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.
Matching indoor coils are available with a thermal expansion valve or
an orifice liquid feed sized for the most common usage. The orifice size
and/or refrigerant charge may need to be changed for some indoor-outdoor unit combinations, elevation differences, or total line lengths. Refer
to Application Data covering “General Piping Recommendations and
Refrigerant Line Length” (Part Number 036-61920-001).
SECTION II: 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.
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 mino r or moderate injury
alert against unsafe practices and hazards involving only property damage.
.
.
. It is also used to
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 assistance or for additional information, consult a qualified contractor, installer, or service agency.
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 possib le damage 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.
359513-UIM-A-0408
Page 2
359513-UIM-A-0408
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 assure a system that will give maximum performance
with minimum service.
4.The maximum allowable line length for this product is 75 feet.
AIR TEMPERATURE AT
OUTDOOR COIL, °F
AIR TEMPERATURE AT
INDOOR COIL, °F
Min.Max.Min.Max.
DB
Cool
1. Operation below this temperature is permissible for a short period of
DB
HeatDBCool
DB
Heat
WB
Cool
50-101157557
time, during morning warm-up.
DB
Heat
50
1
WB
Cool
7280
DB
Heat
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.
MINIMUM 24” SERVICE
48” OVERHEAD
CLEARANCE
ACCESS CLEARANCE
ON ONE SIDE
The outdoor unit must have sufficient clearance for air entrance to the
condenser coil, for air discharge, and for service access. See Figure 1
"Typical Installation with Required Clearances".
NOTE: For multiple unit installations, units must be spaced a minimum
of 18 inches 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 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 system operation and performance.
1.Change-out of the indoor coil to an approved R-22 coil/ condensing unit combination with the appropriate metering device.
2.If the outdoor unit is being replaced due to a compressor burnout,
then installation of a 100% activated alumina suction-line filter
drier 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.
THERMOSTAT
WEATHERPROOF
DISCONNECT
SWITCH
10” CLEARANCE
AROUND PERIMETER
NOTE:
ALL OUTDOOR WIRING
MUST BE WEATHERPROOF.
FIGURE 1: Typical Installation with Required Clearances
CONTROL
ACCESS
PANEL
NEC CLASS 1 WIRING
TO FURNACE OR
AIR HANDLER
TERMINAL BLOCK
NEC CLASS 2 WIRING
TO INDOOR COIL
SEAL OPENING(S) WITH
PERMAGUM OR EQUIVALENT
2Johnson Controls Unitary Products
Page 3
359513-UIM-A-0408
GROUND INSTALLATION
The unit may be installed at ground level on a solid base that will not
shift or settle, causing strain on the refrigerant lines and possible leaks.
Maintain the clearances shown in Figure 1 "Typical Installation with
Required Clearances" and install the unit in a level position.
Normal operating sound levels may be objectionable if the unit is placed
directly under windows of certain rooms (bedrooms, study, etc.).
Condensate will drain from beneath the coil of the outdoor unit during
the defrost cycle. Normally this condensate may be allowed to drain
directly on the ground.
Elevate the unit sufficiently to prevent any blockage of the air entrances
by snow in areas where there will be snow accumulation. Check the
local weather bureau for the expected snow accumulation in your area.
Isolate the unit from rain gutters to avoid any possible wash out of the
foundation.
The outdoor unit should not be installed in an area where mud or
ice could cause personal injury. Remember that condensate will
drip from the unit coil during heat and defrost cycles and that this
condensate will freeze when the temperature of the outdoor air is
below 32°F.
ROOF INSTALLATION
When installing units on a roof, the structure must be capable of supporting the total weight of the unit, including a pad, lintels, rails, etc.,
which should be used to minimize the transmission of sound or vibration into the conditioned space.
UNIT PLACEMENT
1.Provide a base in the pre-determined location.
2.Remove the shipping carton and inspect for possible damage.
3.Compressor tie-down bolts should remain tightened.
4.Position the unit on the base provided.
NOTE: Heat pumps will defrost periodically resulting in water drainage.
The unit should not be located where water drainage may freeze and
create a hazardous condition - such as sidewalks and steps.
LIQUID LINE FILTER-DRIER
The heat pumps have a solid core bi-flow filter/drier located on the liquid
line.
NOTE: 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.
replacement driers.
Failure to do so or using a substitute drier or a granular type may
result in damage to the equipment.
NOTE: Using a larger than specified line size could result in oil return
problems. 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" every 20 feet toward the outdoor unit to facilitate 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 and/or high temperatures must also be
insulated.
5.Tape and suspend the refrigerant lines as shown. DO NOT allow
tube metal-to-metal contact. See Figure 2 "Tubing Hanger".
6.Use PVC piping as a conduit for all underground installations as
shown in Figure 3 "Underground Installation". 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.See Form 690.01-AD1V for additional piping information.
Sheet Metal Hanger
Liquid
Line
Incorrect
Correct
FIGURE 2: Tubing Hanger
TO INDOOR COIL
LIQUID L INE
PVC
CONDUIT
Insulated Vapor Line
INSULATED
VAPOR LINE
Tape
TO O UTD OO R UNI T
CAP
Filter-Drier
Apply with Models
Source 1 Part No.
8837/036-25512-000All
*As listed on the “Energy Guide yellow sticker on the unit.
PIPING CONNECTIONS
The outdoor unit must be connected to the indoor coil using field supplied refrigerant grade 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 036-61920-001 for installing tubing of longer lengths and
elevation differences.
Johnson Controls Unitary Products3
13 SEER
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.
The total system refrigerant charge is retained within the outdoor unit
during shipping and installation. The reusable service valves are provided to evacuate and charge per this instruction.
Serious service problems can be avoided by taking adequate precautions to assure an internally clean and dry system.
Page 4
359513-UIM-A-0408
Dry nitrogen should always be supplied through the tubing while it
is being brazed, because the temperature 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 "Heat Protection". Also, protect all painted surfaces, insulation, and plastic base during brazing. After brazing 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 pressure 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 continue flowing. Refer to the Tabular Data Sheet for proper liquid line
sizing.
3.Carefully remove the rubber plugs from the evaporator liquid and
vapor connections at the indoor 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. Refer to the Tabular Data Sheet for proper vapor line sizing.
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 connection has cooled, remove the nitrogen source from the liquid fitting service port.
7.Replace the Schrader core in the liquid and vapor valves.
8.Go to “SECTION IV” for TXV installation.
9.Leak test all refrigerant piping connections including the service
port flare caps to be sure they are leak tight. DO NOT OVERTIGHTEN (between 40 and 60 inch - lbs. maximum).
10. Evacuate the vapor line, evaporator, and the liquid line to 500
microns or less.
NOTE: 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.
NOTE: Do not use the system refrigerant in the outdoor unit to purge or
leak test.
11. Replace cap on service ports. Do not remove the flare caps from
the service ports except when necessary for servicing the system.
Do not connect manifold gauges unless trouble is suspected.
Approximately 3/4 ounce of refrigerant will be lost each time a standard manifold gauge is connected.
12. Release the refrigerant charge into the system. 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. 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.
SECTION IV: TXV INSTALLATIONS
For installations requiring a TXV, the following are the basic steps for
installation. For detailed instructions, refer to the Installation Instructions
accompanying the TXV kit.
Install TXV kit as follows:
1.First, relieve the holding charge by depressing the Schrader valve
located in the end of the liquid line.
2.After holding charge is completely discharged, loosen and remove
the liquid line fitting from the orifice distributor assembly. Note that
the fitting has right
3.Remove the orifice from the distributor body using a small diame-
FIGURE 4: Heat Protection
The evaporator is pressurized.
4.Braze the liquid line to the evaporator liquid connection. Nitrogen
should be flowing through the evaporator coil.
ter wire or paper clip. Orifice is not used when the TXV assembly
is installed.
4.After orifice is removed, install the thermal expansion valve to the
orifice distributor assembly with supplied fittings. Hand tighten and
turn an additional 1/8 turn to seal. Do not overtighten fittings
5.Reinstall the liquid line to the top of the thermal expansion valve.
Hand modify the liquid line to align with casing opening.
4Johnson Controls Unitary Products
handthreads.
.
Page 5
359513-UIM-A-0408
6.Install the TXV equalizer line into the vapor line as follows:
a.Select a location on the vapor line for insertion of the equal-
izer line which will not interfere with TXV bulb placement.
b.Use an awl to punch through the suction tube and insert the
awl to a depth to achieve a 1/8” diameter hole.
7.Install TXV equalizer line in 1/8” hole previously made in vapor
line. Equalizer line should not be bottomed out in vapor line. Insert
equalizer line at least 1/4” in the vapor line. Braze equalizer line
making sure that tube opening is not brazed closed.
Dry nitrogen should always be supplied through the tubing while it
is being brazed, because the temperature 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.
All connections to be brazed 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.
Install the TXV bulb to the vapor line near the equalizer line, using the
two bulb clamps furnished with the TXV assembly. Ensure the bulb is
making maximum contact. Refer to TXV installation instruction for view
of bulb location.
FIELD CONNECTIONS POWER WIRING
1.Install the proper size weatherproof disconnect switch outdoors
and within sight of the unit.
2.Remove the screws from the control box cover and remove from
unit.
3.Run power wiring from the disconnect switch to the unit.
4.Route wires from disconnect through power wiring opening provided and into the unit control box as shown in Figure 5 "Outdoor
Unit Control Box".
5.Install the proper size time-delay fuses or circuit breaker, and
make the power supply connections.
CONTACTOR
DEFROST
CONTROL
BOARD
LOW
VOLTAGE
BOX
“FINGERED”
BUSHING
REVERSIBLE HIGH
VOLTAGE CONDUIT PLATE
START CAPACITOR
(Optional)
START
RELAY
(Optional)
GROUND
LUG
DUAL
RUN/FAN
CAPACITOR
In all cases, mount the TXV bulb after vapor line is brazed and has
had sufficient time to cool.
1.Bulb should be installed on a horizontal run of the vapor line if possible. On lines under 7/8" OD the bulb may be installed on top of
the line. With 7/8" OD and over, the bulb should be installed at the
position of about 2 or 10 o'clock.
2.If bulb installation is made on a vertical run, the bulb should be
located at least 16 inches 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.
3.Bulb should be insulated using thermal insulation provided to protect it from the effect of the surrounding ambient temperature.
SECTION V: ELECTRICAL CONNECTIONS
GENERAL INFORMATION & 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.
All field wiring must USE COPPER CONDUCTORS ONLY and be
in accordance with Local, National, Fire, Safety & Electrical Codes.
This unit must be grounded with a separate ground wire in accordance with the above codes.
FIGURE 5: Outdoor Unit Control Box
FIELD CONNECTIONS CONTROL WIRING
1.Route low voltage wiring into bottom of control box as shown in
Figure 5 "Outdoor Unit Control Box". Make low voltage wiring connections inside the low voltage box per Figures 7-8.
2.The complete connection diagram and schematic wiring label is
located on the inside surface of the unit service access panel.
3.Replace the control box cover removed in Step 2.
4.All field wiring to be in accordance with national electrical codes
(NEC) and/or local-city codes.
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 outside 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.
NOTE: To eliminate erratic operation, seal the hole in the wall at the
thermostat with permagum or equivalent to prevent air drafts affecting
the operation of in the thermostat.
NOTE: A Start Assist Kit is available and recommended for long line set
applications or in areas of known low voltage problems.
The complete connection diagram and schematic wiring label is located
on the inside surface of the unit service access panel.
Johnson Controls Unitary Products5
Page 6
359513-UIM-A-0408
GND.
LUG
ALL FIELD WIRING TO BE IN ACCORDANCE WITH ELECTRIC CODE (NEC) AND/OR LOCAL CODES
POWER WIRING
208/230-1-60
CONTACTOR
TERMINALS
24 VOLT CONTROL WIRING
MINIMUM 18 GA. WIRE
(NEC CLASS 2)
*
TERMINAL W IS ONLY
REQUIRED ON SYSTEMS
WITH HEAT.
FURNACE OR AIR HANDLER TERMINAL BLOCK
CYRGW
POWER WIRING
CONTROL WIRING
FACTORY WIRING
COIL
CONDENSING UNIT
ALL OUTDOOR WIRING MUST BE WEATHERPROOF. USE COPPER CONDUCTORS ONLY.
A dehumidification control accessory 2HU06700124 may be used with
variable speed air handlers or furnaces in high humidity areas. This
control works with the variable speed indoor unit to provide cooling at a
reduced air flow, lowering evaporator temperature and increasing latent
capacity. The humidistat in this control opens the humidistat contacts on
humidity rise. To install, refer to instructions packaged with the acces-
During cooling, if the relative humidity in the space is higher than the
desired set point of the dehumidification control, the variable speed
blower motor will operate at lower speed until the dehumidification control is satisfied. A 40-60% relative humidity level is recommended to
achieve optimum comfort.
If a dehumidification control is installed, it is recommended that a mini-
mum air flow of 325 cfm/ton be supplied at all times.
sory and Figures 7-8. Prior to the installation of the dehumidification
control, the jumper across the HUMIDISTAT terminals on the indoor
variable speed air handler or furnace CFM selection board must be
removed.
YRGW
ROOM THERMOSTAT
*
6Johnson Controls Unitary Products
Page 7
359513-UIM-A-0408
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.
HP 2CSingle Stage Heat Pump – Single Stage PSC Furnace
THERMOSTAT
*DN22U00124
N/A
THERMOSTAT
*BP21H50124
*BN21H00124
*DP21H40124
*DN21H00124
N/A
THERMOSTAT
*DP32H70124
C
24 – Volt Common
Y1
First Stage Compressor
R
24 – Volt Hot
G
Fan
E
Emergency Heat
W2
Third Stage Heat
O
Reversing Valve
Energized in Cool
L
Malfunction Light
Second Stage Compressor
Second Stage Aux. Heat
3
Y2
W1
External Humidistat
(Optional)
Open on Humidity Rise
24VAC Humidifier
(Optional)
Step 1 of Thermostat
Installer / Configuration
Menu must be set to
Heat Pump 1
Step 9 of Thermostat
Installer / Configuration
Menu must be set to
Pump OFF
ID MODELS
G*(8/9)S
G*9F
L(Y/M)8S
G8C
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
GF(8/9)
LF8
TG(8/9)S
(G/T)GLS
OD MODELS
E*R*
E*ZD
E*B*
*RHS
HP*
*HGD
SINGLE STAGE
HEAT PUMP
2
DEMAND DEFROST
CONTROL
C
24 – Volt Common
Y
Compressor
R
24 – Volt Hot
W1/66(out)
Heat
O
Reversing Valve
Energized in Cool
X/L
Malfunction Light
W
Auxiliary Heat
1
3
FIGURE 7: Thermostat Chart - Single Stage Heat Pump – Single Stage PSC Furnaces
Johnson Controls Unitary Products7
Part Number:
S1-2HU16700124
Other Part Numbers:
SAP = Legacy
265901 = 031-09166
2
Part Numbers:
SAP = Legacy
67297 = 031-01975
1
Page 8
359513-UIM-A-0408
HP 5BSingle Stage Heat Pump – PSC Air Handler
THERMOSTAT
*DN22U00124
C
24 – Volt Common
Y1
First Stage Compressor
R
24 – Volt Hot
(Heat XFMR)
G
Fan
E
Emergency Heat
R
24 – Volt Hot
(Cool XFMR)
O/B
Reversing Valve
L
Malfunction Light
Second Stage Compressor
Thermostat Installer Setup
1-System Type-must be set
to 5 – 2 Heat/1 Heat Pump
Thermostat Installer Setup
2-Changeover Valve-must
be set to 0 – O/B terminal
Y2
AUX
Auxiliary Heat
Energized in Cooling
THERMOSTAT
*BP21H50124
*BN21H00124
*DP21H40124
*DN21H00124
C
24 – Volt Common
Y1
First Stage Compressor
R
24 – Volt Hot
G
Fan
E
Emergency Heat
O
Reversing Valve
Energized in Cool
L
Malfunction Light
Second Stage Compressor
Y2
W2
Second Stage Heat
B/O Switch on Thermostat
must be in the O position
THERMOSTAT
*DP32H70124
C
24 – Volt Common
Y1
First Stage Compressor
R
24 – Volt Hot
G
Fan
E
Emergency Heat
W2
Third Stage Heat
O
Reversing Valve
Energized in Cool
L
Malfunction Light
Second Stage Compressor
Y2
W1
Second Stage Aux. Heat
Step 1 of Thermostat
Installer / Configuration
Menu must be set to
Heat Pump 1
3
External Humidistat
(Optional)
Open on Humidity Rise
24VAC Humidifier
(Optional)
24VAC
Electronic Air Cleaner
(Optional)
ID MODELS
AHP
SHP
MA
PSC
AIR HANDLER
PSC
AIR HANDLER
C
24 – Volt Common
Y/Y2
Second or Full
Stage Compressor
R
24 – Volt Hot
G
Fan
W1
First Stage Aux. Heat
W2
Second Stage Aux. Heat
Y1
Single Stage Compressor
O
Reversing Valve
Energized in Cool
X/L
Malfunction Light
HUM
Humidity Switch
Open on Humidity Rise
HUM OUT
(24VAC out)
EAC (24VAC out)
Electronic Air Cleaner
Move the MODE
jumper to “HP”
Move HUM STAT
jumper to “YES”
if humidistat is to be used.
Refer to AH documentation
for W1 and W2 electric
heat staging options.
OD MODELS
E*R*
E*ZD
E*B*
*RHS
HP*
*HGD
SINGLE STAGE
HEAT PUMP
2
DEMAND DEFROST
CONTROL
C
24 – Volt Common
Y
Compressor
R
24 – Volt Hot
W1/66(out)
Heat
O
Reversing Valve
Energized in Cool
X/L
Malfunction Light
W
Auxiliary Heat
1
FIGURE 8: Thermostat Chart - Single Stage Heat Pump – PSC Air Handler
8Johnson Controls Unitary Products
3
S1-2HU16700124
Part Number:
Part Numbers:
SAP = Legacy
159480 = 031-09156
2
Part Numbers:
SAP = Legacy
67297 = 031-01975
1
Page 9
359513-UIM-A-0408
CFM SELECTION BOARD SETTINGS
For proper system operation the CFM Selection Board jumpers must be
set properly.
Refer to the Tabula r Data Sheet for the recommended air flow sett ings
for each size condensing unit.
Set the cooling speed per the instructions for the air handler or furnace
by selecting the correct COOL and ADJ taps. Verify the airflow using
the LED display on the CFM selection board.
The HEAT PUMP jumper MUST
be removed for proper system opera-
tion.
The HUMIDISTAT jumper must also be removed if a dehumidistat is
installed.
CFM SELECTION BOARD
TAP SELECTION
D
C
B
A
COOLHEATADJDELAY
REMOVE FOR
HEAT PUMPHUMIDISTAT
D
C
B
A
FIGURE 9: CFM Selection Board
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 vacuum pump suction to isolate the pump and hold the system under vacuum. 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, its an indication that the system is leak free but still contains moisture and may require further evacuation if the reading is
above 500 microns.
SECTION VII: SYSTEM CHARGE
The factory charge in the outdoor unit includes enough charge for the
unit, a 15 ft. 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.
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.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.
Refrigerant charging should only be carried out by a qualified air
conditioning contractor.
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 available, add refrigerant accordingly. Otherwise, model-specific charging
charts are provided on the units rating plate for cooling mode only.
There is no accurate method for charging these units in the heating
mode. If charging is required during the heating mode, the unit must be
evacuated and charge weighed in according to the rating plate. If TXV
indoor coils are used with the following subcooling charging method
must be used. Superheat charging charts are not valid with TXV
equipped systems.
Subcooling Charging Method - Cooling Only
The recommended subcooling is 10°F
1.Set the system running in the cooling mode by setting the thermostat 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 1 "R-22
Saturated Properties".
6.Subcooling temperature TC = Saturated T emperature (ST) - Liquid
Temp (T).
Example: The pressure P and temperature T measured at the liquid service port is 196 psig and 90°F, respectively. From Table 1
"R-22 Saturated Properties", the saturated temperature for 196
psig is 100°F. The subcooling temperature TC = 100°-90°=10°F
Do not leave the system open to the atmosphere.
The “TOTAL SYSTEM CHARGE” must be permanently stamped on the
unit data plate.
Johnson Controls Unitary Products9
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 1
"R-22 Saturated Properties" for R-22 saturation temperatures
See Figure 10 "Heat Pump Flow Diagram" to trace the flow of refrigerant through the system.
Check flare caps on service ports to be sure they are leak tight. DO
NOT OVERTIGHTEN (between 40 and 60 inch - lbs. maximum).
** NOTE: The indoor coil is shipped with an orifice. The orifice must be replaced with a TXV Kit.
SECTION VIII: SYSTEM OPERATION
ANTI-SHORT CYCLE DELAY
COIL
AMBIENT
COIL G
AMBG
COMPRESSOR
FIELD CONNECTED LINE
BI-FLOW
TXV/CHECK
VALVE (Cooling) **
The control includes a five-minute anti-short cycle delay (ASCD) timer
to prevent the compressor from short cycling after a power or thermostat signal interruption. The ASCD timer is applied when the control is
first powered from the indoor unit thermostat and immediately following
the completion of a compressor run cycle. The compressor and the outdoor fan will not operate during the five minutes that the timer is active.
The ASCD timer can be bypassed by connecting the TEST terminals
for three seconds while the thermostat is calling for compressor operation (Y input signal energized).
COND
HIGH VOLTAGE
FAN
VALV E
SWITCH
FIGURE 11: Demand Defrost Control Module
10Johnson Controls Unitary Products
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359513-UIM-A-0408
LOW VOLTAGE DETECTION
The control monitors the transformer secondary (24 VAC) voltage and
provides low voltage protection for the heat pump and its components.
In particular, the control prevents contactor chatter during low voltage
conditions. If the voltage drops below approximately 19 VAC, the control will continue to energize any relays that are already energized but
will not energize any additional relays until the voltage level increases.
If the voltage drops below approximately 16 VAC, the control will immediately de-energize the relay outputs and will not energize any relays
until the voltage level increases.
TABLE 2:
connection (seconds)
Connection removedTerminate defrost as normal.
TEST Input Functionality
Duration of
Less than 2No response
2-6Bypass ASCD. If Y is present and pressure switch is closed, contactors will be energized.
More than 6Initiate defrost cycle ignoring the liquid line and outdoor ambient temp. Energize X/L with active defrost curve flash code
Connection
not removed
Continue defrost cycle and X/L flash code until TEST connection removed.
FAULT CODE DISPLAY
X/L Output
The X/L terminal of the heat pump control is typically connected to the
X/L input of the room thermostat. The thermostat uses this signal to
notify the homeowner of a problem with the heat pump using an LED or
LCD display. When the control energizes the X/L terminal, the thermostat displays the flash code so the homeowner can see it.
TABLE 3:
ConditionX/L
Pressure Switch lockout - last mode of operation was heating 2 flashes
Pressure Switch lockout - last mode of operation was defrost 3 flashes
When the control locks out the compressor because of a pressure
switch lockout, it will energize the X/L output as shown in Table 3 "X/L
Output Categories". The control has a three second delay between fault
code flashes.
X/L Output Categories
DEFROST OPERATION
General
The control maintains proper airflow through the outdoor coil during
heating operation by melting frost and ice that may form on the coil.
Frost may accumulate unevenly in different sections of the coil because
of the arrangement of the refrigeration circuit within the coil. The control
may initiate a defrost cycle even when the coil is not completely covered with frost. This is normal operation.
The control regulates the defrost operation of the heat pump based on
accumulated compressor run time, outdoor coil temperature, and outdoor ambient temperature. The control will cause the unit to operate in
the normal heating mode until it determines that a defrost cycle is
needed.
All defrost timings are based on accumulated compressor run time.
Operation
The defrost mode is equivalent to the cooling mode except that the outdoor fan motor is de-energized. The control shall do the following to initiate a defrost cycle.
• De-energize the outdoor fan
• Energize the reversing valve
• Energize the auxiliary heat output through the W1/66 terminal.
• Begin the maximum defrost cycle length timer
TEST INPUT
The control includes a TEST input connector that can be used for various testing functions during installation and service. The TEST input
connector is shown in Figure 11 "Demand Defrost Control Module".
The following table summarizes the behavior of the control when the
two TEST pins are connected. More detailed descriptions of the various
functions are included in other sections of this document.
Control behavior
Clear lockout
If the call for heating (Y) is removed from the control during the defrost
cycle, it will terminate the defrost cycle and de-energize the compressor. The control will also stop the defrost cycle length timer but not reset
it. When the control receives another call for heating, it will restart the
defrost cycle and the timer at the point at which the call for heating was
removed. This will happen only if the liquid line temperature conditions
allow defrost to occur.
Defrost Curves
The control uses a set of defrost curve parameters that are selected
using the defrost curve selection jumper. The location of the defrost
curve selection jumper is shown in Figure 11 "Demand Defrost Control
Module". Table 4 "Defrost Initiate Curves" shows the jumper position
that is appropriate for each heat pump model. Jumper position 4 is not
used and the control will not allow the compressor to operate when the
jumper is in this position.
Defrost Curve Selection
The factory activates the correct defrost curve during production. They
will place the defrost curve selection jumper in the P position or in a
numbered position appropriate for the specific heat pump model. You
should not have to change the defrost curve selection jumper during initial installation.
If the jumper is inadvertently moved, it should be placed in the appropriate numbered location based on the model number and Table4
"Defrost Initiate Curves". If the factory has activated the curve using the
P position, the jumper may also be returned to that position. If, however,
the factory has not activated the curve in the P position and the jumper
is placed in the P position, the control will not energize the compressor.
The control will also not energize the compressor if the defrost curve
selection jumper is in a numbered position that is not described in
Table 4 "Defrost Initiate Curves" o r if the defrost curve selection ju mper
is missing. The control will display the proper fault code when a defrost
curve jumper error is present. If the jumper is missing, the control will
behave as if the jumper was in the P position. If the jumper is placed in
a numbered position, the defrost curve selected by the jumper will override the defrost curve activated at the factory until the jumper is returned
to the P position. The control will display the active defrost curve using
the X/L terminal when the heat pump is operating in a defrost cycle that
has been forced using the TEST inputs.
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359513-UIM-A-0408
It will also display the active defrost curve using the X/L terminal when
the operational mode is being displayed using the LED’s. For instance,
the X/L output will be energized with two flashes when defrost curve 2 is
active. The control only reads the jumper input when the Y and W thermostat inputs are de-energized. If a jumper position is changed while
either of these inputs is energized, the control will not act upon the
jumper changes until the thermostat calls are de-energized or power
(24 VAC) to the control is cycled.
Defrost Cycle Initiation
The control will allow the heat pump to operate in the heating mode until
the combination of outdoor ambient and outdoor coil temperatures indicate that a defrost cycle is necessary.
The control will initiate a defrost cycle when the liquid line temperature
is below the initiate point for the measured ambient temperature (See
Figure 12 "Defrost Operation Curves") continuously for 4-1/2 minutes.
This delay eliminates unnecessary defrost cycles caused by refrigeration surges such as those that occur at the start of a heating cycle.
The control will initiate a defrost cycle every 6 hours (accumulated compressor run time) to recirculate refrigerant lubricants. This forced
defrost timer will be reset and restarted following the completion or termination of a defrost cycle.
The control will also initiate a defrost cycle when the TEST terminals
are shorted. This feature allows an installer or service technician to start
a defrost cycle immediately as required. When the TEST terminals are
shorted for more than six seconds with a Y input energized and the
pressure switch input is closed, the ASCD will be bypassed and the
compressor and the W1/66 terminal to auxiliary heat will be energized.
When the TEST inputs are used to force a defrost cycle, the control will
ignore the state of the liquid line temperature and outdoor ambient temperature inputs. The coil does not have to be cold and the outdoor temperature does not have to be within a certain range for the heat pump to
be forced into a defrost cycle. After the TEST input jumper is removed,
the defrost mode will be terminated as normal. The defrost cycle length
timer will not be started until the TEST input is removed. If the TEST terminals remain shorted, the control will keep the unit in defrost mode.
Defrost Inhibition
The control will not initiate a defrost cycle if the liquid line temperature is
above 40F unless the defrost cycle is forced using the TEST input.
The control will not initiate a defrost cycle when the outdoor ambient
temperature is below –25F or above 55F unless the defrost cycle is
forced using the TEST input.
The control will also prevent a defrost cycle from being initiated too
soon after the initiation of the previous defrost cycle. When power is
applied to the control and after the completion or termination of each
defrost cycle, the control will start a 40-minute timer. When this timer
expires, the control will allow another defrost cycle when needed. The
timer is based on accumulated compressor run time.
Defrost Termination
The control will terminate the defrost cycle immediately after the liquid
line temperature reaches 80F or after eight minutes of defrost operation.
The control will do the following to terminate a defrost cycle.
• Energize the outdoor fan
• De-energize the reversing valve
• De-energize the auxiliary heat output through the W1/66 terminal
• Reset and restart the 40-minute defrost inhibit timer
TABLE 4:
Defrost Initiate Curves
Defrost Curve Selection Jumper Position1234
13 SeerAllNoneNoneNone
REGION C
LIQUID LINE (COIL) TEMPERATURE
Defrost Terminated
REGION E
No call for defrost
Time Defrost (6 hour) prevented
INHIBIT CURVE
REGION B
No call for Defrost
Time Defrost (6 hour) allowed
INITIATE CURVE
TERMINATE CURVE
REGION D
Defrost prevented from starting
REGION A
Call for Defrost
AMBIENT TEMPERATURE
FIGURE 12: Defrost Operation Curves
12Johnson Controls Unitary Products
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359513-UIM-A-0408
COOLING OPERATION
During cooling operation, the control will receive thermostat signals at
the Y and O input terminals. The control will energize the M compressor
output terminal. This signal energizes the coil of the compressor contactor causing the compressor to run. The control also delivers power to
the COND FAN terminals causing the outdoor fan to operate. The control energizes the REV VALVE terminal with 24VAC to switch the
reversing valve.
HEATING OPERATION
During normal heating mode, the control will receive a thermostat signal
at the Y input terminal. The control will energize the M compressor output terminal. This signal energizes the coil of the compressor contactor
causing the compressor to run. The control also delivers power to the
COND FAN terminals causing the outdoor fan to operate. The reversing
valve is not energized in heating mode.
EMERGENCY HEAT
When the thermostat calls for emergency heat operation (W signal without a Y signal), the control will de-energize the compressor and energize the W1/66 terminal immediately.
PRESSURE SWITCH FAULT & LOCKOUT
The heat pump is equipped with a pressure switch and an optional low
pressure switch that are connected to the control at the pressure switch
terminals. If the pressure switch input opens for more than 40 milliseconds, the control will de-energize the compressor. If the pressure switch
closes and a thermostat call for compressor operation is present, the
control will apply the five-minute anti-short cycle delay timer and start
the compressor when the timer expires.
When the compressor is started following a pressure switch fault, the
control will start a six-hour timer based on accumulated compressor run
time. If the control senses another opening of the pressure switch
before the timer expires, it will cause a soft lockout condition. The second opening of the pressure switch must be greater than 160 milliseconds for the lockout to occur. If the second opening is between 40 and
160 milliseconds, the control will de-energize the compressor but not
cause a soft lockout condition. If the control does not sense a second
pressure switch opening before the six-hour timer expires, the timer and
counter will be reset.
During the soft lockout mode, the control will de-energize the compressor and energize the X/L output with the appropriate flash code.
The control will reset the soft lockout condition when any of the following occur following removal of the fault condition.
1.Power is cycled to the R or Y inputs of the control. This will cause
the soft lockout condition to be reset when the thermostat is satisfied or when the thermostat is set to SYSTEM OFF and back to
HEAT or COOL mode.
2.The TEST terminals are shorted for more than two seconds.
When the soft lockout condition is reset, the control will stop displaying
the fault code and will respond to thermostat inputs normally.
INDICATIONS OF PROPER OPERATION
Cooling
Cooling operation is the same as any conventional air conditioning unit.
1.The outdoor fan should be running, with warm air being discharged from the top of the unit.
2.The indoor blower (furnace or air handler) will be operating, discharging cool air from the ducts. Coils or other parts in the air circuit should be cleaned as often as necessary to keep the unit
clean. Use a brush, vacuum cleaner attachment, or other suitable
means.
3.The vapor line at the outdoor unit will feel cool to the touch.
4.The liquid line at the outdoor unit will feel warm to the touch.
Heating
Indications of proper Heating operation is as follows:
1.The outdoor fan should be running, with cool air being discharged
from the top of the unit.
2.The indoor blower (furnace or air handler) will be operating, discharging warm air from the ducts.
3.The vapor line at the outdoor unit will feel warm to the touch.
4.The liquid line at the outdoor unit will feel cool to the touch.
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 operator 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 periods 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.
3.If the coil needs to be cleaned, it should be washed with Calgon
Coilclean (mix one part Coilclean to seven parts water). Allow
solution to remain on coil for 30 minutes before rinsing with clean
water. Solution should not be permitted to come in contact with
painted surfaces.
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.
IT IS UNLAWFUL TO KNOWINGLY VENT, RELEASE OR DISCHARGE 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.