights reserved Supersedes Nothing Johnson Controls Unitary Products 5005 York Drive Norman OK 73069 ...