TECHNICAL APPLICATION MILLENNIUM 25-40 TON …

1 351579-YTS-C-0111 ISO 9001 Certified QualityManagement SystemMILLENNIUM 25-40 TON SINGLE PACKAGE COMMERCIAL ROOFTOP UNIT EQUIPPED WITH SIMPLICITY CONTROLSThis manual includes APPLICATION , programming and service procedures for the MILLENNIUM 25-40 Ton Single Package Commercial Rooftop Unit equipped with Simplicity Controls. These procedures are the same for all 25-40 Ton MILLENNIUM Rooftop units in this series except as manual covers Simplicity controls only, for unit installation information please refer to the TECHNICAL ANDINSTALLATION AIDSM illennium 25-40 Ton Single Package Installation and Operation Manual - 524158 MILLENNIUM 25-40 Ton TECHNICAL Guide - 246837 TECHNICAL APPLICATIONANDPROGRAMMING GUIDEMILLENNIUM SINGLE PACKAGEROOFTOP UNITS25, 30 & 40 TON EQUIPPED WITHSIMPLICITY ELITE CONTROLS351579-YTS-C-01112 Johnson Controls Unitary ProductsTABLE OF CONTENTSMILLENNIUM 25-40 TON SINGLE PACKAGE COMMERCIAL ROOFTOP UNIT EQUIPPED WITH SIMPLICITY CONTROLS.

2 1 RECOMMENDED TECHNICAL ANDINSTALLATION AIDS .. 1 THE MILLENNIUM SIMPLICITY control .. 3 introduction AND OVERVIEW .. 3 DIGITAL LINGO .. 4 ANALOG TO DIGITAL CONVERTER .. 4 COMMUNICATIONS BUS .. 5 OPTIONAL Simplicity LINC TRANSLATOR.. 5 COMPONENT DESCRIPTION.. 5 SIMPLICITY PROGRAMMING OPTIONS .. 11 INTERACTING THROUGH THE MILLENNIUM SIMPLICITY .. 11 INITIAL STARTUP OPTIONS .. 11 METRIC OPERATION (ENGLISH) .. 11 SETTABLE SYSTEM PARAMETERS .. 11 MILLENNIUM SEQUENCE OF OPERATION .. 18 OVERVIEW .. 18 RUN SEQUENCE.. 18 UNIT CONTROLS SEQUENCE .. 18 VARIABLE AIR VOLUME UNIT (VFD & IGV) .. 20 OCCUPIED / UNOCCUPIED / MORNING WARM-UP . 21 UNIT CONTROLS .. 21 HEAD PRESSURE control .

3 26 SEQUENCE OF OPERATION - FOR HEAD PRESSURE control .. 26 INTELLI-START .. 27 DEVICES AND RULES .. 27 COMFORT VENTILATION MODE .. 28 HYDRONIC HEAT .. 29 COOLING LOCKOUT ON OAT .. 29 WATER COIL FREEZE STAT (FSI) .. 29CV OPERATION .. 29 THERMOSTAT OPERATION FOR COOLING WITH Y1,Y2, Y3 AND Y4 INPUTS .. 30 OPERATION FOR HEATING WITH W1, W2, AND W3 INPUTS .. 30 SENSOR OPERATION .. 30 TYPES OF SPACE SENSORS .. 31 VAV OPERATION .. 32 SUPPLY DUCT PRESSURE control ALGORITHM. 34 MORNING WARM UP / VAV OCCUPIED HEATING control ALGORITHM .. 34 CONTROLLING EXCESSIVE SAT (SUPPLY AIRTEMPERATURE) .. 35 SAT SETPOINTS USED DURING COOLING WITH ECONOMIZER OPERATION .. 36 DEMAND VENTILATION.

4 39 EXHAUST OPERATION .. 40 SCHEDULING OPERATION .. 41 COMPRESSOR STATUS MONITORING .. 41 TROUBLESHOOTING A MILLENNIUM SIMPLICITY control .. 43 STATUS LED CHART .. 43 FAILURE MODES AND DEFAULT OPERATION .. 43 SENSOR FAILURES AND DEFAULT OPERATION .. 43 SYSTEM ERRORS .. 44 LIST OF FIGURESFig. #Pg. #1 SIMPLICITY CONTROLLER .. 32 SIMPLICITY CONTROLS PUSH BUTTONS .. 33 ANALOG TO DIGITAL CONVERTER .. 44 VFD control WIRING .. 85 SEQUENCE OF SETTING THE SET POINTS .. 146 COMFORT VENTILATION ECONOMIZERCONTROL .. 287 SAT control BAND .. 34 LIST OF TABLESTbl. #Pg. #1 ACRONYMS .. 62 INPUT SIGNAL TO Y1 ACTUATOR POSITION .. 83 SIMPLICITY control INPUTS .. 94 SIMPLICITY control OUTPUTS.

5 105 SETTABLE SYSTEM PARAMETERS .. 166 COOLING STAGE .. 197 IGNITION control BOARD FLASH CODES .. 238 MODULATING GAS HEAT .. 249 MODULATING GAS HEAT control BOARD FLASH CODES .. 2510 COMPRESSOR MINIMUM OFF TIMES .. 3011 WEEKLY SCHEDULE .. 3412 HOLIDAY SCHEDULE .. 3513 ALARM DEFAULT CODES .. 4214 STATUS LED CHART .. 43351579-YTS-C-0111 Johnson Controls Unitary Products3 THE MILLENNIUM SIMPLICITY CONTROLINTRODUCTION AND OVERVIEWW elcome to the new MILLENNIUM Simplicity control , a digital control system designed specifically for the MILLENNIUM 25 to 40 Ton single package rooftop unit. The Simplicity is composed of 72 monitored and controlled input and output points.

6 The control logic of the Simplicity extends on the rules built in to the Synthesys control , and provides character displays in addition to LED flashes to display information to the Simplicity digital control performs all of the control and monitoring functions that were originally done by separate discrete relays, controls, and interlocking hardware. This reduces manufacturing, service, and maintenance costs. The Simplicity digital controller includes sophisticated control of the individual components of the HVAC cooling/heating unit, and has built-in rules that protect those components and optimize the control to its environment. The cooling and heating modes are protected against frequent cycling, slugging, multiple restarts, 1:Simplicity ControllerOne result is that the system may not immediately respond as you expect.

7 For example, internal digital timers may delay the start of a compressor even though the thermostat calls for cooling. The control may be in the middle of a timing sequence; without the observer knowing what has already happened and the status of current inputs, the system may take action not expected by the the Simplicity control , there are: a list of user-selected option settings and setpoints recorded within the control ; inputs monitored by the Simplicity ; specific fixed rules and timings built in to the control outputs to compressors, heat, economizers, and other Simplicity has a real-time clock function, with minimum of ten hours Time-of-day retention with unit power MILLENNIUM Simplicity control is resistor-configured for Constant Volume (CV) units or Variable Air Volume (VAV) units.

8 The option settings for a specific option configuration will be made as part of unit test at the factory; however, if there is doubt about how a unit is responding in the field, check the option setting for the unexplained connected to a network, the control requests an address by a press of the Address/Down VIA LEDT here is an LED on the board that shows the status of the control and alarms (see Status LED Table). There are two character displays, one 2-digit and one 4-digit, to indicate details of run conditions and alarms (see Alarms Table in the Trouble Shooting section of this manual).When the Alarm / Change Data button (See Figure 2 Simplicity Controller Push Buttons) is pushed and released one time within five seconds, it will re-enunciate the last five alarms on the 2:Simplicity Controls Push ButtonsWhen this button is pushed and released two times within five seconds, it will clear all stored error details for most conditions are stored in summary in the Simplicity control and can be accessed by the digital display, personal computer interface, or Palm Pilot (Some interfaces still in development).

9 Diagnosing requires patience because of internal timings. Normal observable conditions are the same - contactor 1M pulled in, compressor 1 running - but the control does not identify what it has just done or is about to do. The Simplicity control will take action according to its internal rules even though action requests come from smart thermostats. A call for cooling, for example, will be compared with supply air temperature before energizing a cooling HISTORYThe Simplicity control stores up to 5 of the most recent alarms in a First In, First Out (FIFO) manner. As the control collects ProgramAlarms / Change DataAddress / DownTest / Reset / Up351579-YTS-C-01114 Johnson Controls Unitary Productsalarms, it will overwrite the oldest alarm after the history buffer becomes system errors will initiate a controlling response as well as being stored in the error memory buffer.

10 See the Troubleshooting chapter in this manual for a detailed description of how controller errors are items stored for maintenance / run history, in addition to Alarms: Accumulated run times for each compressor and heat stage Unit model number Unit serial number Unit NameDIGITAL LINGOThis training manual is intended to help you with the commissioning process by illustrating the use of tools like the control s digital input and software engineered specifically for starting up and servicing a MILLENNIUM rooftop should become familiar with some common terminology and lingo used in the digital controls industry. (If you are familiar with the Synthesys controller, the logic of the Simplicity will be familiar territory.)