HORIZONTAL, LOW PROFILE FAN COILS

Series D

INSTALLATION, OPERATION & MAINTENANCE Supersedes 115.24-NOM11 (0520) Form 115.24-NOM11 (0121)
 FORM 115.24-NOM11 (0121)

TABLE OF CONTENTS
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . 1

Section One - Receipt & Initial Installation Electric Resistance Heater Assembly . . . . . . . . . . . 18
FH Series Features . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Wiring & Controls . . . . . . . . . . . . . . . . . . . 18
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Valves & Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Unpacking & Inspection . . . . . . . . . . . . . . . . . . . . . . . 3 Filters, Throwaway . . . . . . . . . . . . . . . . . . . . . . . . . 19
Handling & Installation . . . . . . . . . . . . . . . . . . . . . . . . 3 Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Drain Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Optional Item Installation . . . . . . . . . . . . . . . . . . . . . 20
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Condensate Pump . . . . . . . . . . . . . . . . . . . . . . 20
Cooling/Heating Medium Connections . . . . . . . . . . . 6 Current Switch Device . . . . . . . . . . . . . . . . . . . 21
Auxiliary Drain Pans . . . . . . . . . . . . . . . . . . . . . . . . . 7 Differential Air Pressure Switch . . . . . . . . . . . . . 22
Ductwork Connections . . . . . . . . . . . . . . . . . . . . . . . 7 Discharge Air Sensor . . . . . . . . . . . . . . . . . . . . 23
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . 8 Low Temperature Cutout Control . . . . . . . . . . . 23
Electrical Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Condensate Float Switch Installation . . . . . . . . 25
Telescoping Bottom Panel . . . . . . . . . . . . . . . . . . . . . 8 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . 26
Model FHP Horizontal Fan Coil Optional
Telescoping Bottom Panel Assembly,
Typical Installation Instructions . . . . . . . . . . . . . . 9 Section Four - Inspection &
Service & Clearance Requirements . . . . . . . . . . . . 10 Start-Up Checklist
Height Restricted Application . . . . . . . . . . . . . . . . . 11 Inspection & Start-up Checklist . . . . . . . . . . . . . . . . 27
Width Restricted Application . . . . . . . . . . . . . . . . . . 12
External Space Requirements . . . . . . . . . . . . . . . . . 13 Section Five - Fan Relay Board
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Reference Wire Diagram . . . . . . . . . . . . . . . . . . . . . 30
Section Two - Start-Up Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Tools Needed for Installation/Troubleshooting . . . . 32
Cooling/Heating System . . . . . . . . . . . . . . . . . . . . . 14 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Air System Balancing . . . . . . . . . . . . . . . . . . . . . . . 14 Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Motor & Fan Data . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Screw Terminal Signals . . . . . . . . . . . . . . . . . . . . . . 34
Water System Balancing . . . . . . . . . . . . . . . . . . . . . 16 Checking Wire Harnesses . . . . . . . . . . . . . . . . . . . . 35
Controls Operation . . . . . . . . . . . . . . . . . . . . . . . . . 16

Section Six - Troubleshooting

Section Three - Normal Operation & Fan Relay Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Periodic Maintenance PSC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 EC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Motor/Blower Assembly . . . . . . . . . . . . . . . . . . . . . . 17 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Fan Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electric Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ii JOHNSON CONTROLS
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SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to areas of potential hazard:

DANGER indicates an imminently CAUTION identifies a hazard which

hazardous situation which, if not could lead to damage to the machine,
avoided, will result in death or serious damage to other equipment and/or
injury. environmental pollution. Usually an
instruction will be given, together with
a brief explanation.

WARNING indicates a potentially NOTE is used to highlight additional

hazardous situation which, if not information which may be helpful to
avoided, could result in death or you.
serious injury.

SAFETY CONSIDERATIONS
Check that the unit assembly and
component weights can be safely
The equipment covered by this manual is designed for
supported by rigging and lifting
safe and reliable operation when installed and operated
within its design specification limits. To avoid personal equipment.
injury or damage to equipment or property while
installing or operating this equipment, it is essential
that qualified, experienced personnel perform these All assemblies must be adequately
functions using good judgment and safe practices. See secured during lifting and rigging by
the following cautionary statements. temporary supports and restraints until
equipment is permanently fastened
ELECTRICAL SHOCK HAZARDS. and set in its final location.
All power must be disconnected prior
to installation and servicing this All unit temporary and permanent
equipment. More than one source of supports must be capable of safely
power may be present. Disconnect all supporting the equipment’s weight and
power sources to avoid electrocution any additional live or dead loads that
or shock injuries. may be encountered. All supports must
be designed to meet applicable local
MOVING PARTS HAZARDS. Motor codes and ordinances.
and Blower must be disconnected prior
to opening access panels. Motors can All fastening devices must be designed
start automatically, disconnect all to mechanically lock the assembly
power and control circuits prior to in place without the capability of
servicing to avoid serious crushing or loosening or breaking away due to
dismemberment injuries. system operation and vibration.

HOT PARTS HAZARD. Electric Protect adjacent flammable materials

Resistance heating elements must when brazing, Use flame and heat
be disconnected prior to servicing. protection barriers where needed.
Electric Heaters may start automatically, Have fire extinguisher available and
disconnect all power and control circuits ready for immediate use.
prior to servicing to avoid burns.

JOHNSON CONTROLS 1
 FORM 115.24-NOM11 (0121)

SECTION ONE - RECEIPT & INITIAL INSTALLATION

FH SERIES FEATURES

Motor Outside air duct collar

Controls Return air Filter access

(not shown)

Blower
Valve package
(factory mounted
or shipped loose)
Condensate
pump

Electric heat Auxiliary

drain pan
Supply air

Coils
Right or left hand coil
Removable and drain connections,
drain pan same or opposite end

PREFACE No attempt should be made to handle,

JOHNSON CONTROLS fan coils represent a prudent install, or service any unit without
investment which can, with proper installation, following safe practices regarding
operation, and regular maintenance, give trouble-free mechanical equipment.
operation and long service.

Your equipment is initially protected under the All power must be disconnected before
manufacturer’s standard warranty; however, this
any installation or service should
warranty is provided under the condition that the steps
outlined in this manual for initial inspection, proper
be attempted. More than one power
installation, regular periodic maintenance, and everyday source may be supplied to a unit.
operation of the equipment be followed in detail. This Power to remote mounted control
manual should be fully reviewed in advance of any devices may not be supplied through
actual work being done on the equipment. Should the unit. Never wear bulky or loose
any questions arise, please contact your local Sales fitting clothing when working on any
Representative or the factory BEFORE proceeding. mechanical equipment. Gloves should
only be worn when required for proper
The equipment covered by this manual is available with protection from heat or other possible
a vast variety of options and accessories. Consult the injury. Safety glasses or goggles
approved unit submittal, order acknowledgement, and
should always be worn when drilling,
other manuals for details on the options and accessories
provided with the equipment on each project.
cutting, or working with chemicals
such as refrigerants or lubricants.

2 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

Never pressurize any equipment carrier. All equipment should be stored in the factory-
beyond specified operating pressures. shipping carton with internal packing in place until
Always pressure test with some inert installation.
fluid or gas such as clear water or dry
nitrogen to avoid possible damage At the time of receipt, the equipment type and
arrangement should be verified against the order
or injury in the event of a leak or
documents. Should any discrepancy be found, the local
component failure during testing. Sales Representative should be notified immediately
so that the proper action may be instituted. Should
Always protect adjacent flammable any question arise concerning warranty repairs, the
material when welding, brazing or factory must be notified BEFORE any corrective
soldering. Use suitable heat shield action is taken. Where local repairs or alterations can
material to contain sparks or drops of be accomplished, the factory must be fully informed as
solder. Have fire extinguisher available to the extent and expected cost of those repairs before
for use when welding or brazing. work is begun. Where factory operations are required,
the factory must be contacted for authorization to return
The manufacturer assumes no responsibility for personal equipment and a Return Authorization Number will be
injury or property damage resulting from improper issued. Unauthorized return shipments of equipment
or unsafe practices during the handling, installation, and shipments not marked with an authorization number
service, or operation of any equipment. will be refused. In addition, the manufacturer will not
accept any claims for unauthorized expenses.
UNPACKING & INSPECTION
CODE COMPLIANCE
All units are carefully inspected at the factory throughout
the manufacturing process under a strict detailed quality This equipment has been manufactured and certified in
assurance program, and where possible, all major accordance with UL 1995-Standard for Safety, Heating
components and subassemblies are carefully tested for and Cooling Equipment (CAN/CSA C22.2 NO 236-
proper operation and verified to be in full compliance M90) and bears the Electrical Testing Laboratories
with the factory manufacturing documents. Customer (ETL) Mark under ETL File No.: 3036742-002.
furnished components such as control valves, switches
and DDC controls are not factory tested. HANDLING & INSTALLATION
While all equipment is designed for durability and
Each unit is carefully packaged for shipment to avoid fabricated for sturdy construction and may present a
damage during normal transport and handling. The rugged appearance, great care must be taken to assure
equipment should always be stored in a dry place in the that no force or pressure be applied to the coil, piping or
proper orientation as marked on the carton. drain stub-outs during handling. Also, depending on the
options and accessories, some units could contain delicate
All shipments are made F.O.B. factory and it is the components that may be damaged by improper handling.
responsibility of the receiving party to inspect the Wherever possible, all units should be maintained in an
equipment upon arrival. Any obvious damage to the upright position and handled by the chassis as close as
carton and/or its contents should be recorded on the bill of possible to the mounting point locations.
lading and a claim should be filed with the freight carrier.
In the case of a full cabinet unit, the unit must obviously
After determining the condition of the carton exterior, be handled by the exterior casing. This is acceptable
carefully remove each unit from the carton and inspect providing the unit is again maintained in an upright
for hidden damage. At this time check to make sure that position and no impact forces are applied that may
“furnished only” items such as switches, thermostats, damage internal components, access panels, or painted
etc., are accounted for. Any hidden damage should be surfaces. The equipment covered in this manual IS NOT
recorded and immediately reported to the carrier and a suitable for outdoor installations. The equipment should
claim must be filed. In the event a claim for shipping never be stored or installed where it may be subjected
damage is filed, the unit, shipping carton, and all packing to a hostile environment such as rain, snow, or extreme
must be retained for physical inspection by the freight temperatures.

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 FORM 115.24-NOM11 (0121)

During and after installation, special care must be taken TYPICAL CEILING INSTALLATION
to prevent foreign material such as paint, plaster, and
drywall dust from being deposited in the drain pan or
on the motor or blower wheels. Failure to do so may
have serious adverse effects on unit operation and in
the case of the motor and blower assembly, may result A
in immediate or premature failure. All manufacturers’
warranties are void if foreign material is allowed to be
deposited on the motor or blower wheels of any unit.
Some units and/or job conditions may require some form
of temporary covering during construction.

While the manufacturer does not become involved SIDE VIEW

in the design and selection of support methods and

components, it should be noted that unacceptable system FAN COIL UNIT THREADED ROD

operating characteristics and/or performance may result NUT

from improper or inadequate unit structural support.
WASHER
In addition, adequate clearance must be provided for
service and removal of the equipment and its accessory
components. Anchoring the equipment in place is VIBRATION ISOLATOR
accomplished by using the mounting points provided
and positioning the unit to maintain the unit on a LEVEL
WASHER

plane. The drain pan is internally sloped toward the DETAIL A

NUT
outlet connection. Care must be taken to insure that
the unit drain pan does not slope away from the outlet Figure
NOTES: 1: Typical ceiling installation
connection. All units are supplied with integrated hanger 1. ALL BENDS ARE 90 UNLESS OTHERWISE SPECIFIED.
2. ALL FORMED DIMENSIONS ARE OUTSIDE DIMENSIONS.
brackets with optional grommet isolators and brass 3. FEATURE QUANTITIES MAY VARY FOR DIFFERENT
CONFIGURATIONS.
inserts for use with 3/8" all thread hanger rod.

The unit’s drain pan is factory sloped

toward the drain connection when the
unit is installed level and plumb.

4 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

DRAIN PAN
Standard drain pans are externally insulated, single wall
galvanized steel and can be equipped with a secondary
drain connection. The FH drain pan is easily removable
for cleaning. See illustration below. Auxiliary drip pan
to catch condensed moisture from valves and piping
must be sloped toward the drain pan.

The condensate drain pan can be removed without re-

Figure 2a
quiring common hand tools. The drain pan is secured
to the unit by four sheet metal tabs that slide into four
respective slots on the drain pan.

Prior to removing the drain pan, make sure all

accessories and field connections have been
appropriately disconnected from the drain pan.
The drain pan can be removed in three steps. First,
push the drain pan engagement lever to unlock the
drain pan from the coil. Next, while continuing to
push the lever, support the weight of the drain pan
and slide the drain pan towards the drain connection.
After the drain pan slides approximately 1.5 inches,
it will be completely disengaged from the coil. Figure 2b Figure 2c
Lastly, support the weight of the drain pan and
safely lower the drain pan for servicing. Reinstall
prior to unit startup.

COILS
All fan coils are available in 2 or 4 pipe configurations.
Heating coils are available in reheat or preheat position.
Heating and cooling coils are available with right, left
or opposite side connections.

Verify that the proper types of service are actually

provided to the unit. On units with steam heating
coils, the maximum steam pressure applied to the unit
should never exceed 15 PSIG. The drain piping and Figure 2d
steam trap should be sized and routed to allow for
proper condensate flow. The electrical service to the
unit should be compared to the unit nameplate to verify
compatibility. The routing and sizing of all piping, and Figure 2a-2d: Typical drain pan removal
the type and sizing of all wiring and other electrical
components such as circuit breakers, disconnect
switches, etc., should be determined by the individual
job requirements and should not be based on the size
and/or type of connection provided on the equipment.
All installations should be made in compliance with all
governing codes and ordinances. Compliance with all
codes is the responsibility of the installing contractor.

JOHNSON CONTROLS 5
 FORM 115.24-NOM11 (0121)

COOLING/HEATING MEDIUM CONNECTIONS If coil and valve package connections are to be made
Toxic residues and loose particles with “sweat” or solder joint, care should be taken to
assure that no components in the valve package are
resulting from manufacturing and
subjected to a high temperature which may damage seals
field piping techniques such as joint or other materials. Many two-position electric control
compounds, soldering flux, and metal valves, depending on valve operation, are provided with
shavings may be present in the unit a manual-opening lever. This lever should be placed
and the piping system. Not for use with in the “open” position during all soldering or brazing
domestic or potable water systems. operations. Valve bodies should be wrapped with a wet
rag to help dissipate heat encountered during brazing.
Submittals and Product Catalogs detailing unit operation,
controls, and connections should be thoroughly If the valve package connection at the coil is made with
reviewed BEFORE beginning the connection of the a union, the coil side of the union must be prevented
various cooling and/or heating mediums to the unit. from twisting (“backed up”) during tightening to prevent
damage to the coil tubing. Over-tightening must be
All accessory valve packages should be installed as avoided to prevent distorting the union seal surface
required, and all service valves should be checked for and destroying the union. Due to the diversity of valve
proper operation. To prevent condensation accumulation packages for this product, install the valve packages with
and runoff, chilled water valve packages must be no leaks or interference between components during
insulated, or preferably, utilize a factory-provided operation and maintenance. In the case of field installed
auxiliary drip tray. valves and piping, the chilled water valve cluster (or
metering device on DX units) should be installed in
Before brazing or sweating valve such a way that any dripping or sweating is contained
packages and their components into in the auxiliary drain pan or other device. Valves and
place, it is critical to pre-check all TXV’s should be secured or supported to avoid damage
valve package clearances in relation to coil headers or distributor tubes. All valves, pipes,
to the auxiliary drain pan. If the and components must be sufficiently supported to ensure
auxiliary drain pan cannot be properly structural integrity and proper operation of the unit.
affixed to the auxiliary drain pan
After the connections are completed, the system should
support bracket, adjust valve package then be tested for leaks. Since some components are not
component angles until proper designed to hold pressure with a gas, hydronic systems
clearance is achieved. should be tested with water.

All water coils must be protected from

freezing after initial filling with water.
Even if the system is drained, unit coils
may still hold enough water to cause
damage when exposed to temperatures
below freezing.

Refrigerant systems should be tested with dry nitrogen

rather than air to prevent the introduction of moisture
into the system. In the event that leaking or defective
components are discovered, the Sales Representative
must be notified BEFORE any repairs are attempted.
All leaks should be repaired before proceeding with
the installation.

6 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

AUXILIARY DRAIN PANS DUCTWORK CONNECTIONS

Mounted directly to the unit drain pan, AUXILIARY All ductwork and/or supply and return grilles should
DRAIN PANS may also be secured by the mounting be installed in accordance with the project plans and
holes to field supports or to the unit coil utilizing pipe specifications. If not included on the unit or furnished
hanger wire, plastic ties, or metal strapping. from the factory, JOHNSON CONTROLS supply and
return grilles are available in a variety of types.
Prior to removing the auxiliary drain pan, make sure
all accessories have been appropriately disconnected Units can be configured from the factory with duct
from the auxiliary drain pan. The auxiliary drain pan collars for attaching ductwork. The factory suggests
can be removed in three steps. First, remove the two using galvanized sheet metal ductwork or a flexible
screws that attached the auxiliary drain pan to the canvas attached to the duct collars using sheet metal
support bracket near the inlet of the unit. Next, support screws. Duct connections should follow SMACNA
the weight of the auxiliary drain pan and slide the standards and national and local codes.
auxiliary drain pan towards the discharge of the unit so
the auxiliary drain pan lip will clear the drain pan lip. All units must be installed in non-combustible areas.
After the auxiliary drain pan slides approximately 0.75 Some models are designed to be connected to duct-work
inches, the auxiliary drain pan will be free from the with a MINIMUM amount of external static pressure.
drain pan. Lastly, support the weight of the auxiliary Consult the approved submittals and the product catalog
drain pan and safely lower for servicing. Reinstall prior for unit external static pressure limitations.
to unit startup.
Units provided with outside air for ventilation should
have some form of low temperature protection to
prevent coil freeze-up.

It should be noted that none of these methods would

adequately protect a coil in the event of power failure.
The safest method of freeze protection is to use glycol
Figure 3a in the proper percent solution for the coldest expected
air temperature.

The manufacturer assumes no responsibility for

undesirable system operation due to improper design,
equipment or component selection, and/or installation of
ductwork, grilles, and other field supplied components.

Figure 3b

Figure 3a-3b: Typical auxiliary drain pan removal

JOHNSON CONTROLS 7
 FORM 115.24-NOM11 (0121)

ELECTRICAL CONNECTIONS The manufacturer assumes no responsibility for any

The unit nameplate lists the unit electrical characteristics damages and/or injuries resulting from improperly field
such as the required supply voltage, fan and heater installed or wired components.
amperage and required circuit ampacities. The unit-
wiring diagram shows all unit and field wiring. Since This unit is listed to UL/CSAS standards. All
each project is different and each unit on a project may modifications to line voltage wiring must be performed
be different, the installer must be familiar with the in accordance with the NEC and inspected by ETL to
wiring diagram and nameplate on the unit BEFORE maintain product listing. Unauthorized modification to
beginning any wiring. This unit is not acceptable for any wiring may impact unit performance and void ETL
installation in hazardous/explosive areas. listing and/or product warranty.

TELESCOPING BOTTOM PANEL

ELECTRICAL ENCLOSURE
The telescoping bottom panel allows for fully recessing
the unit while permitting service access into the ceiling
plenum. The architectural ceiling panel is finished with
a durable powder coat paint.

Portions of the inlet louver not directly

below unit inlet may require covering
in the field on applications where
infiltration of ceiling plenum air into
space is undesired. Telescoping skirt
Figure 4: Electrical enclosure
and collar assembly must be field
adjusted to assure a proper fit between
The electrical control enclosure provides access to the filter frame and louvered inlet panel
electrical compartment. This compartment houses all assembly. Refer to assembly submittal
electric heat and control components. Terminal strips drawings for specific dimensions.
are furnished for simple power and control wiring
connections. Multiple knockouts allow wiring entries
from either side of the compartment.

All components furnished for field installation, by either

the factory or the controls contractor should be located
and checked for proper function and compatibility. All
internal components should be checked for shipping
damage. After installation and before energizing
the unit, verify voltage and check that all electrical
connections are tight. Electrical connetions should be
periodically checked for tightness.
Any devices such as fan switches or thermostats
that have been furnished from the factory for field
installation must be wired in strict accordance with the
applicable wiring diagrams. Failure to do so could result
in personal injury or damage to components and will
void all manufacturers’ warranties.

All field wiring should be done in accordance with

governing codes and ordinances. Any modification of
the unit wiring without factory authorization will result
in voiding of all factory warranties and will nullify any
agency listings.

8 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

MODEL FHP HORIZONTAL FAN COIL

Optional Telescoping Bottom Panel Assembly, Typical Installation Instructions
Drawings are subject to change without notice. Refer to www.johnsoncontrols.com for current submittal drawings.

FHP UNIT CHASSIS

10 1/2"
264

7 [178]
10 1/2 [267]

FINISHED
CEILING LINE SCREW THE TELESCOPING PANEL TO
AIR

THE CHASSIS 2 SCREWS BOTH SIDE

OPEN THIS
PANEL FIRST

TYPICAL INSTALLATION METHODS INLET COLLAR INSTALLATION

SHIM AS
REQUIRED

CEILING GRID TELESCOPING BOTTOM TELESCOPING BOTTOM

"T" BAR PANEL FRAME EXTRUSION PANEL FRAME EXTRUSION
METAL OR WOOD
SHT MTL OR WOOD CEILING STUD
SCREW AS REQUIRED,
SEE NOTES 4 & 6

SOLID OR LOUVERED SOLID OR LOUVERED DRYWALL

ACOUSTIC FIBRE BOTTOM PANEL BOTTOM PANEL CEILING
CEILING TILE
SHT MTL OR WOOD SHIM AS
SCREW AS REQUIRED, REQUIRED
SEE NOTES 4 & 6
NOTE: CEILING "T" BAR GRID MAY NOT SUPPORT TELESCOPING
BOTTOM PANEL ASSEMBLY. BOTTOM PANEL ASSEMBLY
MAY REQUIRE INDEPENDENT SUPPORT.

SUSPENDED GRID/TILE CEILING SYSTEM STUD/DRYWALL CEILING SYSTEM

NOTE:
1. All dimensions are inches [millimeters]. All dimensions
TABLE 1: TELESCOPING BOTTOM±1/4"PANEL [6mm].WEIGHTS
Metric values(LBS./KG)
are soft conversion.
2. All drawings subject to change without prior notice.
DESCRIPTION 3. Left hand unit shown, right hand unitUNIT SIZE
opposite.
02 03
4. Mounting hardware04not provided.06 Mounting holes 08are 09 10 12
Telescoping bottom panel 10 [5] 11 [5] 12 [5] 14 [6] 16 [7] 17 [8] 20 [9] 21 [10]
located.
5. Remove solid and louvered bottom panels before mounting
frame assembly.
6. Frame assembly must be installed flat and square. Failure
to do so may result in poor bottom panel fit and improper
airflow pattern. Shim frame to support as required.
7. Telescoping skirt assembly must be field adjusted to
assure close fit to louvered bottom panel.
8. Portions of the inlet louver not directly below unit inlet
may require covering in the field on applications where
infiltration of ceiling plenum air into space is undesired.

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 FORM 115.24-NOM11 (0121)

SERVICE AND CLEARANCE REQUIREMENTS

HORIZONTAL, LOW PROFILE EXPOSED UNITS

10 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

SERVICE AND CLEARANCE REQUIREMENTS: HEIGHT RESTRICTED APPLICATION

CORNER PANELS
SHOWN ROTATED 90°

0" CLEARANCE BETWEEN UNIT AND STRUCTURE

UNIT
INSTALLED

0"
CORNER PANELS ROTATE REQUIRED CLEARANCE
ABOUT PIVOT POINT ABOVE UNIT

HALF
OPENED

4" [102] MIN

CORNER PANELS ROTATED 90° REQUIRED CLEARANCE
CAN BE LIFTED AND REMOVED BELOW UNIT

FULLY
OPENED

11" [279] MIN

REQUIRED CLEARANCE
BESIDE UNIT

HORIZONTAL, LOW PROFILE EXPOSED UNITS

JOHNSON CONTROLS 11
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SERVICE AND CLEARANCE REQUIREMENTS: WIDTH RESTRICTED APPLICATION

CORNER PANELS
SHOWN LIFTED AND
ROTATED 5°

3" CLEARANCE BETWEEN 3"

[76] STRUCTURE AND UNIT [76]

ABIDE BY APPLICABLE
UNIT CODES AND STANDARDS
INSTALLED REGUARDING ACCESS
FOR ELECTRICAL OR
PLUMBING COMPONENTS

1" [25] MIN

LIFT AND ROTATE CORNER PANEL REQUIRED CLEARANCE
OFF OF PIVOT POINT ABOVE UNIT

HALF
OPENED

3" [76] MIN

REQUIRED CLEARANCE
BESIDE UNIT
(PANEL REMOVAL
REQUIRED FOR
ELECTRICAL ACCESS)

FULLY
OPENED

DROP CORNER PANELS

STRAIGHT DOWN

HORIZONTAL, LOW PROFILE EXPOSED UNITS

12 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

SERVICE AND CLEARANCE REQUIREMENTS: EXTERNAL SPACE REQUIREMENTS

22"
559

22"
559

TOP VIEW

TOP VIEW

8" SUPPLY AIR

CONTROL ENCLOSURE 204 OPENING WIDTH
SEE NOTE 9 1"
25
SUPPLY AIR
OPENIG WIDTH
LH SHOWN RH 8" 3"
OPPOSITE 206 77

OPTIONAL
SIDE ACCESS 8 1/2"
216
OPTIONAL AUXILIARY
DRIP PAN
8 1/2"
R10 1/2"
216
264
OPTIONAL AUXILIRY
CONTROL ENCLOSURE 10 1/2"
DRIP PAN
SEE NOTE 5
FRONT VIEW 267
FRONT VIEW AIR FILTER CLEARANCE

NOTES:
1. All chilledHORIZONTAL,
water piping thatLOW PROFILE
projects PLENUM
beyond the ANDpan
condensate FREE RETURN
or the optional auxiliary drip pan
must be field insulated by others.
2. Auxiliary drip pan shown above is optional, and is mounted on the outlet side of the drain pan.
NOTES:
3. Drain pan is installed with the outlet tube(s) on cooling coil connection end of coil on 4-pipe units with
1. All chilled water piping that projects beyond the condensate pan or the optional auxiliary drip pan
optional opposite end connection.
must be field insulated by others.
4. Dimensions shown on this drawing apply to standard CW and HW valve packages. Refer to the
2. Auxiliary drip pan shown above is optional, and is mounted on the outlet side of the drain pan.
Piping Package Catalog for valve package code details. Contact factory for details on valve packages
3. Drain pan is installed with the outlet tube(s) on cooling coil connection end of coil on 4-pipe units with
using non-standard or customer furnished components.
optional opposite end connection.
5. Provide sufficient clearance to access electrical components and comply with all applicable codes and
4. Dimensions shown on this drawing apply to standard CW and HW valve packages. Refer to the
ordinances.
Piping Package Catalog for valve package code details. Contact factory for details on valve packages
using non-standard or customer furnished components.
5. Provide sufficient clearance to access electrical components and comply with all applicable codes and
ordinances.

JOHNSON CONTROLS 13
 FORM 115.24-NOM11 (0121)

SECTION TWO - START-UP

GENERAL During system filling, air venting from the unit is

Before beginning any start-up operation, the start- accomplished by the use of the standard manual, or
up personnel should familiarize themselves with the optional automatic, air vent fitting installed on the coil.
unit, options and accessories, and control sequence to In the case of the manual air vent fitting, the screw
understand the proper system operation. All personnel should be turned counterclockwise no more than 1-½
should have a good working knowledge of general turns to operate the air vent. Automatic air vents may
start-up procedures and have the appropriate start-up be unscrewed one turn counterclockwise to speed
and balancing guides available for consultation. initial venting but should be screwed in for automatic
venting after start-up operations. Check to ensure that
The initial step in any startup operation should be a final no leaks are prevalent at the coils, coil connections,
visual inspection. All equipment, plenums, duct-work, piping packages, etc.
and piping should be inspected to verify that all systems
are complete and properly installed and mounted, and The air vent provided on the unit is not
that no debris or foreign articles such as paper or drink intended to replace the main system air
cans are left in the units or other areas. Each unit should vents and may not release air trapped
be checked for loose wires, free blower wheel operation, in other parts of the system. Inspect
and loose or missing access panels or doors. Except as the entire system for potential air
required during start-up and balancing operations, no traps and vent those areas as required,
fan coil units should be operated without all the proper
independently. In addition, some
ductwork attached, supply and return grilles in place,
and all access doors and panels in place and secure. systems may require repeated venting
A clean filter of the proper size and type must also be over a period of time to properly
installed. Failure to do so could result in damage to the eliminate air from the system.
equipment or building and furnishings, and/or void all
manufacturers’ warranties. AIR SYSTEM BALANCING
All duct-work must be complete and connected, and all
Fan coils are not intended for temporary heat/cool grilles, filters, access doors and panels must be properly
or ventilation. Units are not designed or equipped to installed to establish actual system operating conditions
operate in dusty construction environments. Operation BEFORE beginning air balancing operations.
of the units in conditions outlined above could result in
damage to the equipment or building and furnishings Each individual unit and attached duct-work is a unique
and/or void all manufacturer’s warranties. system with its own operating characteristics. For this
reason, air balancing is normally done by balance
COOLING/HEATING SYSTEM specialists who are familiar with all procedures required
Prior to the water system start-up and balancing, the to properly establish air distribution and fan system
chilled/hot water systems should be flushed to clean operating conditions. These procedures should not be
out dirt and debris, which may have collected in the attempted by unqualified personnel. Some selections
piping during construction. During this procedure, may require air balancing in the field.
all unit service valves must be in the closed position.
This prevents foreign matter from entering the unit and After the proper system operation is established,
clogging the valves and metering devices. Strainers the actual unit air delivery and the actual fan motor
should be installed in the piping mains to prevent this amperage draw for each unit should be recorded in
material from entering the units during normal operation. a convenient place for future reference such as the
inspection, installation, & start-up check sheet, a copy
of which is provided on the back of this manual. Contact
the Sales Representative or the factory for additional
copies of this sheet.

14 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

MOTOR AND FAN DATA

TABLE 2A: PSC MOTORS, MODEL FHP, FHX

UNIT PSC MOTOR HP 115 VOLTS 208/230 VOLTS 277 VOLTS
# OF FANS FAN SPEED WATTS2
SIZE (QTY) AMPS1 AMPS1 AMPS1
High 55
02 (1) 1/303 1 Medium 40 0.5 N/A N/A
Low 36
High 61
03 (1) 1/303 1 Medium 45 0.5 N/A N/A
Low 40
High 75
04 (1) 1/20 2 Medium 65 0.8 0.4 0.5
Low 58
High 80
06 (1) 1/20 2 Medium 68 0.8 0.4 0.5
Low 56
High 122
08 (1) 1/10 2 Medium 83 1.1 0.6 0.5
Low 66
High 127
09 (1) 1/10 2 Medium 86 1.1 0.6 0.5
Low 66
High 148
10 (2) 1/20 4 Medium 128 1.6 0.8 1
Low 110
High 160
12 (2) 1/20 4 Medium 139 1.6 0.8 1
Low 115

NOTES:
1. Motor electrical data is nameplate data.
2. Watts are based on an FHP with PSC motor, 3 row coil, 12FPI, 1" throwaway filter, 0.05" ESP at 115V.
3. PSC motors are not available in 208-277V on SZ02 and SZ03.
4. Motor data is subject to change and should not be used for submittal purposes. Refer to Web-Select submittal for actual ratings.

TABLE 2B: PSC MOTORS, MODEL FHF

UNIT PSC MOTOR HP 115 VOLTS 208/230 VOLTS 277 VOLTS
# OF FANS FAN SPEED WATTS2
SIZE (QTY) AMPS1 AMPS1 AMPS1
High 55
02 (1) 1/303 1 Medium 40 0.5 N/A N/A
Low 36
High 61
03 (1) 1/303 1 Medium 45 0.5 N/A N/A
Low 40
High 75
04 (1) 1/20 2 Medium 65 0.8 0.4 0.5
Low 58
High 121
06 (1) 1/10 2 Medium 84 1.1 0.6 0.5
Low 66
High 224
08 (1) 1/6 2 Medium 140 2.1 1.1 0.9
Low 66
High 230
09 (1) 1/6 2 Medium 139 2.1 1.1 0.9
Low 67
High 226
10 (2) 1/10 4 Medium 154 2.2 1.2 1
Low 128
High 248
12 (2) 1/10 4 Medium 171 2.2 1.2 1
Low 133
NOTES:
1. Motor electrical data is nameplate data.
2. Watts are based on an FHF with PSC motor, 3 row coil, 12FPI, 1" throwaway filter, 0.05" ESP at 115V.
3. PSC motors are not available in 208-277V on SZ02 and SZ03.
4. Motor data is subject to change and should not be used for submittal purposes. Refer to Web-Select submittal for actual ratings.

JOHNSON CONTROLS 15
 FORM 115.24-NOM11 (0121)

TABLE 3: EC MOTORS
AMPS1,3
2
UNIT FAN EC MOTOR # OF WATTS 115 VOLTS 208/230 VOLTS 277 VOLTS
SIZE SPEED HP (QTY) FANS (STD/HS) 3-SPEED 3-SPEED 3-SPEED
2-10VDC 2-10VDC 2-10VDC
(STD/HS) (STD/HS) (STD/HS)
High 32 / 45
02 Medium (1) 1/4 1 21 / 36 0.7 / 1.0 0.9 0.5 / 0.6 0.5 0.4 / 0.5 0.5
Low 14 / 26
High 35 / 59
03 Medium (1) 1/4 1 23 / 43 1.0 / 1.5 1.1 0.6 / 0.9 0.7 0.5 / 0.8 0.6
Low 16 / 33
High 50 / 75
04 Medium (1) 1/4 2 33 / 56 1.5 / 1.8 1.2 0.9 / 1.1 0.8 0.8 / 0.9 0.6
Low 21 / 41
High 104 / 132
06 Medium (1) 1/4 2 62 / 89 2.6 / 3.1 2.0 1.6 / 1.9 1.2 1.3 / 1.6 1.0
Low 36 / 62
High 91 / 122
08 Medium (1) 1/4 2 54 / 90 2.3 / 2.9 2.0 1.4 / 1.7 1.2 1.2 / 1.5 1.0
Low 31 / 62
High 119 / 182
09 Medium (1) 1/4 2 72 / 116 3.7 / 4.5 2.7 2.3 / 2.7 1.6 1.9 / 2.3 1.4
Low 39 / 77
High 142 / 207
10 Medium (2) 1/4 4 91 / 139 3.9 / 5.1 3.1 2.3 / 3.1 1.9 2.0 / 2.6 1.6
Low 54 / 104
High 143 / 209
12 Medium (2) 1/4 4 92 / 152 3.2 / 4.5 3.5 2.0 / 2.7 2.1 1.6 / 2.3 1.8
Low 56 / 105

NOTES:
1. Motor electrical data is nameplate data.
2. Watts are based on an FHP with 3-speed EC motor, 3 row coil, 12FPI, 1" throwaway filter, 0.05" ESP at 115V.
3. For neutral conductor sizing, multiply AMPS by 1.73.
4. Motor data is subject to change and should not be used for submittal. Refer to unit submittal for actual ratings.

WATER SYSTEM BALANCING CONTROLS OPERATION

A complete knowledge of the hydronic system, its Before proper control operation can be verified all other
components, and controls is essential to proper water systems must be in proper operation. The correct water
system balancing and this procedure should not be and air temperatures must be present for the control
attempted by unqualified personnel. The system must function being tested. Some controls and features are
be complete and all components must be in operating designed to not operate under certain conditions.
condition BEFORE beginning water system balancing
operations. A wide range of controls and electrical options and
accessories may be used with the equipment covered
Each hydronic system has different operating in this manual. Consult the approved unit submittals,
characteristics depending on the devices and controls order acknowledgement, and other manuals for detailed
in the system. The actual balancing technique may vary information regarding each individual unit and its
from one system to another. controls. Since controls and features may vary from
one unit to another, care should be taken to identify
After the proper system operation is established, the the controls to be used on each unit and their proper
appropriate system operating conditions such as various control sequence. Information provided by component
water temperatures and flow rates should be recorded manufacturers regarding installation, operation, and
in a convenient place for future reference. maintenance of their individual controls is available
upon request.
Before and during water system balancing, conditions
may exist which can result in noticeable water noise
or undesired valve operation due to incorrect system
pressures. After the entire system is balanced, these
conditions will not exist on properly designed systems.

16 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

SECTION THREE - NORMAL OPERATION & PERIODIC MAINTENANCE

GENERAL FAN DECK
Each unit on a job will have its own unique operating The fan assembly is easily removed from the unit
environment and conditions that may dictate a without disconnecting the ductwork for service access
maintenance schedule for that unit that is different to motors and blowers at, or away from the unit.
from other equipment on the job. A formal schedule of
regular maintenance and an individual unit log should Should the assembly require more extensive service,
be established and maintained. This will help to achieve the motor/ blower assembly may be removed from the
the maximum performance and service life of each unit unit to facilitate such operations as motor or blower
on the job. wheel/housing replacement, etc. Dirt and dust should
not be allowed to accumulate on the blower wheel or
Information regarding safety housing. This can result in an unbalanced blower wheel
precautions contained in the preface condition that can damage a blower wheel or motor.
at the beginning of this manual should The wheel and housing may be cleaned periodically
be followed during any service and using a vacuum cleaner and a brush taking care not to
dislodge the factory balancing weights on the blower
maintenance operations.
wheel blades.
For more detailed information concerning service
operations, consult your Sales Representative or the
Factory.

MOTOR/BLOWER ASSEMBLY
The type of fan operation is determined by the control
components and their method of wiring, and may vary
from unit to unit. Refer to the wiring diagram for each Figure 6a
unit for that unit’s individual operating characteristics.
Motors are permanently lubricated, PSC or EC type and
do not require field lubrication.

Figure 6b

Figure 5a

Figure 6c

Figure 5b

Figure 5a-5b: Bottom panel removal Figure 6a-6c: Fan deck removal

JOHNSON CONTROLS 17
 FORM 115.24-NOM11 (0121)

COIL ELECTRICAL WIRING & CONTROLS

Coils may be cleaned in place by removing the motor/ The electrical operation of each unit is determined by
blower assemblies and brushing the entering air face the components and wiring of the unit and may vary
between fins with a soft brush parallel to fins. Do not from unit to unit. Consult the wiring diagram for the
brush perpendicular to fin orientation as damage may actual type and number of controls provided on each
occur. Brushing should be followed by cleaning with a unit. The integrity of all electrical connections should be
vacuum cleaner. If a compressed air source is available, verified at least twice during the first year of operation.
the coil may also be cleaned by blowing air through the Afterwards, all controls should be inspected regularly
coil fins from the leaving air face. Vacuuming should for proper operation. Some components may experience
again follow this. Units provided with the proper type erratic operation or failure due to age. Wall thermostats
of air filters, replaced regularly, may require periodic may also become clogged with dust and lint and should
coil cleaning. be periodically inspected and cleaned to provide reliable
operation.

When replacing any components such as fuses,

contactors, or relays, use only the exact type, size, and
voltage component as furnished from the factory. Any
deviation without factory authorization could result
in personnel injury or damage to the unit and will
void all factory warranties. All repair work should be
done in such a manner as to maintain the equipment in
compliance with governing codes and ordinances or
testing agency listings.

More specific information regarding the use and

ELECTRIC RESISTANCE HEATER ASSEMBLY operating characteristics of the standard controls offered
Electric resistance heaters typically require no normal by this manufacturer is contained in other manuals.
periodic maintenance when unit air filters are changed
properly. Other conditions and equipment may affect the VALVES & PIPING
operation and service life in the system. The two most No formal maintenance is required on the valve package
important operating conditions for an electric heater are components most commonly used with fan coil units
proper airflow and proper supply voltage. High supply other than a visual inspection for possible leaks in the
voltage and/or poorly distributed or insufficient airflow course of other normal periodic maintenance. In the
over the element will result in element overheating. This event that a valve should need replacement, the same
condition may result in the heater cycling on the high precautions taken during the initial installation to protect
limit thermal cutout. Open wire type heaters provided the valve package from excessive heat should also be
have an automatic reset switch with a back-up high used during replacement. If a strainer is ordered with
limit thermal switch. Automatic reset switches are as the unit the strainer must be cleaned periodically along
the name implies; they reset automatically after the with other scheduled maintenance. In some cases, the
heater has cooled down. The high limit thermal cutout valve actuator may fail and usually can be replaced
device is a manual reset safety device. With proper without removing valve body from piping.
unit application and during normal operation, the high
limit thermal cutout will not operate. This device only
operates when some problem exists. ANY condition
that causes high limit cutout MUST be corrected
immediately. Once the high limit trips, it may be reset
once the unit has cooled down. Refer to troubleshooting
section for high limit reset instructions. High supply
voltage also causes excessive amperage draw and may
result in tripping of the circuit breaker or blowing of
the fuses on the incoming power supply.

18 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

FILTERS, THROWAWAY to the chart on page 20 for recommended filter size for
The type of throwaway filter most commonly used on each product type and size. If the replacement filters are
fan coil units should be replaced on a regular basis. not purchased from the factory, the filters used should
The time interval between each replacement should be the same type and size as that furnished from or
be established based on regular inspection of the filter recommended by the factory. Consult the factory for
and should be recorded in the log for each unit. Refer applications using filter types other than the factory
standard or optional product.

Figure 7a Figure 7c

Figure 7b Figure 7d

Figure 7a-7d: Filter removal

JOHNSON CONTROLS 19
 FORM 115.24-NOM11 (0121)

DRAIN
The drain should be checked before initial start-up and Should the growth of algae and/or bacteria be a
at the beginning of each cooling season to assure that concern, consult an air conditioning and refrigeration
the lines are clear. If it is clogged, steps should be taken supply organization familiar with local conditions for
to clear the debris so that condensate will flow easily. chemicals available to control these agents. If cleaners
are used, they should be compatible with the materials
Periodic checks of the drain should be made during the of construction for the coil, drain pan, and condensate
cooling season to maintain a free flowing condensate. pump (if applicable).

TABLE 4: FACE AREA, FREE AREA AND FILTER SIZES

RETURN AIR SUPPLY AIR FILTER FACE
UNIT COIL FACE NOMINAL FILTER SIZES FILTER FACE AREA NOMINAL FILTER SIZES
GRILLE FREE GRILLE FREE AREA (REAR
SIZE AREA (REAR RETURN) (BOTTOM RETURN) (BOTTOM RETURN)
AREA AREA RETURN)
16 x 10.5 x 1 16 x 9.5 x 1
02 0.89 [0.08] 0.83 [0.08] 0.61 [0.06] 1.17 [0.11] 1.06 [0.1]
[406 x 267 x 25] [406 x 241 x 25]
19 x 10.5 x 1 19 x 9.5 x 1
03 1.07 [0.1] 0.83 [0.08] 0.61 [0.06] 1.39 [0.13] 1.25 [0.12]
[483 x 267 x 25] [483 x 241 x 25]
24.25 x 10.5 x 1 24.25 x 9.5 x 1
04 1.35 [0.13] 1.25 [0.12] 0.92 [0.09] 1.77 [0.16] 1.60 [0.15]
[616 x 267 x 25] [616 x 241 x 25]
31 x 10.5 x 1 31 x 9.5 x 1
06 1.72 [0.16] 1.45 [0.14] 1.07 [0.1] 2.26 [0.21] 2.05 [0.19]
[787 x 267 x 25] [787 x 241 x 25]
(2) 19 x 10.5 x 1 (2) 19 x 9.5 x 1
08 2.11 [0.2] 1.87 [0.17] 1.38 [0.13] 2.77 [0.26] 2.51 [0.23]
[483 x 267 x 25] [483 x 241 x 25]
(1) 20, (1) 22.25 x 10.5 x 1 (1) 20, (1) 22.25 x 9.5 x 1
09 2.35 [0.22] 2.08 [0.19] 1.53 [0.14] 3.08 [0.29] 2.79 [0.26]
[508, 565 x 267 x 25] [508, 565 x 241 x 25]
(2) 26 x 10.5 x1 (2) 26 x 9.5 x1
10 2.89 [0.27] 2.7 [0.25] 1.99 [0.18] 3.79 [0.35] 3.43 [0.32]
[660 x 267 x 25] [660 x 241 x 25]
(1) 20, (1) 40 x 10.5 x 1 (1) 20, (1) 40 x 9.5 x 1
12 3.33 [0.31] 3.12 [0.29] 2.3 [0.21] 4.38 [0.41] 3.96 [0.37]
[508, 1016 x 267 x 25] [508, 1016 x 241 x 25]

NOTES:
1. Face and free areas are in square feet [square meters].
2. Filter sizes are in inches [millimeters].
3. Free area of Johnson Controls Model FHX and
Telescoping Bottom Panel return grilles.
4. Free area of Johnson Controls Model FHX supply grille
and minimum free area allowable for a supply grille
supplied by others.

Optional Item Installation

CONDENSATE WATER PUMP

SAFETY WARNING
Risk of electric shock. Make certain
that the entire power supply to the
unit/system is disconnected before
attempting to install, service or remove
this component.

20 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

General Information CURRENT SWITCH DEVICE

The high performance water condensate pump is
suitable for units up to 5.6 tons (67 kBtu - 20 kW). The SAFETY WARNING
piston technology is specifically designed for removing The Current Switch is intended to
condensate from air conditioning systems. It is fully provide an input to equipment under
reliable, in any kind of environment and its operating
normal operating conditions. Where
sound level will remain silent <23 dB whatever the
volume of condensate.
failure or malfunction of the Current
Switch could lead to personal injury
The condensate pump uses a temperature differential or property damage to the controlled
between two measurements to determine if it runs. If equipment or other property, additional
there is greater than 14°F between the measurements, precautions must be designed into
the pump runs. The cold sensor is placed on the chilled the control system. Incorporate and
water supply and the warm sensor is placed in the fan maintain other devices, such as
compartment. The pump is capable of running without supervisory or alarm systems or safety
any water. Discharge tubing is not factory provided and or limit controls, intended to warn of or
must be field provided during the initial installation protect against failure or malfunction
process.
of the Current Switch.
Technical specifications
General information
Operation 120V +/- 10% ~50/60Hz – 4.7W The Current Switch is a non-intrusive device that
voltage 208 - 230V +/- 10% ~50/60Hz – 4.7W detects current flowing through the motor power wire.
Operating
Max 257 °F (125 °C) auto-reset Completely self-powered, the Current Switch draws its
temperature power from current induced by the power wire of the
Thermal motor being monitored. Fig. 5 shows the current switch
protection 257 °F (125 °C) auto-reset wire connections. It is panel mounted with two screws
(overheating) inside the main electrical enclosure; refer to fig. 6.
Max head 23 Ft
Technical specifications
Max suction
16.52 Ft 2.1–0.6 mm (12–22 AWG)
lift Wire size
diameter recommended
Tubing (Not
Flexible tubing 1/4" ID, 3/8" OD Status output Switch normally open
Included)
Switch load 1 A at 30 VAC/42 VDC
Replacement instructions capacity maximum
a. Disconnect the main power on the unit. DIFFERENTIAL AIR PRESSURE SWITCH
b. For wiring connection to unit, refer to unit wire
diagram.
c. For accessories, assembly, and internal wire
connections, refer to condensate water pump
manufacturer instructions.
d. Locate the two alignment holes for the water pump
bracket, right bottom corner of the unit.
e. Attach pump to bracket and mount it to unit with Figure 9 Current Switch in circuit
two screws. (See Figure 1)
f. Complete all assembly prior to mounting pump cover.
g. Connect flexible tubing (not supplied). Once all
of the connections are made, reconnect the main
power of the unit.

Figure 10 Current Switch mounting

JOHNSON CONTROLS 21
 FORM 115.24-NOM11 (0121)

General information
This accessory is a differential pressure switch with Assembly
a normally-open (NO) dry contact that is factory The differential air pressure switch is mounted inside
calibrated to close at a differential pressure of 0.15 the unit with double sided tape behind the filter retention
inches of water or greater. The switch measures the tab. (See figure 12a). Instructions for commissioning or
pressure differential between the unit’s fan section and replacing the differential air pressure switch:
the environmental pressure outside the unit. When the
filter is sufficiently clogged or dirty, differential pressure a. Disconnect main power on the unit.
will rise and the switch will close. b. Secure differential air pressure switch on the filter
retention tab using double sided tape. Position
Technical specifications the pressure port (marked with “+”) outside the
chassis exposed to the environment. The vacuum
Electrical port should extend inside the chassis and be open
Initial resistance <500mW to the unit’s fan section. (See figure 12b.)
3.15ma @ 125VAC c. Wire the NO relay using .187 quick connectors.
Rating d. Verify all connections before reconnecting main
10-20ma @ 5-24VDC
power.
Adjustable set point ranges in H2O
Ranges Min. Max. Proof
DISCHARGE AIR SENSOR
In H2O 0.10 0.50 5.0

Functional
Diaphragm vertical, barbed
Operating positing
fittings horizontal
-40 °F to 140 °F
Operating temp.
(-40 °C to 60 °C)

General measurements: Pressure Switch

Figure 12a

Installation

Figure 11 Figure 12b

22 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

General Information General information

The Discharge Air Sensor is a nickel 1kΩ sensor probe This low temperature device will de-energize the system
with a flanged mounting bracket (no enclosure). if the operating conditions begin to approach freezing
(as water freezes it expands and will rupture the coil
Suggested Location barrel tubes). The function of this low temperature
The Discharge Air Sensor is fitted to the side of the coil device is to cycle a SPST switch in response to changes
flange in the holes provided for this accessory. (See of temperature. Refer to fig. 4 to locate the device on
Figure 13.) your unit.

Replacement instructions Adaptable cold control

a. Disconnect the main power on the unit. Range of adjustments are limited to the rotation of the
b. Mount the Discharge Air Sensor with two screws dial for the required temperature set point needed.
as shown. (See Figure 13.)
c. Secure the plenum-rated cable into control Altitude correction chart
enclosure using the control enclosure knockouts (CW TURNS OF RANGE SCREW)
accordingly. Feet Turns Feet Turns
d. Once all of the connections are made, reconnect 2000 35 8000 215
the main power.
4000 100 9000 250
6000 160 10000 270

Electrical ratings
WARNING: Do not exceed the
maximum wattage, ratings, or
published operating conditions as
noted below.

Replacement instructions

Figure 13

LOW TEMPERATURE CUTOUT CONTROL

JOHNSON CONTROLS 23
 FORM 115.24-NOM11 (0121)

The primary purpose of the low limit cutout is to prevent

the coil from freezing. Therefore, before mounting the
control, you need to consider all possible factors that
help protect the coil from freezing. It is important that
the cutout capillary not be cut, kinked or pinched in
mounting to unit elements. Also, ensure tubing clamps
and wells are of compatible material with the control
sensing element to prevent corrosion.

a. Disconnect the main power on the unit.

b. Locate the two inner mounting holes between
control enclosure and coil.
c. Use two supplied screws to mount the low
temperature cutout in place.
d. Work your way back up to the bellows, stringing
the sensing element throughout the drain pan,
e. Position the sensing element horizontally across
Figure 14
the face of the coil, and secure the sensing element
with mount tape and wire tie. (See Figure 14.)
f. Wire the NC relay using the .250 quick connectors.
g. Once all of the connections are made, reconnect
the main power of the unit.

TABLE 5: UNIT WEIGHT DATA (LBS./KG)

UNIT SIZE
COMPONENT
02 03 04 06 08 09 10 12
FHF BASE UNIT 22 [10] 25 [12] 33 [15] 43 [20] 53 [24] 60 [27] 74 [34] 83 [38]
FHP BASE UNIT 24 [11] 28 [13] 36 [16] 47 [21] 58 [26] 65 [30] 81 [37] 91 [41]
FHX BASE UNIT 56 [25] 63 [29] 75 [34] 92 [42] 108 [49] 118 [54] 141 [64] 158 [72]
1 ROW - DRY 6 [3] 7 [3] 8 [4] 10 [4] 11 [5] 13 [6] 15 [7] 17 [8]
1 ROW - WET 8 [4] 9 [4] 10 [4] 12 [5] 13 [6] 15 [7] 17 [8] 19 [9]
2 ROW - DRY 7 [3] 8 [4] 10 [4] 12 [5] 14 [6] 16 [7] 19 [9] 22 [10]
2 ROW - WET 9 [4] 10 [5] 12 [5] 14 [6] 17 [8] 19 [8] 23 [10] 27 [12]
3 ROW - DRY 8 [4] 10 [4] 12 [5] 14 [6] 17 [8] 19 [9] 23 [10] 26 [12]
COIL 3 ROW - WET 10 [5] 12 [5] 15 [7] 17 [8] 21 [10] 23 [10] 28 [13] 32 [14]
ROWS 4 ROW - DRY 9 [4] 11 [5] 13 [6] 17 [8] 20 [9] 22 [10] 27 [12] 30 [14]
4 ROW - WET 13 [6] 15 [7] 18 [8] 22 [10] 26 [12] 28 [13] 34 [15] 38 [17]
5 ROW - DRY 11 [5] 13 [6] 15 [7] 19 [9] 23 [10] 25 [11] 30 [14] 35 [16]
5 ROW - WET 17 [8] 19 [8] 22 [10] 26 [12] 31 [14] 33 [15] 39 [18] 45 [20]
6 ROW - DRY 12 [5] 14 [6] 17 [8] 21 [10] 26 [12] 28 [13] 34 [16] 39 [18]
6 ROW - WET 19 [9] 21 [10] 25 [11] 29 [13] 36 [16] 38 [17] 45 [21] 51 [23]

24 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

CONDENSATE FLOAT SWITCH INSTALLATION

Ensure float switch assembly is firmly secured to the 1. Disconnect power to unit at main panel.
bracket. Ensure top of float is below rim of pan. Switch 2. Clip switch bracket onto side of pan at low end
will trip when the water level reaches a point even with and press firmly into place ensuring switch wires
top of float when float is in down position. Sensitivity are positioned up ensure float moves freely.
may be adjusted by threading switch assembly 3. Secure bracket into side of pan using self-tapping
downward out of bracket if necessary. sheet metal screw through upper hole in bracket.
4. Ensure float switch assembly is firmly secured
Test switch by lifting float with unit on. Unit should to bracket. Ensure top of float is below rim of
stop running if switch is correctly wired. Test switch pan. Switch will trip when water level reaches
sensitivity by filling pan and confirm switch stops unit a point even with top of float (when float is in
before pan overflows. down position). Sensitivity may be adjusted by
threading switch assembly downward out of
Supplier’s install instructions bracket if necessary.
5. Ensure wiring matches the wiring diagram
provided with the unit.
6. Test switch by lifting float with unit on. Unit
should stop running if switch is correctly wired.
7. Test switch sensitivity. Fill pan and confirm that
switch stops unit before pan overflows.
8. Place warning sticker on air handler or condenser
unit.

Figure 15a: Drain pan float switch installed

Figure 15b: Drain pan float switch diagram

JOHNSON CONTROLS 25
 FORM 115.24-NOM11 (0121)

REPLACEMENT PARTS
Factory replacement parts should be used wherever On warranty replacements, in addition to the information
possible to maintain the unit performance and previously listed, the project CO # that appears on
operating characteristics and the testing agency listings. the unit nameplate, is required. Contact local Sales
Replacement parts may be purchased through the local Representative and refr to warranty policy.
Sales Representative.
All equipment and components sold through the Parts
Contact the local Sales Representative before attempting Department are warranted under the same conditions as
any unit modifications. Any modifications not authorized the standard manufacturer’s warranty with the exception
by the factory could result in personnel injury and that the warranty period is 12 months.
damage to the unit and could void all factory warranties
and regulatory listings.

When ordering parts, the following information must be

supplied to ensure proper part identification:
1. Complete unit model number
2. Unit hand connection (right or left hand) while
facing the direction of airflow at the inlet
3. Complete part description including any numbers.

26 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

SECTION FOUR - INSPECTION & START-UP CHECKLIST

RECEIVING & INSPECTION
□ Unit received undamaged □ Unit received complete as ordered
□ Unit arrangement/hand correct □ Unit structural support complete & correct

HANDLING & INSTALLATION

□ Unit mounted level & square □ Proper access provided for unit & accessories
□ Proper electrical service provided □ Proper overcurrent protection provided
□ Proper service switch/disconnect provided □ Proper hot water line to unit
□ Proper chilled water line size to unit □ Proper steam line sizes to unit
□ Proper refrigerant line sizes to unit □ Proper steam supply pressure to unit (15psi max)
□ Proper steam condensate trap on return line □ All shipping screws & braces removed
□ All services to unit in code compliance

COOLING/HEATING CONNECTIONS
□ Protect Valve Package Components From Heat □ Mount valve packages
□ Connect Field Piping To Unit □ Pressure test all piping for leaks
□ Install Drain Line & Traps As Required □ Insulate all piping as required
□ Install Condensate Pan under Piping as Required

DUCTWORK CONNECTIONS
□ Install Ductwork, Fittings & Grilles As Required □ Proper supply & return grille type & size used
□ Control Outside Air For Freeze Protection □ Insulate all ductwork as required

ELECTRICAL CONNECTIONS
□ Refer to unit wiring diagram □ Connect incoming power service or services
□ All field wiring in code compliance

UNIT STARTUP
□ General visual unit & system inspection □ Record electrical supply voltage
□ Record ambient temperature □ Check all wiring for secure connections
□ Close all unit isolation valves □ Flush water systems
□ Fill systems with water/refrigerant □ Vent water systems as required
□ All ductwork & grilles in place □ All unit panels & filters in place
□ Start fans, etc. □ Check for overload condition of all units
□ Check all ductwork & units for air leaks □ Balance air systems as required
□ Record all final settings for future use □ Check piping & ductwork for vibration
□ Check all dampers for proper operation □ Verify proper cooling operation
□ Verify proper heating operation □ Reinstall all covers & access panels
JOHNSON CONTROLS 27
 FORM 115.24-NOM11 (0121)

FAN RELAY BOARD – INSTALLATION, OPERATION AND MAINTENANCE

The Fan Relay Board assembly (FRBii) provides ensure that electric heat can only be energized when the
electronic control for the fan motor and various fan motor is operational. The assembly includes factory
connections for peripheral devices. The FRBii accepts provided harnesses to allow for faster installation and
incoming single phase power of nominal AC voltages improved troubleshooting by the end user.
120, 208, 240 and 277. The assembly includes a multi-
tap transformer (30VA or 50VA) that steps each of these The FRBii allows for peripheral devices (e.g., thermostat
primary voltages to 24 VAC. The assembly allows for controllers, electric heat relays, water valve actuators,
the control of a three speed fan motor, including a relay condensate drain pan float switches, air dampers) to be
for control of the neutral voltage signal path. connected by either the OEM or by the installer. The fan
relay board also includes a fuse on the secondary side
The FRBii can be connected to an external device (e.g., of the transformer to protect against incorrect wiring of
thermostat, controller, 3-speed switch) to control the external components, shorting the transformer leads.
three fan speeds. The FRBii includes logic to detect
when multiple speeds are commanded simultaneously The signals in the screw terminal block (TB1) and
and block all but the highest of the commanded speeds 18-pin black connector (J1) have a nominal voltage of
from being sent to the motor windings. A signal to 24VAC. These signals are properly insulated from line
call for electric heat from an external controller will voltage present on the assembly (J2-J5).
verify that a fan speed is selected before providing the
command signal to the external electric heat control to

Figure F.1: Fan Relay Board (FRBii) 

28 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

INSTALLATION

MOUNTING WIRING
Important: Do not overtighten the screws. Install the wiring so it does not cause a hazard, and is
Overtightening may strip the threads and will void protected against electrical and mechanical damage. ..
the warranty.
Risk of electric shock
Using #8-3/4" screws (quantity six), install the assembly Ground the FRBii according to local,
using the provided standoffs. national, and regional regulations.
Failure to ground the FRBii may
Risk of Electric Shock result in electric shock and severe
Disconnect or isolate all power supplies personal injury or death.
before making electrical connections.
More than one disconnection or Ground the assembly from the EARTH terminal (W2)
isolation may be required to completely to the enclosure.
de-energize equipment. Contact with
components carrying hazardous Ratings
voltage can cause electric shock and 30VA – PC-01-0134
may result in severe personal injury Model(s)
PK-FCU030-0 (25-3043-7)

or death. 50VA – PC-01-0135

PK-FCU050-0 (25-3043-15)
Voltage 120 through 277VAC
Current (fan relays) 12A
Operating temperature -4°F to 140°F (-20°C to 60°C)

JOHNSON CONTROLS 29
 FORM 115.24-NOM11 (0121)

REFERENCE WIRE DIAGRAM

30 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

FRBii INPUTS AND OUTPUTS

TB1 – Low Voltage Peripheral Devices J2/J3 – Incoming Power

TABLE F.1 – SCREW TERMINAL (TB1) SIGNAL TABLE F.3 – INCOMING POWER (J2 & J3)
IDENTIFICATION SIGNAL IDENTIFICATION
(see Table F.9 for detailed description of each signal)
Pin Signal
Pin Signal 1 NEUT
1 Y1 – Cool 1 2 120
2 Y2 – Cool 2 3 208
3 W1 – Heat 1 4 240
4 L – Low 5 277
5 M – Medium
6 H - High J4/J5 – Motor Output
7 G – Fan Enable TABLE F.4 – MOTOR OUTPUT (J4 & J5)
8 C – Common (through JP2) SIGNAL IDENTIFICATION
9 C – Common (through JP2) Pin Signal
10 R – 24VAC 1 LOW
11 S2 – Auxiliary Input (Heat 2) 2 MED
12 S1 – Common 3 HIGH
4 NEUT
J1 – Low Voltage Peripheral Devices
TABLE F.2 – LOW VOLTAGE PERIPHERAL
DEVICE (J1) SIGNAL IDENTIFICATION W1 – MTR PWR
The MTR PWR quick connect provides voltage to the
Pin Signal line side of the fan speed relays through an external
jumper. For PSC motors, this will be the line voltage
1 R – 24VAC
of the unit. For EC motors, this will either be 24VAC
2 S2 – Aux In (Heat 2) (without PWM) or a switch contact common (with
3 Y1 – Cool 1 PWM).
4 Y2 – Cool 2
5 LOW W2 – EARTH
6 MED EARTH connection grounds the secondary side of the
transformer to the enclosure cabinet through a wire
7 HIGH
bonded to the control enclosure.
8 24V
9 24V
10 G – Fan Enable
11 W1 – Heat 1
12 COM
13 DAMP - Damper
14 COM
15 HEAT – Heat output
16 COM
17 24V
18 S1 – Common

Figure F.2 – Connector layout 

JOHNSON CONTROLS 31
 FORM 115.24-NOM11 (0121)

Tools needed for installation/troubleshooting: Fuse: A fuse is included on the secondary side of the
• Digital multimeter capable of measuring 30 volts transformer to protect the transformer from incorrect
AC wiring of thermostat, controller, etc. that shorts the
• Insulated 1/8" flat bladed screwdriver 24VAC and COM. The fuse is a fast-acting glass body
• Fuse puller (optional) cylindrical fuse (5x20mm). If tripped, replace the fuse
• Mini hook test clips for multimeter (optional) by removing the tripped fuse with fuse pullers and
replace using one of the below listed fuses.

Suggested fuse replacement information:

TABLE F.5 – REPLACEMENT FUSE

Transformer Fuse Part Number Manufacturer Part Number
30VA 2A PE-06-0000 Littelfuse 0235002.MXP
Bussmann BK/GMA-2-R
50VA 3A PE-06-0016 Littelfuse 0235003.MXP
Bussmann BK/GMA-3-R

HEAT Output – The HEAT output connects to an DAMP Output – The DAMP output connects to a
electric heat contactor or relay. This output represents motorized damper actuator used to control airflow
the command signal from the thermostat or controller from an external source. This output provides 24VAC
on the W1 input. The output is interlocked with the fan to energize the damper actuator. This output is
relays to ensure that a fan speed is commanded when interlocked with the fan relays to ensure that a fan speed
electric heat is requested. is commanded before energizing the damper actuator.

TABLE F.6 – FIELD INSTALLED COMPONENT DESCRIPTIONS

Name Description
To install a float switch, wire the float switch leads into S1 and C on the screw
terminals. After wiring the float switch, remove jumper JP2. The JP2 jumper
Field-provided Float Switch must be removed for the float switch to operate correctly.
Note: If a float switch was installed in the factory, the float switch may be connected
through a factory-provided harnesses instead of wired to the screw terminal.
To start or stop the fan from an external controller, wire the leads for the switch
Start/Stop for the fan contacts that will be made or broken to R and G on the screw terminals. After
wiring the switch, remove jumper JP3.
To add a remote 3-speed switch, wire the leads for the switch to G, H, M and L
Remote 3-speed switch
on the screw terminals. After wiring the switch, remove jumper JP1.
 

32 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

JUMPERS TEST POINTS

TABLE F.7 – JUMPER DESCRIPTION TABLE F.8 – TEST POINT DESCRIPTION

Jumper Name Description Test Point Name Description
This jumper is installed between TP1 24VAC These test points can be
24V and HIGH when no three TP2 COM u s e d t o v e r i f y 2 4 VA C
speed switch is included (remote assuming incoming voltage
Speed
or unit mounted). The jumper is within tolerance. They
JP1 Select
will be installed at the end of can be connected to with
Jumper
the harness connected to J1. If a mini-hook test clips for a
three speed switch is added later, digital multimeter. Test point
JP1 must be removed. locations for TP1 and TP2 can
This jumper is installed between be seen in Figure F.3.
Float S1 and C when a float switch  
JP2 Switch is not installed. The jumper is
Jumper removed when a float switch is
installed.
This jumper is installed between
R and G/24V. The jumper is
removed when remote control of
Fan
the fan motor is desired. In most
JP3 Enable
instances, JP3 will be installed
Jumper
(unless a thermostat or controller
is remotely controlling of the
equipment).

JP2 and JP3 locations can be seen in Figure F.3.

Figure F.3: FRBii Jumpers and Test Points

JOHNSON CONTROLS 33
 FORM 115.24-NOM11 (0121)

Screw Terminal Signals:

TABLE F.9 – SCREW TERMINAL SIGNAL IDENTIFICATION

Pin Signal Signal Name Description
1 Y1 Cool 1 Chilled water valve actuator control input, and thermostat cooling
output.
2 Y2 Cool 2 “Close” input of modulating chilled water valve actuator or 2nd stage
chilled water valve actuator control input, and thermostat cooling
output. Y1 is “Open” output if floating {tristate} chilled water valve
actuator is installed.
3 W1 Heat 1 Wire connection point for hot water valve actuator or 1st stage EH
control input, and thermostat heating output.
4 L Low Low speed control input for onboard relay.
5 M Medium Medium speed control for onboard relay.
6 H High High speed control input for onboard relay.
7 G Fan Enable Used to allow external start-stop control from an external source.
8 C Common (through JP2) Device common, including onboard speed relays (all terminals C and
9 C “COM” on board are internally connected).
10 R 24VAC Transformer “hot” connection (24VAC).
11 S2 Auxiliary Input (Heat 2) Used for different functions based on application, such as:
• 2nd stage heat control for two stage EH applications
• Changeover water valve/aquastat for two pipe changeover
applications.
• “Close” input of modulating hot water valve actuator and “Close”
output of thermostat in floating [tristate] water valve applications.
12 S1 Common Common side of transformer. Jumped to C (common) through JP2.
If application calls for float switch JP2 is removed and float switch is
connected between S1 and C.

34 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

CHECKING WIRE HARNESSES

Use ohmmeter to verify that ground wire has continuity To check low voltage wire harnesses:
from S1 to enclosure case. • Remove power from the unit. Unplug low voltage
harness J1 connector and disconnect connections
To check incoming power wire harness: at other end of J1 harness.
• Refer to wiring diagram. • Use ohmmeter to check continuity for each
• Remove power from the unit. Unplug power conductor, then reconnect harness to J1 connector
harness J2 or J3 connector. and to other connections.
• Unplug power wires from connections (line block,
disconnect switch, toggle switch or fuse(s)) in Before reconnecting power to unit, verify all harnesses
electrical enclosure. Verify continuity of wires, then are connected per diagram.
reconnect to J2 or J3 connector.
Use caution when inserting meter probe into plug.
To check motor harness: Excess force will damage contacts.
• Refer to wiring diagram.
• Remove power from the unit. Unplug motor harness
J4 and/or J5 connector.
• Unplug motor harness from motor connection or
PWM board (depending on type of motor). Verify
continuity of wires, then reconnect to J4 or J5
connector and to motor or PWM board.

JOHNSON CONTROLS 35
 FORM 115.24-NOM11 (0121)

FAN RELAY BOARD TROUBLESHOOTING GUIDELINES

Risk of Electric Shock.

Disconnect or isolate all power supplies before making electrical connections. More than one
disconnection or isolation may be required to completely de-energize equipment. Contact with
components carrying hazardous voltage can cause electric shock and may result in severe
personal injury or death.

No routine maintenance is required for the fan relay board.

TABLE F.10 - FAN RELAY BOARD TROUBLESHOOTING GUIDELINES

PROBLEM POSSIBLE CAUSE CORRECTIVE ACTION
Measure resistance across fuse:
• A properly working fuse will measure <1.0
Ω.
Blown fuse onboard (F1)
• A blown fuse will measure as an open circuit.
Replace fuse if blown using replacement fuse
identified above.
Verify incoming voltage to the unit is within
Incorrect incoming line voltage
tolerance.
• Verify that the unit is wired per the unit
wiring diagram for incoming voltage. If the
No 24VAC power unit includes main fusing, verify that the
Improper wiring connections
fuses are not blown.
• Verify wire harness connections are secure.
See “Checking Wire Harnesses” section.
JP2 removed without float switch Verify that either a float switch or JP2 are
installed installed. If neither, install one of them.
Float switch tripped Verify float switch (if present) is made.
JP3 removed without external start/ Verify that either an external start/stop or JP3 are
stop control installed installed. If neither, install one of them.
If all of the above are confirmed, replace the fan
Damaged transformer
relay board.
No 24VAC power See above.
Fan motor will not run Verify a fan speed is commanded from either
Fan speed is not commanded. jumper JP1, a unit-mounted or remote-mounted
three speed switch, or a thermostat.
Verify that fan motor is running. A fan speed
Electric heat signal
must be commanded from one of these sources
is not provided to Fan speed is not commanded.
to allow the electric heat contactor to energize
contactor
on a call for heat.
Outside Air Damper Verify that fan motor is running. A fan speed
actuator will not Fan speed is not commanded. must be commanded from one of these sources
energize to allow the damper actuator to energize.
 

36 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

PSC MOTOR TROUBLESHOOTING GUIDELINES

Problem Possible cause Corrective action

Verify thermostat or control is calling for heating or
No demand.
cooling.
Verify fan run command is present at ‘g’ terminal of fan
Fan speed is not commanded.
relay board (24v units) or of terminal block.
No power to motor. Possible
Verify line voltage at motor terminals. Replace fuse or
blown fuse or open circuit
reset circuit breaker.
breaker
Incorrect voltage applied. Verify proper voltage to unit per unit label.
Verify wiring. If fan coil relay board present, verify all
Improper wiring connections jumpers and harnesses installed. Refer to fan coil relay
board troubleshooting guide.
If fan speed controller present, adjust fan speed control
Fan speed adjustment outside
screw to full clockwise position. Verfiy that motor starts.
operating range
Reduce adjustment.
[24V units] three speed switch Verify three speed switch, if present, is set to desired
in off position. speed.
[24V units] loss of 24v power Refer to fan relay board troubleshooting guide.
If drain pan float switch installed. Verify drain pan is
[24V units] drain pan float
not full. Verify operation of float switch. Adjust switch
switch tripped
position if needed.
Verify operation of float switch, if installed. Disconnect
No air flow [psc [24V units] drain pan float
switch and use volt-ohm meter to verify continuity of
motor] switch fault
switch and of wiring. Replace switch if faulty.
If low temperature cutout present. Examine coil for signs
Low temperature cutout has of freezing. Verify adjustment of freeze stat. Disconnect
tripped switch and use volt-ohm meter to verify continuity.
Replace switch if faulty.
Remove power from unit. Clear blockage. Verify blower
Blower jammed is not damaged and rotates freely while motor is not
energized.
If motor hums or buzzes but does not start. Disconnect
power from unit. Discharge capacitor. Remove motor
capacitor from circuit. Use analog volt-ohm meter to
Failed motor capacitor verify motor capacitor. Set meter to kilo-ohms scale.
Touch probes to capacitor terminals. Needle will jump
to zero ohms then drift back to high ohms. Steady high
ohms or stead low ohms indicates failed capacitor.
Remove power from unit. Verify motor rotates freely by
Motor seized
hand with blower disconnected. If not, replace motor.
Damaged motor harness Replace motor harness
Verify motor is not overheated. Check to ensure blower
rotates freely with motor disconnected. Verify proper
Motor overloaded.
duct static. Wait for motor to cool down and verify motor
start. If motor overheats again, replace motor.

JOHNSON CONTROLS 37
 FORM 115.24-NOM11 (0121)

If fan speed controller present, adjust fan speed control

Fan speed adjustment outside
screw to full clockwise position. Verfiy that motor speed
operating range
stabilizes. Reduce adjustment.
Loose motor wiring Reseat motor connector. Tighten all motor connections.
Loose control wiring Verify and/or tighten all control connections.
Verify operation of any control device such as drain pan
Intermittent control device float switch, freeze stat, thermostat, etc. When in doubt,
Fan speed
jumper out and verify fan operation.
fluctuates [psc
motor] Blower set screw loose Remove power from unit. Tighten screw onto motor shaft.
Verify proper ductwork to unit. Verify ductwork is
Improper duct connections installed per smacna and ashrae guidelines. Improper
ductwork can cause turbulence at the motor.
Verify dampers, if present, are not closed. Verify there
Esp (external static pressure) are no obstructions in the discharge ductwork and/or at
too high the plenum opening. Verify filter is not dirty and does not
obstruct airflow.
Lack of required external static External static pressure not as designed. Adjust external
pressure static pressure to design pressure
[24V units] three speed switch Verify three speed switch, if present, is set to desired
in wrong position. speed.
Poor voltage quality Verify input voltage within acceptable parameters.
If fan speed controller present. Adjust fan speed control
Fan speed control adjustment
screw to full clockwise position. Verify airflow. Reduce
outside fan operating range
Poor airflow adjustment to speed that provides desired performance.
performance Verify ductwork is installed per smacna and ashrae
Improper duct connections
[psc motor] guidelines.
Verify no obstructions. Verify all dampers are full open
Duct obstruction
while fan operates.
Improperly set dampers Verify proper inlet air to unit.
Check cleanliness of coil. Dirty coil fins will restrict
Dirty coil
airflow.
Dirty filters Check for dirty or blocked filters. Replace as needed.
Damaged or blocked blower Verify blower rotates freely. Clear blockage.

38 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

Voltage or ground loss at motor Verify proper voltage and ground at motor.
Clear blockage. Verify blower rotates freely with motor
Blower blocked
disconnected.
Verify operation of thermostat or controller. If 24v unit,
Loss of fan speed command. verify fan speed command at relay board. Refer to fan
relay board troubleshooting guide.
Use amp meter to verify motor amps. Disconnect power
Motor overloaded to unit. Verify motor rotates freely by hand with blower
Fan motor starts disconnected. If not, replace motor.
but stops. [Psc Open ductwork Verify ducts sealed properly.
motor] Verify dampers, if present, are not closed. Verify there
Motor overheated due to lack are no obstructions in the discharge ductwork and/or at
of airflow the plenum opening. Verify filter is not dirty and does not
obstruct airflow.
Verify proper voltage and ground at motor power
Voltage or ground loss at motor
terminals.
Motor fault or end of life. Replace motor.
Reseat connector and verify operation. Disconnect motor
Faulty motor harness
harnesses and verify continuity. Replace motor harness.
Motor mounting bolts loose Tighten motor mounting bolts.
Motor shaft bent Replace motor.
Disconnect power from unit. Verify motor rotates freely
Motor bearing end of life
by hand with blower disconnected.
Verify static pressure per system design. Use amp meter
to verify motor amps. Disconnect power to unit. Verify
Motor overloaded
motor rotates freely with power disconnected. If not,
replace motor.
Motor end of life Use amp meter to verify motor amps. Replace motor.
Dirty filters Verify filters. Replace as needed.
Verify blower is unobstructed. Verify no duct obstruction.
Excessive fan Obstructed airflow
Verify dampers are full open.
noise
Verify ductwork is installed per smacna and ashrae
Improper duct connections
guidelines.
Static pressure too low Verify static pressure per system design.
Improperly balanced system Verify airflow through connected ductwork
Fan wheel rubbing on fan
Remover power from unit. Align wheel in housing.
housing
Remover power from unit. Align wheel in housing and
Loose fan wheel
tighten.
Inspect fan wheel to verify fins are not bent. Replace
Damaged fan wheel
blower as needed.
Imbalanced fan wheel Inspect fan wheel. Replace as needed.

JOHNSON CONTROLS 39
 FORM 115.24-NOM11 (0121)

EC MOTOR TROUBLESHOOTING GUIDELINES

Problem Possible cause Corrective action

No demand. Verify thermostat or control is calling for heating or cooling.
Fan speed is not commanded. Verify fan run command is present at Fan Relay Board.
No power to motor. Possible
Verify line voltage at motor terminals. Replace fuse or
blown fuse or open circuit
reset circuit breaker as needed.
breaker
Incorrect voltage applied. Verify proper voltage to unit per unit label.
Verify wiring. If Fan Coil Relay board present, verify
Improper wiring connections all jumpers and harnesses installed on Fan Relay Board.
Refer to Fan Coil Relay Board Troubleshooting Guide.
Three speed switch in OFF Verify three speed switch, if present, is set to desired
position. speed.
Loss of 24V power Refer to Fan Relay Board Troubleshooting Guide.
If drain pan float switch is present, verify drain pan is
Drain pan float switch tripped not full. Verify operation of float switch. Adjust switch
position if needed.
Verify operation of drain pan float switch, if present.
Disconnect switch and use volt-ohm meter to verify
Drain pan float switch fault
continuity of switch and of wiring. Replace switch if
faulty.
If low temperature cutout is present. Examine coil
Low temperature cutout has for signs of freezing. Verify adjustment of freeze stat.
tripped Disconnect switch and use volt-ohm meter to verify
No air flow continuity. Replace switch if faulty.
[EC motor] Remvoe power from unit. Clear blockage. Verify blower
Blower jammed is not damaged and rotates freely while motor is not
energized.
Remove power from unit. Verify motor rotates freely by
hand with blower disconnected. If not, replace motor.
Motor seized
Note: EC motors may not rotate freely as the rotor aligns
with the stator magnets.
Verify motor is not overheated. Remove power from
unit. Check to ensure blower rotates freely with motor
Motor overloaded. disconnected. Verify proper duct static. Wait for motor
to cool down and verify motor start. If motor overheats
again, replace motor.
Refer to PWM board status LEDs. Verify voltage input,
PWM board faulted wiring and connections. Refer to PWM board IOM.
Replace PWM board if fault returns.
EC motors may run at idle speed if they lose PWM signal
No control signal while enabled. Verify PWM signal at motor connector.
Refer to PWM board IOM.
Wiring harness improperly Unplug harness and re-install, making sure plugs are fully
seated seated.
Wiring harness(es) open or
Replace harness(es). Refer to PWM board IOM.
intermittent
Damaged motor harness Replace motor harness

40 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

Loose motor wiring Reseat motor connector. Tighten all motor connections.
Loose control wiring Verify and/or tighten all control connections.
Verify operation of any control device such as drain pan
Intermittent control device float switch, freeze stat, thermostat, etc. When in doubt,
jumper out and verify fan operation.
[EC motor] Fan speed Refer to Fan Calibration curve on unit. Adjust speed on
adjustment outside operating PWM Controller to value that will allow motor to start.
range See instructions for Adjusting EC Motor Speed.
Fan motor
surges [EC [EC motor] Faulty PWM Verify PWM signal at motor connector. Refer to PWM
motor] signal board IOM.
Blower Set Screw loose Tighten Screw onto motor shaft.
Verify proper ductwork to unit. Verify ductwork is
Improper duct connections installed per SMACNA and ASHRAE guidelines.
Incorrectly sized ducts can cause motor surging.
Verify dampers, if present, are not closed. Verify there
ESP (external static pressure) are no obstructions in the discharge ductwork and/or at
too high the plenum opening. Verify filter is not dirty and does not
obstruct airflow.
Lack of required external static External static pressure not as designed. Adjust external
pressure static pressure to design pressure
[24V units] Three speed switch Verify three speed switch, if present, is set to desired
in wrong position. speed.
Poor voltage quality Verify input voltage within acceptable parameters.
Refer to Fan Calibration curve on unit. Adjust speed on
Speed adjustment outside fan
PWM Controller to value that will allow motor to start.
operating range
See instructions for Adjusting EC Motor Speed.
Poor Airflow Erratic speed command (in Verify 2-10V analog signal at Remote Control Input
Performance Proportional Control mode) terminals.
[ECM motor] Verify ductwork is installed per SMACNA and ASHRAE
Improper duct connections
guidelines.
Verify no obstructions. Verify all dampers are full open
Duct obstruction
while fan operates.
Improperly set dampers Verify proper inlet air to unit.
Check cleanliness of coil. Dirty coil fins will restrict
Dirty coil
airflow.
Dirty filters Check for dirty or blocked filters. Replace as needed.
Damaged or blocked blower Verify blower rotates freely. Clear blockage.

JOHNSON CONTROLS 41
 FORM 115.24-NOM11 (0121)

Voltage or ground loss at motor Verify proper voltage and ground at motor.
Clear blockage. Verify blower rotates freely with motor
Blower blocked
disconnected.
Verify operation of thermostat or controller. Verify fan
Loss of fan speed command. speed command at relay board. Refer to Fan Relay board
troubleshooting guide.
Use amp meter to verify motor amps. Disconnect power
from unit. Verify motor rotates freely by hand with blower
Motor overloaded disconnected. If not, replace motor. Note: EC motors
may not rotate freely as the rotor aligns with the stator
Fan motor starts magnets.
but stops. [EC Open ductwork Verify ducts sealed properly.
motor] Verify dampers, if present, are not closed. Verify there
Motor overheated due to lack are no obstructions in the discharge ductwork and/or at
of airflow the plenum opening. Verify filter is not dirty and does not
obstruct airflow.
Verify proper voltage and ground at motor power
Voltage or ground loss at motor
terminals.
Refer to PWM board status LEDs. Verify all connections.
PWM board error or faulted
Cycle power to the board. Refer to PWM board IOM.
Motor fault or end of life. Replace motor.
Reseat connector and verify operation. Disconnect motor
Faulty motor harness
harnesses and verify continuity. Replace motor harness.
Refer to PWM board status LEDs. Verify all connections.
PWM board error or faulted
Cycle power to the board. Refer to PWM board IOM.
Verify wiring. If Fan Relay board present, verify all
Improper wiring connections
jumpers installed.
Unplug harness and re-install, making sure plugs are fully
EC wiring harness damaged or
seated. See section on checking wire harnesses, below.
improperly seated
Replace harness if damaged.
EC motor
EC motors may run at idle speed if they lose PWM signal
speed cannot be No control signal
while enabled.
adjusted
Verify PWM signal at motor connector. Refer to PWM
board IOM.
Verify dampers, if present, are not closed. Verify there
ESP (external static pressure) are no obstructions in the discharge ductwork and/or at
too high the plenum opening. Verify filter is not dirty and does not
obstruct airflow.
Motor Control failure Replace motor.
EC motor runs
in reverse,
doesn’t respond Motor Control failure Replace motor.
to speed
adjustment

42 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

Motor mounting bolts loose Tighten motor mounting bolts.

Motor shaft bent Replace motor.
Disconnect power from unit. Verify motor rotates freely
by hand with blower disconnected. Note: EC motors
Motor bearing end of life
may not rotate freely as the rotor aligns with the stator
magnets.
Verify static pressure per system design. Use amp meter
to verify motor amps. Disconnect power to unit. Verify
Motor overloaded
motor rotates freely with power disconnected. If not,
replace motor.
Motor end of life Use amp meter to verify motor amps. Replace motor.
Excessive fan Dirty filters Verify filters. Replace as needed.
noise Verify blower is unobstructed. Verify no duct obstruction.
Obstructed airflow
Verify dampers are full open.
Verify ductwork is installed per SMACNA and ASHRAE
Improper duct connections
guidelines.
Static pressure too low Verify static pressure per system design.
Improperly balanced system Verify airflow through connected ductwork
Fan wheel rubbing on fan
Align wheel in housing.
housing
Loose fan wheel Align and tighten.
Inspect fan wheel to verify fins are not bent. Replace
Damaged fan wheel
blower as needed.
Imbalanced fan wheel Inspect fan wheel. Replace as needed.

JOHNSON CONTROLS 43
 FORM 115.24-NOM11 (0121)

COOLING SYSTEM TROUBLESHOOTING GUIDELINES

Problem Possible cause Corrective action

Insufficient airflow Verify proper airflow.
Dirty water coil Check cleanliness of water coil. Clean as needed.
Verify operation of drain pan float switch, if present.
[24V units] Drain pan float
Disonnect switch and use volt-ohm meter to verify continuity
switch fault
of switch and of wiring. Replace switch if faulty.
Cooling valve not operating Verify cooling valve opens with call for cooling. Verify all
properly manual valves are open.
Insufficient Insufficient flow Verify liquid flow per system design.
cooling Verify coil is unobstructed. Verify all manual valves are
Obstructed coil
open and have liquid flow through system.
[DX coils] Improper refrigerant
Charge to proper cooling.
charge
[DX coils] Insufficient cooling Verify coolant flow in coil. Verify proper flow per system
liquid to coil design.
Verify cooling signal at 'Y' terminals. Verify thermostat
No call for cooling.
setting/operation.
Air leak in ducts/unit Verify integrity of unit. Verify ducts are properly sealed.
Pipe insulation Verify pipes are properly insulated
Unit sweats Damaged insulation Verify insulation at point of sweating
Unconditioned air to unit Verify conditioned air to unit
Drain pan is clogged Locate and remove blockage.

44 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

ELECTRIC HEATER TROUBLESHOOTING GUIDELINES

Problem Possible cause Corrective action

Insufficient airflow Verify proper airflow.
Verify thermostat or control is calling for heating. Verify
Loss of demand.
demand voltage is present at unit.
[24V units] Loss of demand. Verify 24V control signal at ‘W’ terminal during demand.
Verify integrity of fuse on Fan Relay Board and replace if
[24V units] Loss of 24V
need be. Refer to Fan Relay Board Troubleshooting Guide.
Electric heat will not operate unless fan motor is enabled.
No airflow.
Verify fan speed is commanded.
Disconnect primary limit wire harness (the purple wire
harness coming out of the heater section.) Verify continuity
Damaged primary limit wire across wire harness. If no continuity, check if primary
harness limit is tripped. If primary limit is verified good, remove
power from unit, disconnect primary limit wire harness, and
measure continuity of wire harness. Replace if bad.
Verify no loss of demand to unit. Verify that voltage exists
on magnetic heater contactor during demand for heat. If
demand reaches unit but not contactor, primary limit is
Primary limit switch tripped.
tripped. The primary limit switch(es) will auto-reset once
Electric Heat
the unit cools down. If unit is hot, wait for heater to cool
will not operate
down. This may take up to an hour.
The secondary limit may be manually reset. If unit is hot,
CAUTION:
Secondary limit switch tripped. wait for the heater to cool down. This may take up to an
UNIT MAY BE
hour. Reset switch(es). Verify if heater will start.
EXTREMELY
HOT. TAKE Improper wiring connections Verify wiring to schematic.
GREAT With power removed, disconnect heater wire harnesses.
CARE WHEN (These are the harnesses with the black plugs.) Use a
TROUBLE- volt-ohm meter to measure resistance across the electric
Open or damaged heater elements
SHOOTING. heat power harness coming out of the heater section. If
the meter measures an open or shorted circuit, inspect the
heating elements.
With power removed, disconnect heater wire harnesses. Use
Damaged electric heat wire
a volt-ohm meter to verify continuity ofelectric heat power
harness
harness wires in the control enclosure section.
With power removed and heater cool, remove primary limit
Primary Limit switch fault switch. Verify continuity across switch. Replace switch if
open.
With power removed and heater cool, remove secondary
Secondary Limit switch fault limit switch. Verify switch is reset. Verify continuity across
switch. Replace switch if open.
Verify heating demand voltage is at magnetic electric heat
contactor control coil terminals. If power is present but
contactor is not actuated, replace contactor. To verify
[Magnetic contactor] Electric
contactor: with power removed, unwire contactor and verify
heat contactor fault
continuity across contacts when manually operated. Cover
of contactor will need to be removed to access manual
operator. Replace contactor if faulty.

JOHNSON CONTROLS 45
 FORM 115.24-NOM11 (0121)

Electric Heat Verify control voltage is at magnetic electric heat contactor control
[Solid state relay] electric heat safety
will not operate coil terminals. If power is present at coil but contactor is not
contactor fault
(cont’d) actuated, replace contactor.
CAUTION: Verify heating demand (control voltage) is at solid state relay
[Solid state relay] Solid State Relay
UNIT MAY BE control terminals. If power is present but relay is not actuated,
fault
replace relay.
EXTREMELY
HOT. TAKE
GREAT Verify DC control signal is present at controller input terminals.
[Solid state relay proportional
CARE WHEN Verify that output control voltage to solid state relay varies with
control] Heat controller fault
TROUBLE- variation in input. Replace controller if not.
SHOOTING.
Verify that thermostat or control command signal is not dropping
Loss of demand.
out. Verify voltage is present at unit during demand for heat.
Verify that signal from thermostat or control is not dropping out.
Electric Heat [24V units] Loss of demand. During demand, there needs to be 24V on 'W1' terminal of Fan
Relay board.
shuts down
unexpectedly Verify no loss of demand to unit. Verify that voltage exists on
heater contactor during demand for heat. If demand reaches unit
but not contactor, primary limit is tripped. The primary limit
CAUTION: Primary limit switch tripped.
switch(es) will auto-reset once the unit cools down. If unit is hot,
UNIT MAY BE wait for heater to cool down. This may take up to an hour. If limit
EXTREMELY trips again, verify heater is not overheating.
HOT. TAKE The secondary limit may be manually reset. If unit is hot, wat
GREAT Secondary limit switch tripped. for the heater to cool down. This may take up to an hour. Reset
CARE WHEN switch(es). If limits trip again, verify heater is not overheating.
TROUBLE- Loss of fan speed command. Heater will not operate if fan is not enabled.
SHOOTING. Verify operation of any control device such as drain pan float
Intermittent control device switch, freeze stat, thermostat, etc. When in doubt, jumper out
and verify fan operation.
Loose wiring Verify and/or tighten all wiring connections.
Verify that airflow is sufficient to provide a minimum of 70 CFM
Insufficient airflow
per kW of electric heat.
Electric heaters require even airflow across the face of the heater
Improper duct connections in order to operate properly. Verify ductwork is installed per
SMACNA and ASHRAE guidelines.
Electric heater is
Verify no obstructions. Verify all dampers are full open while
overheating Obstructed ductwork
fan operates.
Intermittent fan Verify fan motor runs continuously, providing even airflow.
CAUTION:
Incorrect voltage applied. Verify proper voltage to unit per unit label.
UNIT MAY BE
EXTREMELY Verify wiring to schematic. If Fan Coil Relay board present, verify
Improper wiring connections all jumpers and harnesses installed. Refer to Fan Coil Relay Board
HOT. TAKE
Troubleshooting Guide.
GREAT
CARE WHEN Remove power from unit. Access the heater compartment. Verify
Damaged heater elements
heating elements are undamaged.
TROUBLE-
SHOOTING. Remove thermostat or control command signal. Verify no control
Shorted magnetic heater contactor voltage to heater contactor. If electric heat continues to operate
and all wiring has been verified, replace contactor.
Remove thermostat or control command signal. Verify no control
[Solid state relay] Shorted solid
voltage to solid state relay. If electric heat continues to operate
state relay
and all wiring has been verified, replace solid state relay.

46 JOHNSON CONTROLS
 FORM 115.24-NOM11 (0121)

Verify that thermostat or control command signal is not dropping

Intermittent demand for heating. out. Verify voltage is continuously present at unit during demand
for heat.
Heater is short cycling Verify thermostat settings. Verify proper location of thermostat.
With power removed, disconnect heater wire harnesses. (These
are the harnesses with the black plugs.) Use a volt-ohm meter
Insufficient Open or damaged heater elements to measure the resistance across the electric heat power harness
heating coming out of the heater section. Verify ohms approximately
equal to (Unit Volts)2/Unit kW.
Loss of demand for second stage. Verify demand voltage at stage
CAUTION: Loss of stage
2 contactor.
UNIT MAY BE
EXTREMELY Incorrect voltage applied. Verify proper voltage to unit per unit label.
HOT. TAKE Verify heating demand voltage is at each electric heat contactor
GREAT control coil terminals. If power is present but contactor is not
actuated, replace contactor. To verify contactor: with power
CARE WHEN Electric heat contactor fault
removed, unwire contactor and verify continuity across contacts
TROUBLE-
when manually operated. Cover of contactor will need to be
SHOOTING. removed to access manual operator. Replace contactor if faulty.
Verify no loss of demand to unit. Verify that voltage exists
continuously on heater contactor during demand for heat. If
demand reaches unit but not contactor, primary limit is tripped.
Primary limit switch cycling.
The primary limit switch(es) will auto-reset once the unit cools
down. If unit is hot, wait for heater to cool down. This may take
up to an hour. If limit trips again, verify heater is not overheating.

JOHNSON CONTROLS 47
Johnson Controls is a mark and/or registered mark. Unauthorized use is strictly prohibited.

Catalog: 115.24-NOM11 (0121) Supersedes 115.24-NOM11 (0520)

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