Johnson Controls F) Air Conditioner User Manual
Contents
1. ln R 410A OUTDOOR SPLIT SYSTEM AIR CONDITIONING MODELS 13 amp 14 5 SEER TCG D F GCGD TCJ D F YCJ D F SERIES 1 5 TO 6 3 TONS 1 amp 3 PHASE CERTIFIED www ahridirectory org Unitary Small HP AHRI Standard 210 240 when the compl ES o 2000 REX SERV ISO 9001 US Certified Quality Management System LIST OF SECTIONS GENERAL rk ex RR SS ar eaten 1 SYSTEM CHARGE 2 Ie pened uy 6 SAFETY aa era 1 ELECTRICAL CONNECTIONS 7 UNIT INSTALLATION 22 29 x9 ek eR 2 INSTRUCTING THE OWNER 13 ORIFICE INSTALLATION 5 WIRING DIAGRAM Ie RU 14 TXV INSTALLATION 5 START UP SHEET uti ARE tere 17 EVACUATION 2 2 e o Rn mem ehem EET 5 LIST OF FIGURES Typical Installation 2 Thermostat Chart Single Stage AC with PSC Air Handler 9 Installation of Vapor Line 3 Thermostat Chart Single Stage AC with PSC Air Handler 10 Underground Installation 3 Thermostat Chart Single Stage AC with PSC Furnace 11 Heat Protection sse e e emer rrr 4 Thermostat Chart Single2. FIGURE 2 Installation of Vapor Line TO INDOOR COIL TO OUTDOOR UNIT Insulated Vapor Line FIGURE 3 Underground Installation 872678 UIM C 0213 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 The total system refrigerant charge is retained within the outdoor unit during shipping and installation The reusable service valves are pro vided 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 CAUTION 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 pro vided 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
3. Compressor Contactor RH RH R 24 Volt Hot 24 Volt Hot Heat XFMR Heat XFMR G G G Fan Fan Fan Ww Full Stage Heat RC RC 24 Volt Hot 24 Volt Hot Cool XFMR Cool XFMR Ww Ww Full Stage Heat Full Stage Heat FIGURE 13 Thermostat Chart Single Stage AC with PSC Furnace 12 Johnson Controls Unitary Products 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 instruct 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
4. SECTION VII SYSTEM CHARGE The factory charge in the outdoor unit includes enough charge for the unit a 15 ft 4 6 m line set and the smallest indoor coil match up Some indoor coil matches may require additional charge See tabular data sheet provided in unit literature packet for charge requirements CAUTION 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 outdoor unit charge from tabular data sheet 2 Determine indoor coil adjustment from tabular data sheet 3 Calculate the line charge using the tabular data sheet if line length is greater than 15 feet 4 6 m 4 Total system charge item 1 item 2 item 3 5 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 DO NOT attempt to pump Total System Charge into outdoor unit for maintenance service etc This may cause damage to the com pressor and or other components the outdoor unit only has enough volume for the factory charge not the Total System Charge A CAUTION Refrigerant charging should only be carried out by a qualified air conditioning contractor A CAUTION Compressor damage will occur if system is improperly charged On new
5. 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 Johnson Controls Unitary Products 872678 UIM C 0213 IMPORTANT Only 1TVM900 series valves are to be used on this product 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 Schrader 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 equalizer line into the vapor line as follows a tighten the 1 4 SAE nut to the Schrader fitting and an additional 1 3 turn to seal 7 Install the 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 f bu
6. WIRE NEC CLASS 2 FURNACE OR AIR HANDLER TERMINAL BLOCK 9 CO 9 TERMINAL W IS ONLY 7 52 REQUIRED SYSTEMS WITH HEAT 4 1 GND LUG CONTACTOR 1 l TERMINALS o A a es oa J l Oy RUM HEUS J CONDENSING UNIT ROOM THERMOSTAT ALL OUTDOOR WIRING MUST BE WEATHERPROOF USE COPPER CONDUCTORS ONLY FIGURE 8 Typical Field Wiring Air Handler Electrical Heat Single Phase ALL FIELD WIRING TO BE IN ACCORDANCE WITH ELECTRIC CODE NEC AND OR LOCAL CODES 7 POWER WIRING CONDENSING UNIT ROOM THERMOSTAT ES 24 VOLT CONTROL WIRING 777 7 ACTOR WIRING E POWER WIRING MINIMUM 18 GA WIRE gw NEC CLASS 2 FURNACE OR AIR HANDLER TERMINAL BLOCK Y Ry G TERMINAL W IS ONLY 9 2 L REQUIRED ON SYSTEMS d GNE 1 4 WITH HEAT Ei 0 CONTACTOR TERMINALS 3 GND LUG ALL OUTDOOR WIRING MUST BE WEATHERPROOF USE COPPER CONDUCTORS ONLY FIGURE 9 Typical Field Wiring Air Handler Electrical Heat Three Phase 8 Johnson Controls Unitary Products 872678 UIM C 0213 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 H
7. suitable means 2 The outdoor fan motor is permanently lubricated and does not require periodic oiling Johnson Controls Unitary Products 872678 UIM C 0213 3 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 clean ers 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 5 The indoor coil and drain pan should be inspected and cleaned regularly to prevent odors and assure proper drainage CAUTION 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 SUBCOOLING CHARGE TABLE IS ON THE UNIT RATING PLATE 13 872678 UIM C 0213 SECTION X WIRING DIAGRAM FAN DANGER SHOCK HAZARD TURN OFF ELECTRICAL POWER BEFORE SERVICING TOPREVENT POSSIBLE DAMAGE TO THE EQUIPMENT AND POSSIBLE PERSONAL INJURY CAUTION TO PREVENT ELECTRICAL SHOCK OPEN REMOTE DISCONNECT 50 ELECTRICAL SUPPLY TO AIR CONDITIONER IS SHUT OFF e COMPONENTS SHOWN IN DASHED LINES ARE OPTIONAL BROWN COMPRESSOR MOTOR UAL CAPACITOR SHOWN SEPARATE CAPACITORS MAY BE USED ON ACTUAL UN WIRING M
8. ID MODELS G 8 9 S GF 8 9 G 9F LF8 L Y M 8S TG 8 9 S THERMOSTAT G8C GIT GLS SINGLE STAGE SINGLE STAGE PP11C70224 PSC AIR FURNACE CONDITIONER SINGLE STAGE PSC D SINGLE STAGE FURNACE AIR CONDITIONER 24 Volt Common 24 Volt Common Y 2 Y Full Stage Compressor Full Stage Compressor Compressor Contactor RH R 24 Volt Hot Heat XFMR 24 Volt Hot G G Fan Fan Ww Full Stage Heat RC 24 Volt Hot Cool XFMR 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 265901 031 09166 FIGURE 12 Thermostat Chart Single Stage AC with PSC Furnace Johnson Controls Unitary Products 11 872678 UIM C 0213 24VAC Humidifier Optional AC 5E Single Stage Air Conditioner Single Stage PSC Furnace ID MODELS G 8 9 S GF 8 9 G 9F LF8 L Y M 8S TG 8 9 S THERMOSTAT THERMOSTAT ae 515 SINGLE STAGE SINGLE STAGE BN11C00124 DP11C40124 PSC AIR DN11C00124 FURNACE CONDITIONER 24 Volt Common 24 Volt Common 24 Volt Common 24 Volt Common Y 2 57 Full Stage Compressor Full Stage Compressor Full Stage Compressor
9. 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 A WARNING 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 Connect the refrigerant lines using the following procedure 1 Remove the cap and Schrader core from both the liquid and vapor service valve service ports at the outdoor unit Connect low pres sure nitrogen to the liquid line service port 2 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 FIGURE 4 Heat Protection CAUTION 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 g
10. of the system Install Schrader Valve Core and Orifice 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 tighten 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 LIQUID LINE SWIVEL COUPLING gt This fitting is a right hand thread turn counter clockwise to remove j ORIFICE Ps DISTRIBUTOR FIGURE 5 Orifice Installation SECTION V TXV INSTALLATION CAUTION When using a TXV 13 SEER models 12 48 require a hard start kit Models 12 48 with a on the end of the model number have a factory installed hard start
11. refrigerant temperature of the pressure measured at the liquid base valve and the liquid tube temperature as measured at the liquid base valve Subcooling Temp TC Saturated Temp TS Liquid Temp T CAUTION 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 Johnson Controls Unitary Products TABLE 2 R 410A Saturation Properties 872678 UIM C 0213 oc PRESSURE oe PRESSURE oc PRESSURE oc PRESSURE oc PRESSURE TEMP PEIG TEMP F TEMP F Ben TEMP F Bn TEMP F 45 130 60 170 75 217 90 274 105 341 46 132 61 173 76 221 91 278 106 345 47 135 62 176 77 224 92 282 107 350 48 137 63 179 78 228 93 287 108 355 49 140 64 182 79 232 94 291 109 360 50 142 65 185 80 235 95 295 110 365 51 145 66 188 81 239 96 299 111 370 52 147 67 191 82 243 97 304 112 375 53 150 68 194 83 247 98 308 113 380 54 153 69 197 84 250 99 313 114 385 55 156 70 201 85 254 100 317 115 391 56 158 7i 204 86 258 101 322 116 396 57 161 72 207 87 262 102 326 117 401 58 164 78 211 88 266 103 331 118 407 59 167 74 214 89 270 104 336 119 412 SECTION VIII ELECTRICAL TUNES 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 w
12. E HEATER CC CONTACTOR COIL ASCT ANTI SHORT CYCLE TIME RED LAP LOW AMBIENT PRESSURE SWITCH OPTIONAL WIRING DANGER SHOCK HAZARD TURN OFF ELECTRICAL POWER BEFORE SERVICING TO PREVENT POSSIBLE DAMAGE TO THE EQUIPMENT AND POSSIBLE PERSONAL INJURY CAUTION TO PREVENT ELECTRICAL SHOCK OPEN REMOTE DISCONNECT SO ELECTRICAL SUPPLY TO AIR CONDITIONER IS SHUT OFF HIGH VOLTAGE FACTORY WIRING LOW VOLTAGE FACTORY WIRING FIELD WIRING LINE VOLTAGE RED COMPRESSOR MOTOR FAN CAPACITOR TRANSFORMER lt ORG 208 230 VAC 60 Hz 3Ph 4 lt 380 415 50 Hz 3Ph 460 VAC 60 Hz 3Ph USE COPPER CONDUCTOR ONLY FIGURE 16 Wiring Diagram Three Phase 6 3 Ton 1 LAP RELAY Optional Low Ambient Kit 1 5 RELAY T ai 2 1 gt o Seri GND g 2 YEL PNK LUG s fs 1 Qi 81 GND 872677 UWD A 0712 6 3 TON CONDENSING UNIT LOW VOLTAGE BOX 7 5 TON AIR HANDLER 24V TERMINAL BLOCK BLUE YELLOW A 830 7 Xt USED WITH ELECTRIC HEAT ACCESSORIES FIGURE 17 24 VAC Connection Wiring for 2 pipe A C 6 3 Ton Condensing Unit with 7 5 Ton Air Handler 16 Johnson Controls Unitary Produ
13. MENT AND POSSIBLE PERSONAL INJURY CAUTION TO PREVENT ELECTRICAL SHOCK OPEN REMOTE DISCONNECT SO ELECTRICAL SUPPLY TO AIR CONDITIONER IS SHUT OFF O COMPONENTS SHOWN IN DASH LINES ARE OP TIONAL 2 RED WIRE WILL BE REMOVE AMBIENT KIT IS INSTALLED BLUE WIRE WILL BE REMOVED IF PRESSURE SWITCH KIT IS INTALL WIRING MUST CONFORM TO NATIONAL LOCAL CODES IF L 5 IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED IT MUST BE REPLACED WITH 105 C THERMOPLASTIC OR ITS EQUIVALENT CONTACTOR 1 208 230 VAC 60 Hz 3 PHASE SUPPLY 460 VAC 60 Hz 3 PHASE SUPPLY 515 VAC 60 Hz 3 PHASE SUPPLY 380 415 VAC 50 Hz 3 PHASE SUPPLY USE COPPER CONDUCTORS ONLY 24 VAC CTRL CIRCUI 20VA MIN EL PNK TN FIGURE 15 Wiring Diagram Three Phase 2 5 5 Tons Johnson Controls Unitary Products 15 872678 UIM C 0213 COMPONENTS SHOWN IN DASHED LINES ARE OPTIONAL RED WIRE WILL BE REMOVED IF LOW AMBIENT IS INSTALLED YELLOW WIRE WILL BE REMOVED IF PRESSURE SWITCH KIT IS INSTALLED IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED IT MUST BE REPLACED WITH TYPE 105 C THERMOPLASTIC OR ITS EQUIVALENT WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES HPS HIGH PRESSURE SWITCH LP LOW PRESSURE SWITCH CCH CRANKCAS
14. Stage AC with PSC Furnace 12 Orifice Installation RR ea daton 5 Wiring Diagram Single 14 Outdoor Unit Control Box Single Phase 7 Wiring Diagram Three Phase 2 5 5 15 Outdoor Unit Control Box Three 7 Wiring Diagram Three Phase 6 3 Ton 16 Typical Field Wiring Air Handler Electrical Heat Single Phase 8 24 VAC Connection Wiring for 2 pipe A C 6 3 Ton Typical Field Wiring Air Handler Electrical Heat Three Phase 8 Condensing Unit with 7 5 Air Handler 16 LIST OF TABLES Application Limitations 2 R 410A Saturation Properties 7 SECTION 1 GENERAL The outdoor units are designed to be connected to a matching indoor coil with sweat connect lines Sweat connect units are factory charged with refrigerant for a matching indoor coil plus 15 feet of field supplied lines 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 SECTION SAFETY This is a safety alert symbol When you see this symbol on labels or in manuals be alert to the potential for personal injury Understa
15. UST CONFORM TO NATIONAL AND LOCAL CODES CAPACITOR 0 F ANY OF THE ORIGINAL WIRE UPPLIED WITH THIS UNIT MUST BE EPLACED IT MUST BE REPLACED ITH TYPE 105 C THERMOPLASTIC ITS EQUIVALENT HERE POWER SUPPLY HAS ONE 1 40 VOLT CONDUCTOR AND ONE 1 EUTRAL CONDUCTOR CONNECT L2 F CONTACTOR TO NEUTRAL Nc HIGH VOLTAGE FACTORY WIRING LOW VOLTAGE FACTORY WIRING ie OPTIONAL WIRING FIELD WIRING LINE VOLTAGE BLACK CONTACTOR YEL PNK N CONDUCTORS I prm ONLY 9 du 24 VAC GND CONTROL HPS HIGH PRESSURE SWITCH CIRCUIT CCH CRANKCASE HEATER 20 VA MIN HS HEATER SWITCH SR START RELAY SC START CAPACITOR 208 230 VAC 60 Hz PHASE SUPPLY CC CONTACTOR COIL 220 240 VAC 50 Hz PHASE SUPPLY 161242 UWD D 1009 FIGURE 14 Wiring Diagram Single Phase 14 Johnson Controls Unitary Products 872678 UIM C 0213 CAPACITOR CONTACTOR COIL CRANKCASE HEATER CONTROL HIGH PRESS SWITCH HEATER SWITCH LOW AMBIENT PRESS SWITCH LOW HIGH VOL LOW VOLT RESS SWITCH AGE FACTORY WIRING AGE FACTORY WIRING OPTIONAL LOW VOLTAGE WIRING OPTIONAL HIGH VOLTAGE WIRING FIELD WIRING LINE VOLTAGE FIELD WIRING CTRL CIRCUIT DANGER SHOCK HAZARD TURN OFF ELECTRICAL POWER BEFORE SERVICING TO PREVENT POSSIBLE DAMAGE TO THE EQUIP
16. andler ID MODELS AHP SHP MA THERMOSTAT PSC SINGLE STAGE PP11C70224 AIR AIR HANDLER CONDITIONER PSC e SINGLE STAGE AIR HANDLER CONTROL AIR CONDITIONER COM 24 Volt Common 24 Volt Common Y YIY2 Y Second or Full 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 RC 24 Volt Hot Ti Cool XFMR Single Stage Compressor Reversing Valve Energized in Cool XIL Malfunction Light Ww w1 Full Stage Heat First Stage Heat HM1 24 Humidifier 7 m idi Optional umidity Switc d Open on Humidity Rise HUM OUT 24VAC 24 VAC out Electronic Air Cleaner Humidifier Optional EAC 24 VAC out Clipping Jumper W914 for Electronic Air Cleaner electric heat on thermostat is not necessary Move HUM STAT jumper to YES if humidistat is to be used Refer to AH documentation for W1 and W2 electric heat staging options Part Numbers SAP Legacy 159480 031 09156 FIGURE 10 Thermostat Chart Single Stage AC with PSC Air Handler Johnson Controls Unitary Products 9 872678 UIM C 0213 AC 1B Single Stage Air Conditioner PSC Air Handler 24 Vo
17. as 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 Replace the Schrader core in the liquid and vapor valves 8 Go to SECTION IV or SECTION V for orifice or TXV installation depending on application 9 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 Ibs maximum NOTICE Line set and indoor coil can be pressurized to 250 psig with nitrogen and leak tested with a bubble type leak detector Then release the nitrogen charge Do not use the system refrigerant in the outdoor unit to purge or leak test 10 Evacuate the vapor line evaporator and liquid line to 500 microns or less 11 Replace cap on service ports Do not remove the flare
18. ate FIGURE 7 Outdoor Unit Control Box Three Phase 872678 UIM C 0213 FIELD CONNECTIONS CONTROL WIRING 5 Mount the thermostat about 5 ft above the floor where it will be 1 Route low voltage wiring into bottom of control box as shown in exposed to normal room air circulation Do not place it on an out Figure 6 Make low voltage wiring connections inside the low volt side wall or where it is exposed to the radiant effect from exposed age box per Figures 7 11 glass or appliances drafts from outside doors or supply air grilles 6 Route the 24 volt control wiring NEC Class 2 from the outdoor 2 complete connection diagram and schematic wiring label is unit to the indoor unit and thermostat located on the inside surface of the unit service access panel 3 Replace the corner cover removed in Step 2 4 All field wiring to be in accordance with national electrical codes NOTICE NEC and or local city codes To eliminate erratic operation seal the hole in the wall at the ther NOTE A Start Assist Kit is available and recommended for long line set mostat with permagum or equivalent to prevent air drafts affecting applications or in areas of known low voltage problems the operation of in the thermostat ALL FIELD WIRING TO BE IN ACCORDANCE WITH ELECTRIC CODE NEC AND OR LOCAL CODES POWER WIRING CONTROL WIRING FONS 24 VOLT CONTROL WIRING FACTORY WIRING MINIMUM 18 GA
19. aximum performance with minimum service TABLE 1 Application Limitations 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 When this unit is being used as a replacement for an R 410A unit it is required that the outdoor unit indoor coil and metering device all be replaced The following steps should be performed in order to insure proper system operation and performance Line set change out is also recommended 1 Change out of the indoor coil to an approved R 410A coil con Ambient Air Temperature Air Temperature on densing unit combination with the appropriate metering device on Outdoor Coil Indoor Coil 2 of the line set when replacing an R 22 unit with an Min DB Max DB Min WB Max WB R410 A unit is highly recommended to reduce cross contamina so TET DF tion of oils and refrigerants 3 of the line set is not practical then the following pre 4 The unit should not be operated at outdoor temperatures below cautions should be taken 50 F without an approved low ambient operation accessory kit Inspect the line set for kinks sharp bends or other restrictions installed and for corrosion 5 The maximum a
20. caps from the service ports except when necessary for servicing the system CAUTION 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 12 Release the refrigerant charge into the system Open both the liq uid 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 cresent wrench to turn valve stem one quater turn counterclockwise to open Do not overturn or the valve stem may break or become damaged See PRECAUTIONS DURING BRAZING SERVICE VALVE 13 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 Johnson Controls Unitary Products SECTION IV ORIFICE INSTALLATION A WARNING Failure to install Schrader Valve Core on orifice applications could result in total refrigerant loss
21. cts 872678 UIM C 0213 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 Technician Performing Start Up Installing Contractor Name Owner Information Name Address City State or Province Zip or Postal Code Equipment Data Upflow C Downflow Horizontal Left 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
22. d 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 Requirements For Installing Servicing R 410A Equipment Gauge sets hoses refrigerant containers and recovery system must be designed to handle the POE type oils and the higher pressures of R 410A Manifold sets should be high side and low side with low side retard All hoses must have a 700 psig service pressure rating Leak detectors should be designed to detect HFC refrigerant Recovery equipment including refrigerant recovery containers must be specifically designed to handle R 410A Donotuse an R 22 TXV Aliquid line filter drier is required on every unit 872678 UIM C 0213 872678 UIM C 0213 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 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 m
23. eet The charge given is applicable for total tubing lengths up to 15 feet 4 6 m 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 of capacity and other problems caused by insufficient refrigerant flow Slope horizontal vapor lines at least 1 2 5 cm every 20 feet 6 1 m toward the out door unit to facilitate proper oil return Johnson Controls Unitary Products 872678 UIM C 0213 CAUTION This system uses 410 refrigerant which operates at higher pres sures than H 22 No other refrigerant may be used in this system Gauge sets hoses refrigerant containers and recovery system must be designed to handle R 410A If you are unsure consult the equipment manufacturer A WARNING Never install a suction line filter drier in the liquid line of an R 410A system Failure to follow this warning can cause a fire injury or death 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 rest
24. he system longer than 50 hours of run time 60 OVERHEAD CLEARANCE 10 CLEARANCE NOTES ALL OUTDOOR WIRING MUST BE WEATHERPROOF MINIMUM 24 UNIT TO UNIT CLEARANCE FIGURE 1 Typical Installation MINIMUM 18 SERVICE ACCESS CLEARANCE THERMOSTAT ON ONE SIDE WEATHERPROOF 1 NEC CLASS 1 WIRING DISCONNECT SWITCH 4 f 4 NEC CLASS 2 WIRING TO FURNACE OR AIR HANDLER TERMINAL BLOCK TO INDOOR COIL CONTROL ACCESS PANEL SEAL OPENING S WITH PERMAGUM OR EQUIVALENT Johnson Controls Unitary Products GROUND INSTALLATION The unit should be installed on a solid base that is 2 5 1 cm 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 in a level position The base pad should not come in con tact with the foundation 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 acc
25. 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 Instructions 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 Electric Air Handler Natural Gas 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 17 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 Re
26. iring control low voltage wiring disconnect switches and over current protection must be supplied by the installer Wire size should be sized per NEC requirements CAUTION 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 accor dance 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 Figures 6 amp 7 5 Install the proper size time delay fuses or circuit breaker make the power supply connections Johnson Controls Unitary Products Ground Lug Low Voltage Box Dual Run Fan Fj d s Capacitor Bushing Reversible High Voltage Conduit Plate FIGURE 6 Outdoor Unit Control Box Single Phase Contactor Ground Lug Low Voltage Box Capacitor Fingered Bushing Reversible High Voltage Conduit Pl
27. is 63 F Temperature of the suction tube at the service valve is 68 F It would be necessary to add refrigerant to drop the suction tube temperature to 63 F SUBCOOLING CHARGING METHOD TXV INDOOR For cooling operation unless otherwise specified the default subcool ing is 10 F 1 Set the system running in cooling mode by setting the thermostat at least 6 F below the room temperature and operate system for at least 10 15 minutes 2 Refer to the technical guide for the recommended indoor airflow and verify it is correct it should be about 400 SCFM per ton 3 Measure and record the indoor wet bulb WB and the outdoor ambient dry bulb DB temperature 4 Using the charging chart located on the unit find the intersection of the indoor wet bulb and the outdoor dry bulb This is the recom mended liquid pressure and subcooling value 5 Measure and record the pressure at the liquid valve pressure port and compare to the value obtained in step 4 6 Add charge if the measured liquid pressure is lower than the rec ommended value Remove recover charge if the measured liquid pressure is above the recommended value Example The liquid pressure listed at the intersection of the indoor WB and the outdoor DB 320 psig Pressure at the liquid valve is 305 psig It would be necessary to add refrigerant to increase the liquid pressure to 320 psig Condenser subcooling is obtained by calculating the difference of the saturated
28. lb installation is made on a vertical run the bulb should be located at least 16 40 6 cm from any bend and on the tubing 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 CAUTION In all cases mount the TXV bulb after vapor line is brazed and has had sufficient time to cool A WARNING Schrader valve core MUST NOT be installed with TXV installation Poor system performance or system failure could result 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 isolate 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 872678 UIM C 0213
29. llowable line length for this product is 75 feet Determine if there are any low spots which might be serving as oil traps SECTION III UNIT INSTALLATION Flush the line set with a commercially available flush kit to LOCATION remove as much of the existing oil and contaminants as possible RT Install a suction line filter drier to trap any remaining contami Before starting the installation select and check the suitability of the nants and remove after 50 hours of operation location for both the indoor and outdoor unit Observe all limitations and ie 4 Ifthe outdoor unit is being replaced due to a compressor burnout 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 18 46 cm apart coil face to coil face then installation of a 10096 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 t
30. lt Common THERMOSTAT THERMOSTAT BP11C50124 wucena MINA DN11C00124 C C 24 Volt Common Full Stage Heat Y Y Full Stage Compressor Full Stage Compressor RH RH 24 Volt Hot 24 Volt Hot Heat XFMR Heat XFMR G G Fan Fan RC RC 24 Volt Hot 24 Volt Hot Cool XFMR Cool XFMR Ww Ww Full Stage Heat ID MODELS AHP SHP MA PSC AIR HANDLER COM 24 Volt Common SINGLE STAGE AIR CONDITIONER 2 Second or Full Stage Compressor 24 Volt Common R 24 Volt Hot Y Compressor Contactor G Fan w2 Second Stage Heat Y1 Single Stage Compressor Reversing Valve Energized in Cool Malfunction Light w1 First Stage Heat HUM Humidity Switch Open on Humidity Rise 24VAC Humidifier Optional 24 VAC out Humidifier 24VAC Electronic Air Cleaner EO 840 Optional Electronic Air Cleaner FIGURE 11 Thermostat Chart Single Stage AC with PSC Air Handler 10 Johnson Controls Unitary Products 872678 UIM C 0213 AC 5D Single Stage Air Conditioner Single Stage PSC Furnace
31. nd 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 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 against unsafe practices and hazards involving only property dam age CAUTION 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 Johnson Controls Unitary Products CAUTION H 410A systems operate at higher pressures than 22 systems Do not use H 22 service equipment or components on H 410A equipment Service equipment Must Be Rated for R 410A 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 mainte nance can cause injury or property damage Refer to this manual for assistance or for additional information consult a qualified con tractor installer or service agency INSPECTION As soon as a unit is receive
32. orrecting any problems Clean Up Installation debris disposed of and indoor and outdoor areas cleaned up Owner Education p Provide owner with the owner s manual Explain operation of system to equipment 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 872678 UIM C 0213 Supersedes 872678 UIM B 0712 York International Corp 5005 York Drive Norman OK 73069
33. riction 2 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 refrigerant lines where they penetrate a wall to reduce vibration and to retain some flexibility 8 For systems with total line length exceeding 70 feet 21 3 m see APPLICATION DATA and worksheet General Piping Recommen dations and Refrigerant Line Length for vapor and liquid line siz ing calibration of liquid line pressure loss or gain determination of vapor line velocity elevation limitations orifice connections sys tem charging traps etc Sheet Metal Hanger Liquid i Line Incorrect DER m Correct Th
34. 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 SUPERHEAT CHARGING METHOD PISTON INDOOR 1 Set the system running in cooling mode by setting the thermostat at least 6 F below the room temperature and operate system for at least 10 15 minutes 2 Refer to the technical guide for the recommended airflow and ver ify indoor airflow it should be about 400 SCFM per ton 3 Measure and record the outdoor ambient DB temperature and the suction pressure at the suction service valve 4 Using the charging chart located on the unit find the intersection of the outdoor ambient dry bulb and the suction pressure obtained in step 3 This is the recommended suction tube temperature at the service valve 5 Measure and record the suction tube temperature at the service valve and compare to the recommended temperature obtained in step 4 6 Add charge if the measured suction temperature in step 5 is above the recommended value Remove recover refrigerant if the mea sured suction temperature is below the recommended value Example The suction tube temperature listed on the table at the intersection of the outdoor DB and the suction pressure
35. turn Static in w c after filter furnace side Maximum Rated ESP in w c COOL CA C B C CD ADJUST ECM CA C B Oc CD Cooling BEDS Indoor CA C B 26 CD Blower Set Up X313 C1 2 3 4 C5 PSC C Low Medium Low gt Medium Medium High C High Return Air Dry Bulb Wet Bulb Supply Air Dry Bulb Temperature Drop Outside Air Dry Bulb ECM HEAT CA C B C CD Heating Indoor Ox O2 O 4 C5 Blower Set Up Medium Medium C PSC Low C Low Medium C High C 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 45s Total Added Ibs Oz Orifice Size Liquid Line Temp High Side Pressure Suction Line Temp Low Side Pressure Subcooling Superheat Cycle Test Operate the unit through continuous fan cycles from the thermostat noting and correcting any problems 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 c
36. umulating 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 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 LIQUID LINE FILTER DRIER The air conditioning unit s filter dryer is located on the liquid line NOTICE Replacements for the liquid line drier must be exactly the same as marked on the original factory drier See Source for O E M CAUTION Failure to do so or using a substitute drier or a granular type may result in damage to the equipment Filter Drier Source 1 Part No Apply with Models 51 02922195000 All 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 sh
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