Johnson Controls Inc. Air Conditioner 13 SEER - GCGD User's Manual
Contents
1. piers Temp F ee Temp F Peer Temp F sot Temp F Biot i Temp F ot i Temp F 80 48 110 64 140 78 170 91 200 101 230 111 82 49 112 65 142 79 172 91 202 102 232 112 84 50 114 66 144 80 174 92 204 103 234 112 86 51 116 67 146 81 176 93 206 103 236 113 88 52 118 68 148 82 178 94 208 104 238 114 90 54 120 69 150 83 180 94 210 105 240 114 92 55 122 70 152 84 182 95 212 105 242 115 94 56 124 71 154 84 184 96 214 106 244 115 96 57 126 72 156 85 186 97 216 107 246 116 98 58 128 73 158 86 188 97 218 107 248 117 100 59 130 74 160 87 190 98 220 108 250 117 102 60 132 75 162 88 192 99 222 109 252 118 104 61 134 76 164 88 194 99 224 109 254 118 106 62 136 77 166 89 196 100 226 110 256 119 108 63 138 78 168 90 198 101 228 111 258 119 ACAUTION ACAUTION IT IS UNLAWFUL TO KNOWINGLY VENT RELEASE OR DIS CHARGE REFRIGERANT INTO THE OPEN AIR DURING REPAIR SERVICE MAINTENANCE OR THE FINAL DISPOSAL OF THIS UNIT WHEN THE SYSTEM IS FUNCTIONING PROPERLY AND THE OWNER HAS BEEN FULLY INSTRUCTED SECURE THE OWNER S APPROVAL SECTION VIII ELECTRICAL CONNECTIONS GENERAL INFORMATION amp GROUNDING Check the electrical supply to be sure that it meets the values specified on the unit nameplate and wiring label Power wiring control low voltage wiring disconnect switches and over current protection must be supplied by the installer Wire size should be sized per NEC r2. Technician Performing Start Up Installing Contractor Name Owner Information Name Address City State or Province Zip or Postal Code Equipment Data C Upflow C Downflow C Horizontal Left C Horizontal Right Indoor Unit Model Indoor Unit Serial Indoor Coil Model Indoor Coil Serial Outdoor Unit Model Outdoor Unit Serial Filter Thermostat Accessories Filter Type Filter Size Filter Location s Thermostat Type Other System Equipment and Accessories Connections Per Installation Instructions and Local Codes Unitislevel Supply plenum and return ducts are connected and sealed Refrigerant piping complete and leak tested Gas piping is connected if applicable Vent system is connected if applicable Condensate drain for indoor coil properly connected Condensate drain for furnace if applicable Electrical Line Voltage Indoor unit volts AC Outdoor unit volts AC Overcurrent Protection Breaker Fuses Amperes Ground wire is connected Polarity is correct 120vac indoor units black is L1 hot white is N neutral Electrical Low Voltage Thermostat wiring complete Heat anticipator Heat anticipator is set to the recommended value listed in the Installation Instructi
3. COOL CA C B Oc CD ADJUST C ECM CA C B O cC CD Cooling D Indoor CA C B Oc CD Blower Set Up C X 13 O1 O2 O 3 C 4 O5 PSC C Low C Medium Low gt Medium C Medium High C High Return Air Dry Bulb Wet Bulb Supply Air Dry Bulb Temperature Drop Outside Air Dry Bulb C ECM HEAT CA C B Oc CD Heating Indoor C X 13 O1 C2 C3 O4 O5 Blower Set Up C PSC C Low Medium medum Medium G High Low High Return Air Dry Bulb Wet Bulb Supply Air Dry Bulb Temperature Rise Refrigerant Charge and Metering Device Additional Lineset Length Adder per foot Ibs Oz A Rea STOR TAV PREA ONNES a Eibs 45s Total Added Ibs Oz Orifice Size Liquid Line Temp High Side Pressure Suction Line Temp Low Side Pressure TXV Subcooling Superheat Cycle Test Operate the unit through continuous fan cycles from the thermostat noting and correcting any problems Operate the unit through a cooling cycles noting and correcting any problems Operate the unit through several heating cycles if applicable from the thermostat noting and correcting any problems Clean Up r Installation debris disposed of and indoor and outdoor areas cleaned up Owner Education C m Provide owner with the owner s manual Explain operation of system to equipmen
4. ROOF INSTALLATION When installing units on a roof the structure must be capable of sup porting the total weight of the unit including a pad lintels rails etc which should be used to minimize the transmission of sound or vibra tion into the conditioned space Johnson Controls Unitary Products LIQUID LINE FILTER DRIER The air conditioning units copper spun filter dryer is located on the liq uid line NOTICE Replacements for the liquid line drier must be exactly the same as marked on the original factory drier See Source 1 for O E M replace ACAUTION Failure to do so or using a substitute drier or a granular type may result in damage to the equipment Filter Drier Apply with Models Source 1 Part No 13 SEER 1 02922156000 1 5 to 3 Tons 1 02922157000 3 5 to 5 Tons PIPING CONNECTIONS The outdoor condensing unit must be connected to the indoor evapora tor coil using field supplied refrigerant grade ACR copper tubing that is internally clean and dry Units should be installed only with the tubing sizes for approved system combinations as specified in tabular data sheet The charge given is applicable for total tubing lengths up to 15 feet See Application Data Part Number 247077 for installing tubing of longer lengths and elevation differences NOTICE Using a larger than specified line size could result in oil return prob lems Using too small a line will result in loss
5. Total System Charge into outdoor unit for maintenance service etc This may cause damage to the compres sor and or other components the outdoor unit only has enough vol ume for the factory charge not the Total System Charge ACAUTION Refrigerant charging should only be carried out by a qualified air con ACAUTION Compressor damage will occur if system is improperly charged On new system installations charge system per tabular data sheet for the matched coil and follow guidelines in this instruction If a calibrated charging cylinder or accurate weighing device is avail able add refrigerant accordingly Otherwise model specific charging charts are provided on the access panel of the unit 1031452 UIM B 0513 SUPERHEAT CHARGING METHOD PISTON INDOOR 1 Operate system until temperatures and pressures stabilize mini mum of 10 minutes 2 Measure and record indoor wet bulb WB temperature using a sling psychrometer and the outdoor dry bulb DB temperature using a thermometer 3 Measure and record the suction pressure at the suction service valve port 4 Using charts located on the unit note the superheat value corre sponding to the intersection of the indoor wet bulb and the outdoor dry bulb 5 With the superheat value obtained in step 4 and the suction pres sure value from step 3 find the intersection of the values on the chart This is the required suction tube temperature at the sucti
6. 10 Orifice Installation 2 0 2c 5 Thermostat Chart Single Stage AC with PSC Furnace 11 Outdoor Unit Control Box 0 eee 7 Wiring Diagram ficscaue esas eae d warn eae eed ead ee 13 LIST OF TABLES Application Limitations 0 0 00 cece 2 R 22 Saturated Properties 0 eee eee eee 6 SECTION l GENERAL The outdoor units are designed to be connected to a matching indoor coil with sweat connect lines Sweat connect units have been shipped from the factory with a nitrogen holding charge The refrigerant charge may need to be changed for some indoor out door unit combinations elevation differences or total line lengths Refer to Application Data covering General Piping Recommendations and Refrigerant Line Length Part Number 247077 This unit has a com pressor containing POE oil ACAUTION This unit does not contain any refrigerant It contains a nitrogen hold ing charge Operating this unit with the nitrogen holding charge will damage the compressor IMPORTANT Before operating this unit vent the nitrogen and evacuate the entire system below 500 microns Weigh in the refrigerant using the Tabular Data Sheet and Installation Manual WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It is also used to alert
7. against unsafe practices and hazards involving only property dam AWARNING Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual for assis tance or for additional information consult a qualified contractor installer or service agency SECTION II SAFETY This is a safety alert symbol When you see this symbol on A labels or in manuals be alert to the potential for personal injury Understand and pay particular attention to the signal words DANGER WARNING or CAUTION DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury Johnson Controls Unitary Products ACAUTION This product must be installed in strict compliance with the enclosed installation instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes INSPECTION As soon as a unit is received it should be inspected for possible dam age during transit If damage is evident the extent of the damage should be noted on the carrier s delivery receipt A separate request for inspection by the carrier s agent should be made in writing See Local Distributor for more information 1031452 UIM B 0513 10
8. of capacity and other problems caused by insufficient refrigerant flow Slope horizontal vapor lines at least 1 every 20 feet toward the outdoor unit to facili tate proper oil return PRECAUTIONS DURING LINE INSTALLATION 1 Install the lines with as few bends as possible Care must be taken not to damage the couplings or kink the tubing Use clean hard drawn copper tubing where no appreciable amount of bending around obstruction is necessary If soft copper must be used care must be taken to avoid sharp bends which may cause a restriction 2 The lines should be installed so that they will not obstruct service access to the coil air handling system or filter 3 Care must also be taken to isolate the refrigerant lines to minimize noise transmission from the equipment to the structure 4 The vapor line must be insulated with a minimum of 1 2 foam rub ber insulation Armaflex or equivalent Liquid lines that will be exposed to direct sunlight high temperatures or excessive humid ity must also be insulated 5 Tape and suspend the refrigerant lines as shown DO NOT allow tube metal to metal contact See Figure 2 6 Use PVC piping as a conduit for all underground installations as shown in Figure 3 Buried lines should be kept as short as possible to minimize the build up of liquid refrigerant in the vapor line during long periods of shutdown 7 Pack fiberglass insulation and a sealing material such as perma gum around
9. 31452 UIM B 0513 LIMITATIONS The unit should be installed in accordance with all National State and Local Safety Codes and the limitations listed below 1 Limitations for the indoor unit coil and appropriate accessories must also be observed 2 The outdoor unit must not be installed with any duct work in the air stream The outdoor fan is the propeller type and is not designed to operate against any additional external static pressure 3 The maximum and minimum conditions for operation must be observed to ensure a system that will give maximum performance with minimum service TABLE 1 Application Limitations Ambient Air Temperature Air Temperature on on Outdoor Coil Indoor Coil Min DB Max DB Min WB Max WB 50 F 115 F 57 F 72 F 4 The unit should not be operated at outdoor temperatures below 50 F without an approved low ambient operation accessory kit installed 5 The maximum allowable line length for this product is 75 feet SECTION III UNIT INSTALLATION LOCATION Before starting the installation select and check the suitability of the location for both the indoor and outdoor unit Observe all limitations and clearance requirements The outdoor unit must have sufficient clearance for air entrance to the condenser coil air discharge and service access See Figure 1 NOTICE For multiple unit installations units must be spaced a minimum of 24 inches apart coil face to co
10. 452 UIM B 0513 AC 5A Single Stage Air Conditioner Single Stage PSC Furnace ID MODELS PS 8 9 L 8S F 8 9 S G8C G 8 9 S GF 8 9 THERMOSTAT Ge SINGLE STAGE SINGLE STAGE PP11C70224 PSC AIR FURNACE CONDITIONER SINGLE STAGE PSC D SINGLE STAGE FURNACE AIR CONDITIONER Cc 24 Volt Common 24 Volt Common Vi vid Y Full Stage Compressor Single Stage Compressor Compressor Contactor RH R 24 Volt Hot Heat XFMR 24 Volt Hot G G Fan Fan WwW Full Stage Heat RC VINZ 24 Volt Hot Second or Full Cool XFMR Stage Compressor Ww Full Stage Heat HM1 24VAC Humidifier Humidistat Optional Clipping Jumper W914 for electric heat on thermostat is not necessary Other Part Numbers SAP Legacy 265902 031 09167 FIGURE 10 Thermostat Chart Single Stage AC with PSC Furnace 10 Johnson Controls Unitary Products 1031452 UIM B 0513 AC 5B Single Stage Air Conditioner Single Stage PSC Furnace ID MODELS PS 8 9 L 8S F 8 9 S G8C G 8 9 S GF 8 9 THERMOSTAT THERMOSTAT G OF BrT SoA SINGLE STAGE SINGLE STAGE BN11C01124 BN11C00124 DP11C40124 PSC AIR DN11C00124 FURN
11. ACE CONDITIONER C C Cc C 24 Volt Common 24 Volt Common 24 Volt Common 24 Volt Common k y Y1 Y Full Stage Compressor Full Stage Compressor Single Stage Compressor Compressor Contactor RH RH R 24 Volt Hot 24 Volt Hot Heat XFMR Heat XFMR NRR G G G Fan Fan Fan Ww Full Stage Heat RC RC Y Y2 24 Volt Hot 24 Volt Hot Second or Full Cool XFMR Cool XFMR Stage Compressor Ww Ww Full Stage Heat Full Stage Heat 24VAC Humidifier Optional FIGURE 11 Thermostat Chart Single Stage AC with PSC Furnace Johnson Controls Unitary Products 11 1031452 UIM B 0513 SECTION IX INSTRUCTING THE OWNER Assist owner with processing warranty cards and or online registration Review Owners Guide and provide a copy to the owner and guidance on proper operation and maintenance Instruct the owner or the opera tor how to start stop and adjust temperature setting When applicable instruct the owner that the compressor is equipped with a crankcase heater to prevent the migration of refrigerant to the compressor during the OFF cycle The heater is energized only when the unit is not running If the main switch is disconnected for long peri ods of shut down do not attempt to start the unit until 8 hours after the switch has been connected This will allow sufficient time for all liquid refrigerant to be driven out of the compressor The installer should also inst
12. AL C PAC TUAL CA AC WIRING ATION CAPACITOR ANY PPLI PLAC TH T ITS HERE 40 VO EUTRA F CON BLACK CONTACTOR YEL PNK USE COPPER CONDUCTORS ONLY BOX 208 230 VAC 60 Hz PHASE SUPPLY 220 240 VAC 50 Hz PHASE SUPPLY EVENT EL C COMPONE DANGER SHOCK HAZARD ECTRICAL POWER BEFORE OPREVENT POSSIBLE DAMAGE PMENT AND POSSIBLE JURY CAUTION ECTRICAL SHOCK OPEN NNECT SO ELECTRICAL R CONDITIONER IS SHUT OFF 0 ENTS SHOWN IN DASHED ARE OPTIONAL APAC TORS NI TOR SHOWN SEPARATE MAY BE USED ON M AL CONFORM TO ND LOCAL CODES Da OF THE ORIGINAL WIRE TH THIS UNIT MUST BE T MUST BE REPLACED 05 C THERMOPLASTIC VALENT E E Y DE EQU POWER SUPPLY HAS ONE LT CONDUCTOR AND ONE L CONDUCTOR CONNECT L TACTOR TO NEUTRAL 1 1 2 HIG LOW OPT FIEL VOLTAGE FACTORY WIRING VOLTAGE FACTORY WIRING ONAL WIRING D WIRING LINE VOLTAGE HIGH PRESSURE SWITCH CRANKCASE HEATER HEATER SWITCH START RELAY START CAPACITOR CONTACTOR COIL 167242 UWD D 1009 FIGURE 12 Wiring Diagram Johnson Controls Unitary Products 13 1031452 UIM B 0513 NOTES 14 Johnson Controls Unitary Products 1031452 UIM B 0513 SECTION XI START UP SHEET Air Conditioning and Heating Start Up Sheet Proper start up is critical to customer comfort and equipment longevity Start Up Date
13. L OPENING S WITH PANEL PERMAGUM OR EQUIVALENT 4 N NEC CLASS 1 WIRING 4 NEC CLASS 2 WIRING TO FURNACE OR AIR HANDLER TERMINAL BLOCK TO INDOOR COIL FIGURE 1 Typical Installation GROUND INSTALLATION The unit should be installed on a solid base that is 2 above grade and will not shift or settle causing strain on the refrigerant lines and possible leaks Maintain the clearances shown in Figure 1 and install the unit ina level position The base pad should not come in contact with the foun dation or side of the structure because sound may be transmitted to the residence The length of the refrigerant tubing between the outdoor unit and indoor coil should be as short as possible to avoid capacity and efficiency losses Excessive spacing of the outdoor unit from the home can result in the refrigerant lines being restricted by trampling or being punctured by lawn mowers Locate the outdoor unit away from bedroom windows or other rooms where sound might be objectionable Adverse effects of snow or sleet accumulating on the outdoor coil can be eliminated by placing the outdoor unit where the prevailing wind does not blow across the unit Trees shrubs corners of buildings and fences standing off from the coil can reduce capacity loss due to wind chill effect Provide ample clearance from shrubs to allow adequate air to pass across the outdoor coil without leaves or branches being pulled into the coil
14. N Dry nitrogen should always be supplied through the tubing while it is being brazed because the temperature required is high enough to cause oxidation of the copper unless an inert atmosphere is provided The flow of dry nitrogen should continue until the joint has cooled Always use a pressure regulator and safety valve to insure that only low pressure dry nitrogen is introduced into the tubing Only a small flow is necessary to displace air and prevent oxidation PRECAUTIONS DURING BRAZING SERVICE VALVE Precautions should be taken to prevent heat damage to service valve by wrapping a wet rag around it as shown in Figure 4 Also protect all painted surfaces insulation and plastic base during brazing After braz ing cool joint with wet rag AWARNING This is not a backseating valve The service access port has a valve core Opening or closing valve does not close service access port If the valve stem is backed out past the chamfered retaining wall the O ring can be damaged causing leakage or system pressure could force the valve stem out of the valve body possibly causing personal injury Valve can be opened by removing the plunger cap and fully inserting a hex wrench into the stem and backing out counter clockwise until valve stem just touches the chamfered retaining wall 1031452 UIM B 0513 Connect the refrigerant lines using the following procedure 1 Remove the cap and Schrader core from both the liquid and v
15. T wi ln R 22 OUTDOOR SPLIT SYSTEM AIR CONDITIONING SHIPPED WITH NITROGEN CHARGE ONLY lt LILON Hp N in pr 4 gt aE CERTIFIED www ahridirectory org Unitary Small AC ndare io WS MODELS 13 SEER GCGD 9000 REGIST ISO 9001 1 5 TO 5 TONS Certified Quality C US Management System LIST OF SECTIONS GENERAL seciicicdceeaceusend pon renon sack cea eed eames 1 SYSTEM CHARGE 2 ics0cciceniseeiwie dee EEEN tenes 5 SAFETY Jnter ete OEN pane IE echoes EEN aorteann enna 1 ELECTRICAL CONNECTIONS 2 02 cece eee e renee eee 6 UNIT INSTALLATION cic sje ses cae ceca eee ean enkan KETE 2 INSTRUCTING THE OWNER 2 000 c cece eee eee eee 12 ORIFICE INSTALLATION 0 cece eee eee eee eee 4 WIRING DIAGRAM 0 0 cece eee tee eee 13 TXV INSTALLATIONS 2 22 22 c eee een eet eee ene ee 5 START UP SHEET i iaptenid nrin a EOR cane 15 EVACUATION crci riceneioneies ni hes ni eet En Ea 5 LIST OF FIGURES Typical Installation oanig da eaan i oe bees esa E 2 Typical Field Wiring Air Handler Electrical Heat 7 Installation of Vapor Line susuaaurnanarunna nann 3 Thermostat Chart Single Stage AC with PSC Air Handler 8 Underground Installation 0 0 0 cee eee eee 3 Thermostat Chart Single Stage AC with PSC Air Handler 9 Heat Protection 240 cia cci scenes nore r eae tieni ae eae eee es 4 Thermostat Chart Single Stage AC with PSC Furnace
16. apor service valve service ports at the outdoor unit Connect low pres sure nitrogen to the liquid line service port 2 Braze the liquid line to the liquid valve at the outdoor unit Be sure to wrap the valve body with a wet rag Allow the nitrogen to con tinue flowing 3 Carefully remove the plugs from the evaporator liquid and vapor connections at the indoor coil COs FIGURE 4 Heat Protection ACAUTION Do not install any coil in a furnace which is to be operated during the heating season without attaching the refrigerant lines to the coil The coil is under 30 to 35 psig inert gas pressure which must be released to prevent excessive pressure build up and possible coil damage 4 Braze the liquid line to the evaporator liquid connection Nitrogen should be flowing through the evaporator coil 5 Slide the grommet away from the vapor connection at the indoor coil Braze the vapor line to the evaporator vapor connection After the connection has cooled slide the grommet back into original position 6 Protect the vapor valve with a wet rag and braze the vapor line connection to the outdoor unit The nitrogen flow should be exiting the system from the vapor service port connection After this con nection has cooled remove the nitrogen source from the liquid fit ting service port 7 Vent the nitrogen holding charge in the outdoor unit by opening both service valves slowly and waiting for the pressure t
17. equirements All field wiring must USE COPPER CONDUCTORS ONLY and be in accordance with Local National Fire Safety amp Electrical Codes This unit must be grounded with a separate ground wire in accordance with the above codes The complete connection diagram and schematic wiring label is located on the inside surface of the unit service access panel FIELD CONNECTIONS POWER WIRING 1 Install the proper size weatherproof disconnect switch outdoors and within sight of the unit 2 Remove the screws at the top and sides of the corner cover Slide corner cover down and remove from unit 3 Run power wiring from the disconnect switch to the unit 4 Route wires from disconnect through power wiring opening pro vided and into the unit control box as shown in Figure 6 5 Install the proper size time delay fuses or circuit breaker and make the power supply connections Johnson Controls Unitary Products CONTACTOR GROUND LUG LOW VOLTAGE BOX FINGERED RUN FAN BUSHING REVERSIBLE HIGH CAPACITOR VOLTAGE CONDUIT PLATE FIGURE 6 Outdoor Unit Control Box 1031452 UIM B 0513 FIELD CONNECTIONS CONTROL WIRING 1 Route low voltage wiring into bottom of control box as shown in Figure 6 Make low voltage wiring connections inside the low volt age box per Figures 7 11 The complete connection diagram and schematic wiring label is located on the inside surface of the unit service access
18. hten and turn an additional 1 8 turn to seal Do not over tighten fittings 7 Leak test system Replace black plastic cap on equalizer fitting 9 Slide indoor coil back into cabinet Johnson Controls Unitary Products LIQUID LINE SWIVEL COUPLING Pa This fitting is a right hand thread turn counter clockwise to remove a oriFice Ps DISTRIBUTOR FIGURE 5 Orifice Installation SECTION V TXV INSTALLATIONS ACAUTION When using a TXV models 18 48 require a hard start kit The following are the basic steps for installation For detailed instruc tions refer to the Installation Instructions accompanying the TXV kit Install TXV kit as follows 1 Relieve the holding charge by pulling off the rubber cap plug on the suction manifold line of the coil 2 After holding charge is completely discharged loosen and remove the schraeder cap seal 3 Loosen and remove distributor cap seal 4 Install the thermal expansion valve to the orifice distributor assem bly with supplied fittings Hand tighten and turn an additional 1 4 turn to seal Do not overtighten fittings 5 Install the liquid line to the top of the thermal expansion valve with fitting supplied with the liquid line Hand modify the liquid line to align with casing opening Hand tighten the liquid line and an addi tional 1 4 turn to seal 6 Install the TXV equalizer line into the vapor line as fol
19. il face If the unit is to be installed on a hot sun exposed roof or a black topped ground area the unit should be raised sufficiently above the roof or ground to avoid taking the accumulated layer of hot air into the outdoor unit Provide an adequate structural support ADD ON REPLACEMENT RETROFIT The following steps should be performed in order to insure proper sys tem operation and performance 1 Change out the indoor coil if required to an approved R 22 coil condensing unit combination with the appropriate metering device 2 Ifthe outdoor unit is being replaced due to a compressor burnout then installation of a 100 activated alumina suction line filter drier in the suction line is required in addition to the factory installed liquid line drier Operate the system for 10 hours Monitor the suction drier pressure drop If the pressure drop exceeds 3 psig replace both the suction line and liquid line driers After a total of 10 hours run time where the suction line pressure drop has not exceeded 3 psig replace the liquid line drier and remove the suction line drier Never leave a suction line drier in the system longer than 50 hours of run time 60 OVERHEAD CLEARANCE Da 10 CLEARANCE AROUND PERIMETER N NOTE ALL OUTDOOR WIRING MUST BE WEATHERPROOF MINIMUM 18 SERVICE ACCESS CLEARANCE ON ONE SIDE THERMOSTAT E WEATHERPROOF DISCONNECT SWITCH p CONTROL ACCESS SEA
20. lows a Hand tighten the 1 4 SAE nut to the schraeder fitting and an additional 1 3 turn to seal 7 Install the TXV bulb to the vapor line near the equalizer line using the bulb clamp s furnished with the TXV assembly Ensure the bulb is making maximum contact a Bulb should be installed on a horizontal run of the vapor line if possible The bulb should be installed on top of the line b If bulb installation is made on a vertical run the bulb should be located at least 16 inches from any bend and on the tub ing sides opposite the plane of the bend The bulb should be positioned with the bulb tail at the top so that the bulb acts as a reservoir c Bulb should be insulated using thermal insulation provided to protect it from the effect of the surrounding ambient tempera ture Cover completely to insulate from air stream ACAUTION In all cases mount the TXV bulb after vapor line is brazed and has had sufficient time to cool AWARNING Schrader valve core MUST NOT be installed with TXV installation Poor system performance or system failure could result Johnson Controls Unitary Products 1031452 UIM B 0513 SECTION VI EVACUATION It will be necessary to evacuate the system to 500 microns or less If a leak is suspected leak test with dry nitrogen to locate the leak Repair the leak and test again To verify that the system has no leaks simply close the valve to the vac uum pump suction to isola
21. o dissi pate Open both the liquid and vapor valves by removing the plunger cap and with an allen wrench back out counter clockwise until valve stem just touches the chamfered retaining wall If the service valve is a ball valve use a crescent wrench to turn valve stem one quarter turn counterclockwise to open Do not overturn or the valve stem may break or become damaged See PRECAU TIONS DURING BRAZING SERVICE VALVE 8 Replace the Schrader core in the liquid and vapor valves 9 Goto SECTION V or SECTION IV for orifice or TXV installation depending on application 10 Leak test all refrigerant piping connections including the service port flare caps to be sure they are leak tight DO NOT OVER TIGHTEN between 40 and 60 inch lbs maximum NOTICE Line set and indoor coil can be pressurized to 250 psig with dry nitro gen and leak tested with a bubble type leak detector Then release the nitrogen charge 11 Evacuate the vapor line evaporator and liquid line to 500 microns or less 12 Replace cap on service ports Do not remove the flare caps from the service ports except when necessary for servicing the system ACAUTION Do not connect manifold gauges unless trouble is suspected Approximately 3 4 ounce of refrigerant will be lost each time a stan dard manifold gauge is connected 13 Release the refrigerant charge into the system since these units have been shipped from the factory with a ni
22. on service valve 6 To bring the tube temperature in line with the required value from chart add refrigerant to the service port to cause the tube temper ature to fall and reclaim refrigerant to cause the temperature to rise TABLE 2 R 22 Saturated Properties SUBCOOLING CHARGING METHOD TXV INDOOR The recommended subcooling is 10 F 1 Set the system running in the cooling mode by setting the thermo stat at least 6 F below the room temperature 2 Operate the system for a minimum of 15 20 minutes 3 Refer to the tabular data sheet for the recommended airflow and verify this indoor airflow it should be about 400 SCFM per ton 4 Measure the liquid refrigerant pressure P and temperature T at the service valve 5 Calculate the saturated liquid temperature ST from Table 2 6 Subcooling temperature TC Saturated Temperature ST Liquid Temp T Example The pressure P and temperature T measured at the liq uid service port is 196 psig and 90 F respectively From Table 2 the saturated temperature for 196 psig is 100 F The subcooling temperature TC 100 90 10 F Add charge if the calculated subcooling temperature TC in Step 6 is lower than the recommended level Remove and recover the refrigerant if the subcooling TC is higher than the recommended level See Table 2 Check flare caps on service ports to be sure they are leak tight DO NOT OVERTIGHTEN between 40 and 60 inch lbs maximum
23. ons recommended value Low voltage values R and C at Indoor unit control board volts AC R and C Outdoor unit control board volts AC Heating Set Up Heating Type C Electric Air Handler C Natural Gas C LP Gas Requires LP Conversion Kit Inlet Gas Pressure in w c Manifold Gas Pressure in w c LP Gas Conversion Kit Part Used Calculated input in btuh clock the gas meter Nat Gas Only LP Kit Installed By Electric Heat Kit Part if applicable KW installed Rated BTU H furnaces Venting if applicable Venting system properly sized within the limitations of the charts in the installation instructions Intake Size of 90 Degree Ells Of 45 Degree Ells Length Exhaust Size of 90 Degree Ells Of 45 Degree Ells Length Continued on next Page Johnson Controls Unitary Products 15 Air Side System Total External Static Pressure Supply static before indoor coil in w c Return Static in w c before filter Total External Static Pressure Supply static after indoor coil in w c Return Static in w c after filter furnace side Maximum Rated ESP in w c
24. panel Replace the corner cover removed in Step 2 All field wiring to be in accordance with national electrical codes NEC and or local city codes A Start Assist Kit is available and recommended for long line set NOTICE applications or in areas of known low voltage problems 5 Mount the thermostat about 5 ft above the floor where it will be exposed to normal room air circulation Do not place it on an out side wall or where it is exposed to the radiant effect from exposed glass or appliances drafts from outside doors or supply air grilles Route the 24 volt control wiring NEC Class 2 from the outdoor unit to the indoor unit and thermostat NOTICE To eliminate erratic operation seal the hole in the wall at the thermo stat with permagum or equivalent to prevent air drafts affecting the operation of in the thermostat ALL FIELD WIRING TO BE IN ACCORDANCE WITH ELECTRIC CODE NEC AND OR LOCAL CODES POWER WIRING 208 230 1 60 Fore CONTACTOR GND LUG WITH HEAT COIL CONDENSING UNIT TERMINAL W IS ONLY REQUIRED ON SYSTEMS 24 VOLT CONTROL WIRING MINIMUM 18 GA WIRE NEC CLASS 2 TERMINALS A POWER WIRING a CONTROL WIRING FACTORY WIRING FURNACE OR AIR HANDLER TERMINAL BLOCK ROOM THERMOSTAT ALL OUTDOOR WIRING MUST BE WEATHERPROOF USE COPPER CONDUCTORS ONLY FIGURE 7 Typical Field Wiring Air Handle
25. ptions Part Numbers SAP Legacy 159480 031 09156 FIGURE 8 Thermostat Chart Single Stage AC with PSC Air Handler Johnson Controls Unitary Products 1031452 UIM B 0513 AC 1B Single Stage Air Conditioner PSC Air Handler ID MODELS AHP SHP MA THERMOSTAT THERMOSTAT x PARER SINGLE STAGE BN11C00124 BN11C01124 PSC AIR DP11C40124 AIR HANDLER CONDITIONER DN11C00124 Cc Cc COM Cc 24 Volt Common 24 Volt Common 24 Volt Common 24 Volt Common Full S 5 Full St 5 Second or Er Es 5 Contact ull Stage Compressor ull Stage Compressor Stage Compressor ompressor Contactor RH RH R 24 Volt Hot 24 Volt Hot Heat XFMR Heat XFMR a Wala G G G Fan Fan Fan W2 Second Stage Heat RC RC y1 24 Volt Hot 24 Volt Hot i Cool XFMR Cool XFMR Single Stage Compressor fe Reversing Valve Energized in Cool X L Malfunction Light w w Wi Full Stage Heat Full Stage Heat First Stage Heat HUM Humidity Switch Open on Humidity Rise RA HUM OUT Sere fem 24 VAC out Humidifier 24VAC eet EAC 24 VAC out Beh Se as Electronic Air Cleaner Johnson Controls Unitary Products FIGURE 9 Thermostat Chart Single Stage AC with PSC Air Handler 1031
26. r Electrical Heat Johnson Controls Unitary Products 1031452 UIM B 0513 For additional connection diagrams for all UPG equipment refer to Low Voltage System Wiring document available online at www upgnet com in the Product Catalog Section AC 1A Single Stage Air Conditioner PSC Air Handler ID MODELS AHP SHP MA THERMOSTAT PSC SINGLE STAGE PP11C70224 AIR AIR HANDLER CONDITIONER PSC K SINGLE STAGE AIR HANDLER CONTROL AIR CONDITIONER COM C 24 Volt Common 24 Volt Common y a Full y Full Stage Compressor Stage Compressor Compressor Contactor RH R 24 Volt Hot Heat XFMR 24 Volt Hot G G Fan Fan W2 Second Stage Heat 24 ee Hot Ya Cool XFMR Single Stage Compressor fe Reversing Valve Energized in Cool X L Malfunction Light WwW Wi Full Stage Heat First Stage Heat HM1 24VAC Humidifier Gj nee on ae Optional umidity Switcl gudistat Optional Open on Humidity Rise HUM OUT 24VAC 24 VAC out Clipping Jumper W914 for lelectric heat on thermostat isnotnecessary Electronic Air Cleaner Humidifier Optional EAC 24 VAC out Electronic Air Cleaner Move HUM STAT jumper to YES if humidistat is to be used Refer to AH documentation for W1 and W2 electric heat staging o
27. refrigerant lines where they penetrate a wall to reduce vibration and to retain some flexibility 8 For systems with total line length exceeding 50 feet see APPLI CATION DATA and worksheet General Piping Recommendations and Refrigerant Line Length for vapor and liquid line sizing cali bration of liquid line pressure loss or gain determination of vapor line velocity elevation limitations orifice connections system charging traps etc Johnson Controls Unitary Products 1031452 UIM B 0513 Sheet Metal Hanger Liquid KO Line ee Incorrect Correct Tape Insulated Vapor Line FIGURE 2 Installation of Vapor Line TO INDOOR COIL TO OUTDOOR UNIT Liquid Line Insulated Vapor Line gt FIGURE 3 Underground Installation PRECAUTIONS DURING BRAZING OF LINES All outdoor unit and evaporator coil connections are copper to copper and should be brazed with a phosphorous copper alloy material such as Silfos 5 or equivalent DO NOT use soft solder The outdoor units have reusable service valves on both the liquid and vapor connections Units are shipped from factory with a nitrogen holding charge Refer to Tabular Data Sheet for refrigerant charge quantities Reusable service valves are provided to evacuate and charge per this instruction Serious service problems can be avoided by taking adequate precau tions to assure an internally clean and dry system ACAUTIO
28. ruct the owner on proper operation and maintenance of all other system components MAINTENANCE 1 Dirt should not be allowed to accumulate on the outdoor coils or other parts in the air circuit Clean as often as necessary to keep the unit clean Use a brush vacuum cleaner attachment or other suitable means 12 2 The outdoor fan motor is permanently lubricated and does not require periodic oiling If the coil needs to be cleaned use clean water to wash dust dirt and debris from outdoor condensing coil NOTICE DO NOT use coil cleaners to clean outdoor condensing coil cleaners containing HF hydroxides chlorides and sulfates can greatly reduce the lifetime of the aluminum condensing coil 4 Refer to the furnace or air handler instructions for filter and blower motor maintenance The indoor coil and drain pan should be inspected and cleaned reg ularly to prevent odors and assure proper drainage ACAUTION 5 IT IS UNLAWFUL TO KNOWINGLY VENT RELEASE OR DIS CHARGE REFRIGERANT INTO THE OPEN AIR DURING REPAIR SERVICE MAINTENANCE OR THE FINAL DISPOSAL OF THIS UNIT WHEN THE SYSTEM IS FUNCTIONING PROPERLY AND THE OWNER HAS BEEN FULLY INSTRUCTED SECURE THE OWNER S APPROVAL Johnson Controls Unitary Products SECTION X WIRING DIAGRAM 1031452 UIM B 0513 FAN TURN OFF EL SERVICING T TO THE EQUI PERSONAL IN TO PR REMOTE DISC SUPPLY TO A COMPRESSOR MOTOR BROWN LINES
29. t owner Explain thermostat use and programming if applicable to owner Explain the importance of regular filter replacement and equipment maintenance Comments Section Subject to change without notice Published in U S A Copyright 2013 by Johnson Controls Inc All rights reserved Supersedes York International Corp 5005 York Drive Norman OK 73069 1031452 UIM B 0513 1031452 UIM A 0413
30. te the pump and hold the system under vac uum Watch the micron gauge for a few minutes If the micron gauge indicates a steady and continuous rise it s an indication of a leak If the gauge shows a rise then levels off after a few minutes and remains fairly constant it s an indication that the system is leak free but still con tains moisture and may require further evacuation if the reading is above 500 microns SECTION VII SYSTEM CHARGE See tabular data sheet provided in unit literature packet for charge requirements Each unit has been shipped from the factory with a nitro gen holding charge and POE oil in the compressor ACAUTION This unit does not contain any refrigerant It contains a nitrogen hold ing charge Operating this unit with the nitrogen holding charge will damage the compressor ACAUTION Do not leave the system open to the atmosphere The TOTAL SYSTEM CHARGE must be permanently stamped on the unit data plate Total system charge is determined as follows 1 Determine initial unit charge from tabular data sheet 2 Calculate the line charge using the tabular data sheet if line length is greater than 15 feet 3 Total system charge item 1 item 2 4 Permanently stamp the unit data plate with the total amount of refrigerant in the system Use the following charging method whenever additional refrigerant is required for the system charge AWARNING DO NOT attempt to pump
31. trogen holding charge 14 Replace plunger cap finger tight then tighten an additional 1 12 turn 1 2 hex flat Cap must be replaced to prevent leaks AWARNING Never attempt to repair any brazed connections while the system is under pressure Personal injury could result See System Charge section for checking and recording system charge Supplied with the outdoor unit is a Schrader Valve Core and Orifice for highest sales volume indoor coil The valve core must be installed in equalizer fitting of the indoor coil SECTION IV ORIFICE INSTALLATION AWARNING Failure to install Schrader Valve Core on orifice applications could result in total refrigerant loss of the system Install Schrader Valve Core as follows 1 Slide indoor coil out of cabinet far enough to gain access to equal izer fitting on the suction line 2 After holding charge is completely discharged remove black plas tic cap on equalizer fitting 3 Install Schrader Valve Core supplied with the outdoor unit into equalizer fitting using a valve core tool 4 Loosen and remove the liquid line fitting from the orifice distributor assembly Note that the fitting has right hand threads 5 Install proper size orifice supplied with outdoor unit Refer to sup plied Tabular Data Sheet for specific orifice size and indoor coil match up 6 After orifice is installed reinstall the liquid line to the top of the ori fice distributor assembly Hand tig
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