Winchester 4RAC36S21-30 Installation Guide
Contents
1. R 410A OUTDOOR SPLIT SYSTEM AIR CONDITIONING MODELS 13 amp 14 5 SEER TCG D F GCGD TCJ D F YCu D F SERIES 1 5 TO 6 3 TONS 1 amp 3 PHASE os mr A Y XEN us A EV I mn 1 DN HEEN NI I RA 42 e MY 1 A M A a M AA E y Zw i I DN A leat md Ed kan ERE 4 A MY Pai NHN RE EZ Cd E DNR 1 fe GE ET MA DE MT r JE B GA A DE I mn A 1 dd A M rs M A A A E M A i MA MS E A EM A ECCT EE lO Elem EC I 03 DW Z 1 ER MMMM MY AAA P m A A E MA MA A A GN 008 A A ood I nm EN NE HM A MA HE 3 GH OPEN EE E E I E A ri sss TOD a X A M S E E ae A I M A ee l A E A A i M A SS E M I E SOG ir E I TUE mH OE KC p EEE I HA I1 DH 1 E oaa a CE z O A I E E NS AAA AS 465 EE Ar CERTIFIED www ahridirectory org Unitary Small HP AHRI Standard 210 240 Certification applies only when the complete system is listed with AHRI Ay a Sr i oO Hy REGISTRAS ISO 9001 Certified Quality Management System C LIST OF SECTIONS GENERAL seende 1 EVACUATION Lisas eee de 5 SAFETY sad td 1 SYSTEM CHARGE ooo 6 UNIT INSTALLATION ooo 2 ELECTRICAL CONNECTIONS 7 ORIFICE INSTALLATION sigar teases eed ened ek cen 5 INSTRUCTING THE OWNER 2202 e eee eee eens 13 TXV INSTALLATION 22. 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 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 lbs maximum NOTICE Line set and indoor coil can be pressurized to 250 psig with dry 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
3. 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 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 Apply with Models 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 B 0712 A CAUTION This system uses R 410A refrigerant which operates at higher pres sures than R 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 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
4. C THERMOPLASTIC OR ITS EQUIVALENT YEL PNK 208 230 VAC 60 Hz 3 PHASE SUPPLY 460 VAC 60 Hz 3 PHASE SUPPLY 575 VAC 60 Hz 3 PHASE SUPPLY 380 415 VAC 50 Hz 3 PHASE SUPPLY USE COPPER CONDUCTORS ONLY 24 eerie ciel AGN 2217 uno a o608 FIGURE 15 Wiring Diagram Three Phase 2 5 5 Tons Johnson Controls Unitary Products 15 DANGER SHOCK HAZARD COMPONENTS SHOWN IN DASHED LINES ARE OPTIONAL TURN OFF ELECTRICAL POWER BEFORE RED WIRE WILL BE REMOVED IF LOW AMBIENT KIT IS SERVICING TO PREVENT POSSIBLE DAMAGE INSTALLED TO THE EQUIPMENT AND POSSIBLE PERSONAL INJURY G YELLOW WIRE WILL BE REMOVED IF PRESSURE SWITCH ae oe KIT IS INSTALLED CAUTION TO PREVENT ELECTRICAL SHOCK OPEN IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED IT MUST BE REPLACED WITH TYPE REMOTE DISCONNECT SO ELECTRICAL 105 C THERMOPLASTIC OR ITS EQUIVALENT SUPPLY TO AIR CONDITIONER IS SHUT OFF WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES HIGH VOLTAGE FACTORY WIRING HPS HIGH PRESSURE SWITCH LOW VOLTAGE FACTORY WIRING LP LOW PRESSURE SWITCH FIELD WIRING LINE VOLTAGE LAP LOW AMBIENT PRESSURE SWITCH OPTIONAL WIRING CCH CRANKCASE HEATER CC CONTACTOR COIL ASCT ANTI SHORT CYCLE TIME LAP RELAY Pal 1 Optional Low Ambient Kit E 6 COMPRESSOR MOTOR BRN WHT TRANSFORMER BLK porro oo 208 230 VAC 60 Hz 3Ph A 380 415 VAC 50 Hz 3Ph gt 460 VAC 60 Hz 3Ph
5. 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 B 0712 FIGURE 11 Thermostat Chart Single Stage AC with PSC Air Handler 10 AC 1B Single Stage Air Conditioner PSC Air Handler THERMOSTAT THERMOSTAT BP11C50124 BN11C01124 REE appr ie40 104 DN11C00124 C C 24 Volt Common 24 Volt Common 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 W W Full Stage Heat Full Stage Heat ID MODELS AHP SHP MA 24VAC Humidifier Optional 24VAC Electronic Air Cleaner Optional PSC AIR HANDLER COM 24 Volt Common SINGLE STAGE AIR CONDITIONER YN2 Second or Full Stage Compressor 24 Volt Common R 24 Volt Hot Y Compressor Contactor G Fan W2 Second Stage Heat Y
6. 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 TSF 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 18 46 cm apart coil face to coil 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 o
7. eee eee 5 WIRING DIAGRAM 0 0 ccc eee 14 LIST OF FIGURES Typical INStAN ANON ses errar jack eee ees ee he ae sgn woe 2 Thermostat Chart Single Stage AC with PSC Air Handler 9 Installation of Vapor Line 0 000 ee 3 Thermostat Chart Single Stage AC with PSC Air Handler 10 Underground Installation 0 es 3 Thermostat Chart Single Stage AC with PSC Furnace 11 Heal PIOleClon sarna eee mee ke Se Re Re ee ee ee ae 4 Thermostat Chart Single Stage AC with PSC Furnace 12 ONUCEIMSTANAHON 445 cso nce ened adressere nede 5 Wiring Diagram Single Phase 0 cc eee ees 14 Outdoor Unit Control Box Single Phase 7 Wiring Diagram Three Phase 2 5 5 Tons 205 15 Outdoor Unit Control Box Three Phase o o o o 7 Wiring Diagram Three Phase 6 3 Ton 0000 0 eee 16 Typical Field Wiring Air Handler Electrical Heat Single Phase 8 24 VAC Connection Wiring for 2 pipe A C Typical Field Wiring Air Handler Electrical Heat Three Phase 8 6 3 Ton Condensing Unit with 7 5 Ton Air Handler 16 LIST OF TABLES Application Limitations 000 0c ee 2 R 410A Saturation Properties 0 0000 eee 7 SECTION I 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
8. 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 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 SECTION VI EVACUATION It will be necessary to evacuate the system to 500 microns or less lf 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 B 0712 SECTION VII SYSTEM CHARGE The factory charg
9. 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 is 63 F Temperature of the suction tube at the service va
10. 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 A 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 B 0712 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 SO ELECTRICAL SUPPLY TO AIR CONDITIONER IS SHUT OFF BROWN COMPRESSOR T MOTOR COMPONENTS SHOWN IN DASHED LINES ARE OPTIONAL 2 DUAL CAPACITOR SHOWN SEPARATE CAPACITORS MAY BE USED ON OS ACTUAL UNIT 2 3 WIRING MUST CONFORM TO o NATIONAL AND LOCAL CODES A WO 4 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 ee eta 5 WHERE POWER SUPPLY HAS ONE 1 i S imi 240 VOLT CONDUCTOR AND ONE 1 NEUTRAL CONDUCTOR CONNECT L2 OF CONTACTOR TO NEUTRAL HIGH VOLTAGE FACTORY WIRING LOW VOLTAGE FACTORY WIRING se Sos OPTIONAL WIRING ee FJELD WIRING LINE VOLTAGE kim em e e e e e
11. 1 Single Stage Compressor O Reversing Valve Energized in Cool X L Malfunction Light W1 First Stage Heat HUM Humidity Switch Open on Humidity Rise HUM OUT 24 VAC out Humidifier EAC 24 VAC out Electronic Air Cleaner Johnson Controls Unitary Products 872678 UIM B 0712 AC 5D 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 G8C G TJGLS SINGLE STAGE SINGLE STAGE PP11C70224 PSC AIR FURNACE CONDITIONER SINGLE STAGE PSC 1 SINGLE STAGE FURNACE AIR CONDITIONER C C 24 Volt Common 24 Volt Common Y YN2 Y Full Stage Compressor Full Stage Compressor Compressor Contactor RH R 24 Volt Hot Heat XFMR 24 Volt Hot G G Fan Fan W Full Stage Heat RC 24 Volt Hot Cool XFMR W 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 B 0712 THERMOSTAT THERMOSTAT BP11C50124 BN11C01124 pe DP11C40124 DN11C00124
12. C C 24 Volt Common 24 Volt Common 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 W W Full Stage Heat Full Stage Heat External Humidistat Optional Open on Humidity Rise ID MODELS G 8 9 S GF 8 9 G 9F LF8 L Y M 8S TG 8 9 S G8C G TJGLS 24VAC Humidifier Optional Thermostat Installer Setup 1 System Type must be set to 0 Selection of GAS ELEC switch on thermostat is not necessary Thermostat Installer Setup 15 Compressor Protection must be set to 5 Part Number S1 2HU16700124 FIGURE 13 Thermostat Chart Single Stage AC with PSC Furnace 12 SINGLE STAGE PSC FURNACE SINGLE STAGE PSC FURNACE C 24 Volt Common Y Y2 Full Stage Compressor R 24 Volt Hot G Fan W Full Stage Heat Other Part Numbers SAP Legacy 265901 031 09166 AC 5E Single Stage Air Conditioner Single Stage PSC Furnace SINGLE STAGE AIR CONDITIONER SINGLE STAGE AIR CONDITIONER C 24 Volt Common Y Compressor Contactor Johnson Controls Unitary Products SECTION IX INSTRUCTING THE OWNER Assist owner with processing warranty cards and or online registration Review Owners Guide and prov
13. H HEAT CONTACTOR TERMINALS COIL Y Ry CS y CONDENSING UNIT y ROOM THERMOSTAT 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 B 0712 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 a gt SINGLE STAGE AIR HANDLER CONTROL AIR CONDITIONER COM C 24 Volt Common 24 Volt Common Y Y Y2 Y Full Stage Compressor SE Compressor Contactor Stage Compressor RH R 24 Volt Hot Heat XFMR 24 Volt Hot G G Fan Fan W2 Second Stage Heat RC Y1 24 Volt Hot Cool XFMR Single Stage Compressor O Reversing Valve Energized in Cool X L Malfunction Light W W1 Full Stage Heat First Stage Heat HM1 24VAC Humidifier a a is mn Octonal umidity Switc spiel enone Open on Humidity Rise HUM OUT 24VAC 24 VAC out Electronic Air
14. YEL PNK LUG COOLING USE COPPER CONDUCTOR ONLY 872677 UWD A 0712 FIGURE 16 Wiring Diagram Three Phase 6 3 Ton 6 3 TON CONDENSING UNIT LOW VOLTAGE BOX 7 5 TON AIR HANDLER A 24 V TERMINAL BLOCK LA BET ERR AA ee am 830 BR gt gt oe YELLOW B aa A p Xs fu RED A oe AZ s2 gt a GI 210 Y A BRI B 66 J 832 BK A EHR be i pre Y ON USED WITH ELECTRIC i 1 w HEAT ACCESSORIES o TYPICAL WALL THERMOSTAT FIGURE 17 24 VAC Connection Wiring for 2 pipe A C 6 3 Ton Condensing Unit with 7 5 Ton Air Handler Subject to change without notice Published in U S A 872678 UIM B 0712 Copyright O 2012 by Johnson Controls Inc All rights reserved Supersedes 872678 UIM A 0712 York International Corp 5005 York Drive Norman OK 73069
15. 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 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 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 lt is also used to alert against unsafe practices and hazards involving only property dam A 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 A CAUTION R 410A systems operate at higher pressures than R 22 systems Do not use R 22 service equipment or components on R 410A equipment Service
16. 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 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 replacement driers A 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 1 029221 95000 PIPING CONNECTIONS
17. cated on the inside surface of the unit service access panel 3 Replace the corner cover removed in Step 2 4 Al 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 POWER WIRING ere WIRING CONTROL WIRING MINIMUM 18 GA WIRE FACTORY WIRING NEC CLASS 2 FURNACE OR AIR HANDLER TERMINAL BLOCK REQUIRED ON SYSTEMS O WITH HEAT CONTACTOR TERMINALS COIL y CONDENSING UNIT ROOM THERMOSTAT ALL OUTDOOR WIRING MUST BE WEATHERPROOF USE COPPER CONDUCTORS ONLY TERMINAL W IS ONLY Y O 0 Ow 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 POWER WIRING CONTROL WIRING 24 VOLT CONTROL WIRING o FACTORY WIRING POWER WIRING MINIMUM 18 GA WIRE Ss NEC CLASS 2 FURNACE OR AIR HANDLER TERMINAL BLOCK I I OW R Co w TERMINAL W IS ONLY 7 7 REQUIRED ON SYSTEMS WIT
18. d 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 Incorrect Sheet Metal Hanger Liquid Line Correct Insulated Vapor Line FIGURE 3 Underground Installation 872678 UIM B 0712 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 A 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 oxi
19. dation 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 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 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 FIGURE 4 Heat Protection A CAUTION Do not install any coil in a furnace which is to be operated during
20. e e u u BLACK CONTACTOR YEL PNK eee NO o HPS ENE eee J YEL PNK gt CONDUCTORS JUNCTION ONLY eg BOX De d 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 30 Hz PHASE SUPPLY 167242 UWD D 1009 FIGURE 14 Wiring Diagram Single Phase a Johnson Controls Unitary Products CAPACITOR CONTACTOR COIL CRANKCASE HEATER CONTROL HIGH PRESS SWITCH HEATER SWITCH LOW AMBIENT PRESS SWITCH LOW PRESS SWITCH HIGH VOLTAGE FACTORY WIRING LOW VOLTAGE FACTORY WIRING OPTIONAL LOW VOLTAGE WIRING OPTIONAL HIGH VOLTAGE WIRING FIELD WIRING LINE VOLTAGE FIELD WIRING CTRL CIRCUIT D m e 872678 UIM B 0712 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 1 COMPONENTS SHOWN IN DASH LINES ARE OPTIONAL 2 RED WIRE WILL BE REMOVED IF LOW AMBIENT KIT IS INSTALLED 3 BLUE WIRE WILL BE REMOVED IF PRESSURE SWITCH KIT IS INTALLED 4 WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES 5 IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED IT MUST BE REPLACED WITH 105
21. e 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 A 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 system installations charge system per
22. equioment 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 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 Requirements For Installing Servicing R 410A Equipment e Gauge sets hoses refrigerant containers and recovery system must be designed to handle the POE type oils and the higher pressures of R 410A e Manifold sets should be high side and low side with low side retard e All hoses must have a 700 psig service pressure rating e Leak detectors should be designed to detect HFC refrigerant e Recovery equipment including refrigerant recovery containers must be specifically designed to handle R 410A e Do not use an R 22 TXV e A liquid line filter drier is required on every unit 872678 UIM B 0712 872678 UIM B 0712 LIMITATIONS The unit should be installed in accordance with all National
23. ide 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 suitable means 2 The outdoor fan motor is permanently lubricated and does not require periodic oiling Johnson Controls Unitary Products 872678 UIM B 0712 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
24. ing 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 B 0712 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 TXV equalizer line into the vapor line as follows a Hand tighten the 1 4 SAE nut to the Schrader 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
25. led 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 MINIMUM 18 SERVICE ACCESS CLEARANCE 60 OVERHEAD ere ON ONE SIDE ee THERMOSTAT WEATHERPROOF DISCONNECT SWITCH NEC CLASS 1 WIRING NEC CLASS 2 WIRING 10 CLEARANCE AROUND PERIMETER Ni TO FURNACE OR AIR HANDLER TERMINAL BLOCK A NOTES ALL OUTDOOR WIRING MUST BE WEATHERPROOF MINIMUM 24 UNIT TO UNIT CLEARANCE CONTROL ACCESS PANEL SEAL OPENING S WITH PERMAGUM OR EQUIVALENT FIGURE 1 Typical Installation 2 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
26. line evaporator and liquid line to 500 microns or less 11 Replace cap on service ports Do not remove the flare caps from the service ports except when necessary for servicing the system A 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 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 Failure to insta
27. ll Schrader Valve Core on orifice applications could result in total refrigerant loss 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 8 Replace black plastic cap on equalizer fitting 9 Slide indoor coil back into cabinet LIQUID LINE SWIVEL COUPLING This fitting is a right hand thread turn counter clockwise to remove p ORIFICE he DISTRIBUTOR FIGURE 5 Orifice Installation SECTION V TXV INSTALLATION A CAUTION When using a TXV 13 SEER models 12 48 require a hard start kit Models 12 48 with a H on the end of the model number have a factory installed hard start The follow
28. lve 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 refrigerant temperature of the pressure measured at the li
29. 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 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 liqui
30. quid base valve and the liquid tube temperature as measured at the liquid base valve Subcooling Temp TC Saturated Temp TS Liquid Temp T A 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 a PRESSURE 5 PRESSURE z PRESSURE E PRESSURE a PRESSURE TEMP F PSIG TEMP F PSIG TEMP F TEMP F TEMP F 1 105 a ai 278 406 8 130 170 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 requirements A 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
31. r 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 densing unit combination with the appropriate metering device 2 Change out of the line set when replacing an R 22 unit with an R410 A unit is highly recommended to reduce cross contamina tion of oils and refrigerants 3 If change out of the line set is not practical then the following pre cautions should be taken e Inspect the line set for kinks sharp bends or other restrictions and for corrosion e Determine if there are any low spots which might be serving as oil traps e Flush the line set with a commercially available flush kit to remove as much of the existing oil and contaminants as possible e Install a suction line filter drier to trap any remaining contami nants and remove after 50 hours of operation 4 If the 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 instal
32. 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 and make the power supply connections Johnson Controls Unitary Products 872678 UIM B 0712 Voltage Box y Dual Run Fan Ej a ok Capacitor Bushing Reversible High Voltage Conduit Plate FIGURE 6 Outdoor Unit Control Box Single Phase Contactor Voltage Box Capacitor Fingered Bushing Reversible High Voltage Conduit Plate FIGURE 7 Outdoor Unit Control Box Three Phase 872678 UIM B 0712 FIELD CONNECTIONS CONTROL WIRING 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 6 Route the 24 volt control wiring NEC Class 2 from the outdoor unit to the indoor unit and thermostat 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 2 The complete connection diagram and schematic wiring label is lo
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