Johnson Controls 18 SEER - CZH, 18 SEER - AC8B, 18 SEER - AL8B series, 18 SEER-CZH SERIES, AC8B SERIES Installation Manual
...
R-410A
INSTALLATION MANUAL
LISTED
ISO 9001
Certified Quality
Management System
OUTDOOR SPLIT-SYSTEM
AIR CONDITIONING
MODELS: 18 SEER - CZH / AC8B / AL8B SERIES
2 TO 5 TONS
TABLE OF CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
TXV INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
LIST OF FIGURES
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Tubing Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Typical Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Communications Harness Connection . . . . . . . . . . . . . . . . . . . . . . . . .6
CFM Selection Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Communicating AC with Communicating Air Handler or Furnace . . . .7
Communicating AC with Non-Communicating Air Handler
or Furnace using Communicating Interface Control . . . . . . . . . . . . . . .7
EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Instructing the Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Thermostat Chart - Two Stage AC –
Two Stage Variable Speed Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . .8
Thermostat Chart - Two Stage AC –
Two Stage Variable Speed Furnaces . . . . . . . . . . . . . . . . . . . . . . . . . .9
Thermostat Chart - Two Stage AC – Variable Speed Furnaces . . . . .10
Thermostat Chart - Two Stage AC – Variable Speed Furnaces . . . . .11
Thermostat Chart - Two Stage AC – Variable Speed Furnaces . . . . .12
Thermostat Chart - Two Stage AC – Variable Speed Furnaces . . . . .13
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
LIST OF TABLES
R-410A Saturation Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
TEST Input Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Operational Mode Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Status Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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 the smallest rated 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 system
combinations, elevation differences, or total line lengths. See Tabular
Data Sheet provided in unit literature packet for charge requirements.
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
.
.
Status Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Operational Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Sensor or Switch Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Wiring Related Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
CAUTION indicates a potentially hazardous situation, which, if not
avoided may result in minor or moderate injury
alert against unsafe practices and hazards involving only property damage.
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.
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 equipment
Must Be Rated for R-410A.
. It is also used to
501562-UIM-A-0909
501562-UIM-A-0909
INSPECTION
As soon as a unit is received, it should be inspected for possible 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.
Requirements For Installing/Servicing R-410A Equipment
• Gauge sets, hoses, refrigerant containers, and recovery systems
must be designed to handle POE oils and the higher pressures of
R-410A.
• Manifold sets should be 800 PSIG high side and 250 PSIG low
side with 550 PSIG 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.
• Do not use an R-22 TXV.
• A liquid-line filter drier is required on every unit.
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. Only variable speed air handlers or variable speed furnaces should
be used with these models.
3. 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.
4. The maximum and minimum conditions for operation must be
observed to ensure a system that will give maximum performance
with minimum service.
5. The unit should not be operated at outdoor temperatures below 60°
F without an approved low ambient operation accessory kit
installed.
6. The maximum allowable line length for this product is 75 feet.
7. Indoor evaporator coil orifice mu
tion of a factory supplied balanced port TXV kit.
st be removed prior to the installa-
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, for air discharge, and for service access. See Figure 1.
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
When this unit is being used as a replacement for an R-22 unit, it is
required that the outdoor unit, indoor coil, and metering device all be
replaced. Line-set change out is also recommended. 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-410A coil with the
appropriate metering device.
2. Change-out of the line-set when replacing an R-22 unit with an
R-410A unit is highly recommended to reduce cross-contamination
of oils and refrigerants.
3. If change-out of the line set is not practical, then the following precautions should be taken.
• Inspect the line set for kinks, sharp bends, or other restrictions,
and for corrosion.
• Determine if there are any low spots which might be serving as oil
traps.
• Flush the line set with a commercially available flush kit to
remove as much of the existing oil and contaminants as possible.
• Install a suction line filter-drier to trap any remaining contaminants, 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
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 suctionline 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.
2 Johnson Controls Unitary Products
FIGURE 1: Typical Installation
THERMOSTAT
NEC CLASS 1
WIRING
TO INDOOR
BLOWER
NEC CLASS 2
WIRING
TO COIL
WEATHERPROOF
DISCONNECT SWITCH
48” OVERHEAD
CLEARANCE
24” SERVICE
ACCESS
CLEARANCE
18” FRONT
& SIDES
NOTE: ALL OUTDOOR WIRING MUST BE WEATHERPROOF
SEAL OPENINGS WITH
PERMAGUM OR EQUIVALENT
501562-UIM-A-0909
GROUND INSTALLA TION
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 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.).
Isolate the unit from rain gutters to avoid any possible wash out of the
foundation.
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.
LIQUID LINE FILTER-DRIER
The air conditioning unit’s copper spun filter/dryer is 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.
Filter-Drier
Source 1 Part No.
029-22195-000 All
Apply with Models
CZH
PIPING CONNECTIONS
This system uses R-410A refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system.
Gauge sets, hoses, refrigerant containers, and recovery systems
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.
The outdoor condensing unit must be connected to the indoor evaporator 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 036-61920-000 for installing tubing of
longer lengths and elevation differences.
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.
Johnson Controls Unitary Products 3
501562-UIM-A-0909
LIQUID
LINE
INCORRECT
CORRECT
TAPE
SHEET METAL
HANGER
INSULATED
VAPOR LINE
TO INDOOR
COIL
TO OUTDOOR
COIL
CAP
INSULATED
VAPOR LINE
LIQUID
LINE
PVC
CONDUIT
4. The vapor line must be insulated with a minimum of 1/2" foam rubber 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.
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 permagum around refrigerant lines where they penetrate a wall to reduce
vibration and to retain some flexibility.
8. See application part number 036-61920-000 for additional piping
information.
PRECAUTIONS DURING BRAZING SERVICE VALVE
Wrap a wet rag around the service valve as shown in Figure 4 to prevent heat damage. 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.
The 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.
FIGURE 2: Tubing Hanger
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 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 ensure an internally clean and dry system.
4 Johnson Controls Unitary Products
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.
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.
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.
501562-UIM-A-0909
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).
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.
10. Evacuate the vapor line, evaporator, and the 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.
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 Page 4 "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
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. Relieve the holding charge by pulling off the rubber cap plug on the
suction manifold line of the coil.
2. After holding charge is completely discharged, loosen and remove
the schraeder cap seal.
3. Loosen and remove distributor cap seal.
4. Install the thermal expansion valve to the orifice distributor assembly 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 additional 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 schraeder fitting and an
additional 1/3 turn to seal.
7. Install the TXV bulb to the vapor line near the equalizer line, using
the bulb clamp(s) furnished with the TXV assembly. Ensure the bulb
is making maximum contact.
a. Bulb should be installed on a horizontal run of the vapor line if
possible. The bulb should be installed on top of the line.
b. If bulb installation is made on a vertical run, the bulb should be
located at least 16 inches from any bend, and on the 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 temperature. 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.
Dry nitrogen should always be supplied through the tubing while it
is being brazed, because the temperature required is high enough
to cause oxidation of the copper unless an inert atmosphere is provided. The flow of dry nitrogen should continue until the joint has
cooled. Always use a pressure regulator and safety valve to insure
that only low pressure dry nitrogen is introduced into the tubing.
Only a small flow is necessary to displace air and prevent oxidation.
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.
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.
The complete connection diagram and schematic wiring label is located
on the inside surface of the unit service access panel.
Johnson Controls Unitary Products 5
501562-UIM-A-0909
CONTROL
WIRING
POWER WIRING
CORNER
COVER
SERVICE
ACCESS
PANEL
COMMUNICATIONS PORT
CONTROL BOARD
COMMUNICATIONS
HARNESS
JUNCTION
BOX
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 bottom of the corner cover. Slide corner
cover down and remove from unit. See Figure 5.
3. Run power wiring from the disconnect switch to the unit.
4. Remove the service access panel to gain access to the unit wiring.
Route wires from disconnect through power wiring opening provided and into the unit control box.
5. Install the proper size time-delay fuses or circuit breaker, and make
the power supply connections.
FIGURE 5: Typical Field Wiring
FIELD CONNECTIONS CONTROL WIRING
(CONVENTIONAL)
1. Route low voltage wiring into bottom of control box. Make low volt-
age wiring connections inside the junction box per Figures 10-15.
2. The complete connection diagram and schematic wiring label is
located on the inside surface of the unit service access panel.
3. Replace the corner cover and service access panel that were
removed in Steps 2 and 4 of the “Field Connections Power Wiring”
section.
NOTE: Ambient temperature sensor should extend below control box
by 1”.
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.
FIELD CONNECTIONS CONTROL WIRING
(SERIAL COMMUNICATION)
1. The Communications Harness is provided with the communicating
thermostat.
2. Route low voltage four conductor shielded thermostat communications harness into junction box and connect to communications
port on control board. See Figure 6.
3. Route low voltage wiring into bottom of control box. Make low voltage wiring connections inside the junction box per Figures 8-9.
4. The complete connection diagram and schematic wiring label is
located on the inside surface of the unit service access panel.
If unit is going to be setup as a communicating system, the conventional wiring must be removed from the Outdoor Control Board, if
not damage to control board or indoor control could occur.
FIGURE 6: Communications Harness Connection
5. Replace the corner cover and service access panel that were
removed in Steps 2 and 4 of the “Field Connections Power Wiring”
section.
NOTE: Ambient temperature sensor should extend below control box
by 1”.
6. 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.
7. 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 Pergamum or equivalent to prevent air drafts affecting
the operation of the thermostat.
6 Johnson Controls Unitary Products
CFM SELECTION BOARD SETTINGS
HEAT
DELAY COOL
ADJUST
A
B
C
D
A
B
C
D
LED 2
R
C
Y1
Y2
Touch Control
Communicating
Control
Air Handler/Furnace
Communicating
Control
Air Conditioner
Communicating
Control
GND
or C
GND
or C
B-
R
A+
GND
or C
GND
or C
B-
R
A+
GND
or C
GND
or C
B-
R
A+
R
C
Y1
Y2
HUM
W2
DHUM
W
G
C
R
O
Y
Y2
HUM
W2
DHUM
W
G
C
R
O
Y
Y2
Touch Control
Communicating
Control
Communicating
Indoor
Interface Control
Non-Communicating
Indoor Unit
Air Conditioner
Communicating
Control
Wire per
non-comm.
installation
manual
Assume that
connections
are from
thermostat
GND
or C
GND
or C
B-
R
A+
GND
or C
GND
or C
B-
R
A+
GND
or C
GND
or C
B-
R
A+
For proper system operation the CFM Selection Board jumpers must be
set properly.
Refer to the Tabular Data Sheet for the recommended air flow settings
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 HUMIDISTAT jumper must also be removed if a dehumidistat is
installed.
If installed as a communicating system (outdoor, indoor and thermostat), the system will automatically adjust to the optimal airflow settings.
These parameters can also be modified using the communicating thermostat. Refer to the communicating thermostat owner’s manual for this
procedure. Manual setting of the airflow jumpers on the ID equipment
is not necessary with the communicating thermostat.
501562-UIM-A-0909
FIGURE 8: Communicating AC with Communicating Air Handler or
Furnace
FIGURE 7: CFM Selection Board
Johnson Controls Unitary Products 7
FIGURE 9: Communicating AC with Non-Communicating Air Handler
or Furnace using Communicating Interface Control
501562-UIM-A-0909
24VAC Humidifier
(Optional)
External Humidistat
(Optional)
Open on Humidity Rise
2
C
24 – Volt Common
Y1
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*PP32U70124
THERMOSTAT
AUX
Auxiliary Heat
R
24 – Volt Hot
(Heat XFMR)
R
24 – Volt Hot
(Cool XFMR)
C
24 – Volt Common
Y1
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*DN22U00124
THERMOSTAT
W2
Second Stage Heat
R
24 – Volt Hot
(Heat XFMR)
R
24 – Volt Hot
(Cool XFMR)
E/W1
Emergency Heat
E/W1
First Stage Heat
TWO STAGE
AIR
CONDITIONER
C
24 – Volt Common
R
24 – Volt Hot
Y1
First Stage Compressor
Y2
Second Stage
Compressor
External Humidistat
(Optional)
Open on Humidity Rise
2
Connection of the “C”
terminal, 24-Volt common
is optional when used with
batteries
Thermostat Installer Setup
0170-System Type-must
be set to 8-2 Heat/2 Cool
Multistage Conventional
Connection of the “C”
terminal, 24-volt common
is optional when used with
batteries
Thermostat Installer Setup
1-System Type-must
be set to 6-2 Heat/2 Cool
Multistage Conventional
Thermostat Installer Setup
15-Compressor Protection
-must be set to 5
Part Number:
S1-2HU16700124
2
Part Numbers:
SAP = Legacy
265904 = 031-09169
1
C
24 – Volt Common
R
24 – Volt Hot
Y1
Single Stage Compressor
TWO STAGE
VARIABLE SPEED
FURNACE CONTROL
G
Fan
TWO STAGE
VARIABLE SPEED
FURNACE
W/W1
First Stage Heat
Y/Y2
Second or Full
Stage Compressor
W2
Second Stage Heat
O
Reversing Valve
X/L
Malfunction Light
DHUM
Dehumidification
1
Move DHUM
jumper to “YES”
if humidistat is to be used.
(G/L)*(8/9)V
(F/L)*(8/9)V
PV(8/9)
ID MODELS
AC 24A Two Stage Air Conditioner – Two Stage Variable Speed Furnace
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.
FIGURE 10: Thermostat Chart - Two Stage AC – Two Stage Variable Speed Furnaces
8 Johnson Controls Unitary Products
AC 24B Two Stage Air Conditioner – Two Stage Variable Speed Furnace
Connection of the “C”
Terminal, 24-Volt Common,
is optional when used with
batteries
Part Numbers:
SAP = Legacy
265904 = 031-09169
1
C
24 – Volt Common
R
24 – Volt Hot
Y1
Single Stage Compressor
TWO STAGE
VARIABLE SPEED
FURNACE CONTROL
G
Fan
TWO STAGE
VARIABLE SPEED
FURNACE
W/W1
First Stage Heat
Y/Y2
Second or Full
Stage Compressor
W2
Second Stage Heat
O
Reversing Valve
X/L
Malfunction Light
DHUM
Dehumidification
1
Move DHUM
jumper to “YES”
if humidistat is to be used.
(G/L)*(8/9)V
(F/L)*(8/9)V
PV(8/9)
ID MODELS
TWO STAGE
AIR
CONDITIONER
C
24 – Volt Common
R
24 – Volt Hot
Y1
First Stage Compressor
Y2
Second Stage
Compressor
External Humidistat
(Optional)
Open on Humidity Rise
24VAC Humidifier
(Optional)
External Humidistat
(Optional)
Open on Humidity Rise
2
2
Part Number:
S1-2HU16700124
2
C
24 – Volt Common
R
24 – Volt Hot
Y
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*DN22C00124
THERMOSTAT
W2
Second Stage Heat
C
24 – Volt Common
R
24 – Volt Hot
Y1
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*DP22U70124
THERMOSTAT
W2
Second Stage Heat
Step 1 of Thermostat User
Configuration Menu must
be set to MS 2
W
First Stage Heat
E/W1
First Stage Heat
Connection of the “C”
Terminal, 24-Volt Common,
is optional when used with
batteries
501562-UIM-A-0909
FIGURE 11: Thermostat Chart - Two Stage AC – Two Stage Variable Speed Furnaces
Johnson Controls Unitary Products 9
501562-UIM-A-0909
AC 26A Two Stage Air Conditioner – Variable Speed Modulating Furnace
C
24 – Volt Common
Y1
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*PP32U70124
THERMOSTAT
AUX
Auxiliary Heat
R
24 – Volt Hot
(Heat XFMR)
R
24 – Volt Hot
(Cool XFMR)
C
24 – Volt Common
Y1
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*DN22U00124
THERMOSTAT
W2
Second Stage Heat
R
24 – Volt Hot
(Heat XFMR)
R
24 – Volt Hot
(Cool XFMR)
E/W1
Emergency Heat
E/W1
First Stage Heat
TWO STAGE
AIR
CONDITIONER
C
24 – Volt Common
R
24 – Volt Hot
Y1
First Stage Compressor
Y2
Second Stage
Compressor
C
24 – Volt Common
R
24 – Volt Hot
Y1
Single Stage Compressor
VARIABLE SPEED
MODULATING
FURNACE CONTROL
G
Fan
VARIABLE SPEED
MODULATING
FURNACE
Y/Y2
Second or Full
Stage Compressor
HUM
Dehumidification-
Open on Humidity Rise
W
Modulating Heat
Part Numbers:
SAP = Legacy
171334 = 031-09153
1
1
Move HUMIDISTAT
jumper to “YES”
if humidistat is to be used.
FL9C
FC9C
PC9
ID MODELS
External Humidistat
(Optional)
Open on Humidity Rise
24VAC Humidifier
(Optional)
External Humidistat
(Optional)
Open on Humidity Rise
2
2
Connection of the “C”
terminal, 24-Volt common
is optional when used with
batteries
Thermostat Installer Setup
0170-System Type-must
be set to 8-2 Heat/2 Cool
Multistage Conventional
Connection of the “C”
terminal, 24-volt common
is optional when used with
batteries
Thermostat Installer Setup
1-System Type-must
be set to 6-2 Heat/2 Cool
Multistage Conventional
Thermostat Installer Setup
15-Compressor Protection
-must be set to 5
Part Number:
S1-2HU16700124
2
FIGURE 12: Thermostat Chart - Two Stage AC – Variable Speed Furnaces
10 Johnson Controls Unitary Products
AC 26B Two Stage Air Conditioner – Variable Speed Modulating Furnace
TWO STAGE
AIR
CONDITIONER
C
24 – Volt Common
R
24 – Volt Hot
Y1
First Stage Compressor
Y2
Second Stage
Compressor
C
24 – Volt Common
R
24 – Volt Hot
Y1
Single Stage Compressor
VARIABLE SPEED
MODULATING
FURNACE CONTROL
G
Fan
VARIABLE SPEED
MODULATING
FURNACE
Y/Y2
Second or Full
Stage Compressor
HUM
Dehumidification-
Open on Humidity Rise
W
Modulating Heat
Part Numbers:
SAP = Legacy
171334 = 031-09153
1
1
Move HUMIDISTAT
jumper to “YES”
if humidistat is to be used.
FL9C
FC9C
PC9
ID MODELS
External Humidistat
(Optional)
Open on Humidity Rise
24VAC Humidifier
(Optional)
External Humidistat
(Optional)
Open on Humidity Rise
2
2
Part Number:
S1-2HU16700124
2
C
24 – Volt Common
R
24 – Volt Hot
Y
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*DN22C00124
THERMOSTAT
W2
Second Stage Heat
C
24 – Volt Common
R
24 – Volt Hot
Y1
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*DP22U70124
THERMOSTAT
W2
Second Stage Heat
W
First Stage Heat
E/W1
First Stage Heat
Step 1 of Thermostat User
Configuration Menu must
be set to MS 2
Connection of the “C”
terminal, 24-Volt common
is optional when used with
batteries
Connection of the “C”
terminal, 24-Volt common
is optional when used with
batteries
501562-UIM-A-0909
FIGURE 13: Thermostat Chart - Two Stage AC – Variable Speed Furnaces
Johnson Controls Unitary Products 11
501562-UIM-A-0909
AC 31A Two Stage Air Conditioner – Variable Speed Air Handler
C
24 – Volt Common
Y1
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*PP32U70124
THERMOSTAT
AUX
Auxiliary Heat
R
24 – Volt Hot
(Heat XFMR)
R
24 – Volt Hot
(Cool XFMR)
Connection of the “C”
terminal, 24-Volt common
is optional when used with
batteries
Thermostat Installer Setup
0170-System Type-must
be set to 8-2 Heat/2 Cool
Multistage Conventional
C
24 – Volt Common
Y1
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*DN22U00124
THERMOSTAT
W2
Second Stage Heat
R
24 – Volt Hot
(Heat XFMR)
R
24 – Volt Hot
(Cool XFMR)
E/W1
Emergency Heat
E/W1
First Stage Heat
Connection of the “C”
terminal, 24-volt common
is optional when used with
batteries
Thermostat Installer Setup
1-System Type-must
be set to 6-2 Heat/2 Cool
Multistage Conventional
COM
24 – Volt Common
R
24 – Volt Hot
W1
First Stage Heat
W2
Second Stage Heat
Y1
Single Stage Compressor
Y/Y2
Second or Full
Stage Compressor
O
Reversing Valve
Energized in Cool
X/L
Malfunction Light
HUM
Humidity Switch
Open on Humidity Rise
VARIABLE SPEED
AIR HANDLER CONTROL
G
Fan
VARIABLE SPEED
AIR HANDLER
1
AV
ID MODELS
SV
MV
EAC (24VAC out)
Electronic Air Cleaner
HUM OUT
(24VAC out)
Humidifier
Part Number:
S1-2HU16700124
2
Part Numbers:
SAP = Legacy
159481 = 031-09157
1
External Humidistat
(Optional)
Open on Humidity Rise
2
24VAC Humidifier
(Optional)
24VAC
Electronic Air Cleaner
(Optional)
TWO STAGE
AIR
CONDITIONER
C
24 – Volt Common
R
24 – Volt Hot
Y1
First Stage Compressor
Y2
Second Stage
Compressor
Move the HUM STAT
jumper to “YES”
if humidistat is to be used.
Refer to AH documentation
for W1 and W2 electric
heat staging options.
Thermostat Installer Setup
15-Compressor Protection
-must be set to 5
FIGURE 14: Thermostat Chart - Two Stage AC – Variable Speed Furnaces
12 Johnson Controls Unitary Products
AC 31B Two Stage Air Conditioner – Variable Speed Air Handler
Connection of the “C”
Terminal, 24-Volt Common,
is optional when used with
batteries
C
24 – Volt Common
R
24 – Volt Hot
Y
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*DN22C00124
THERMOSTAT
W2
Second Stage Heat
C
24 – Volt Common
R
24 – Volt Hot
Y1
First Stage Compressor
Y2
Second Stage
Compressor
G
Fan
*DP22U70124
THERMOSTAT
W2
Second Stage Heat
Step 1 of Thermostat User
Configuration Menu must
be set to MS 2
W
First Stage Heat
E/W1
First Stage Heat
Connection of the “C”
Terminal, 24-Volt Common,
is optional when used with
batteries
COM
24 – Volt Common
R
24 – Volt Hot
W1
First Stage Heat
W2
Second Stage Heat
Y1
Single Stage Compressor
Y/Y2
Second or Full
Stage Compressor
O
Reversing Valve
Energized in Cool
X/L
Malfunction Light
HUM
Humidity Switch
Open on Humidity Rise
VARIABLE SPEED
AIR HANDLER CONTROL
G
Fan
VARIABLE SPEED
AIR HANDLER
1
AV
ID MODELS
SV
MV
EAC (24VAC out)
Electronic Air Cleaner
HUM OUT
(24VAC out)
Humidifier
Part Number:
S1-2HU16700124
2
Part Numbers:
SAP = Legacy
159481 = 031-09157
1
External Humidistat
(Optional)
Open on Humidity Rise
2
24VAC Humidifier
(Optional)
24VAC
Electronic Air Cleaner
(Optional)
TWO STAGE
AIR
CONDITIONER
C
24 – Volt Common
R
24 – Volt Hot
Y1
First Stage Compressor
Y2
Second Stage
Compressor
Move the HUM STAT
jumper to “YES”
if humidistat is to be used.
Refer to AH documentation
for W1 and W2 electric
heat staging options.
501562-UIM-A-0909
FIGURE 15: Thermostat Chart - Two Stage AC – Variable Speed Furnaces
Johnson Controls Unitary Products 13
501562-UIM-A-0909
DEHUMIDIFICATION CONTROL
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 accessory and Figures 7-9. 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.
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 minimum air flow of 325 cfm/ton be supplied at all times.
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, it’s 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
R-410A refrigerant cylinders are rose colored, and have a dip tube
which allows liquid to flow out of the cylinder in the Upright Posi-
tion. Always charge the system slowly with the tank in the upright
position.
The factory charge in the outdoor unit includes enough charge for the
unit, a 15 ft. line set and the smallest rated indoor coil match-up. Some
indoor coil matches may require additional charge. See tabular data
sheet provided in unit literature packet for charge requirements.
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.
Use the following subcooling charging method whenever additional
refrigerant is required for the system charge. A superheat charging
method is not suitable for TXV equipped systems.
Refrigerant charging should only be carried out by a qualified air
conditioning contractor.
Measurement Method
If a calibrated charging cylinder or accurate weighing device is available, add refrigerant accordingly.
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.
Check flare caps on service ports to be sure they are leak tight. DO
NOT OVERTIGHTEN (between 40 and 60 inch - lbs. maximum).
Subcooling Charging Method
This condensing unit must only be used with the matching thermostatic
expansion valve kit listed in the Tabular Data Sheet. This unit must be
charged during second-stage (Y1 & Y2) operation only. Charging
should be matched per the subcooling chart located on the rating plate.
For mix matched systems, the recommended subcooling is 10°F
1. Set the system running in the Second-Stage (Y1 + Y2) 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 tech guide for the recommended airflow and verify this
indoor airflow.
4. Measure the liquid refrigerant pressure P and temperature T at the
service valve.
5. Calculate the saturated liquid temperature ST from Table 1.
6. Subcooling temperature TC = Saturated Temperature (ST) - Liquid
Temp (T).
Do not leave the system open to the atmosphere. Unit damage
could occur due to moisture being absorbed by the POE oil in the
system. This type of oil is highly susceptible to moisture absorption.
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.
Example: The pressure P and temperature T measured at the liquid
service port is 360 Psig and 93°F. From Table 1, the saturated temperature for 360 Psig is 109°. The subcooling temperature TC =
109°-93°=16°F
Add charge if the calculated subcooling temperature TC in Step 6 is
lower than the recommended level. Remove and recover the refrigerant
if the subcooling TC is higher than the recommended level. See T able 1
for R-410A saturation temperatures.
14 Johnson Controls Unitary Products
501562-UIM-A-0909
SECTION VIII: INSTRUCTING THE OWNER
Assist owner with processing warranty cards and/or online registration.
Review Owners Manual, provide a copy to the owner, and provide guidance on proper operation and maintenance. Instruct the owner or the
operator how to start, stop, and adjust temperature setting.
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.
NOTE: The outdoor fan motor is a permanent magnet DC brushless
type. The motor requires a separate Electronic Control to operate. Do
not attempt to replace this motor with a typical PSC type. Damage to
Electronic Control may result.
TABLE 1:
R-410A Saturation Properties
TEMP. °F
45 129.70 60 169.60 75 217.40 90 274.10 105 340.50
46 132.20 61 172.60 76 220.90 91 278.20 106 345.30
47 134.60 62 175.50 77 224.40 92 282.30 107 350.10
48 137.10 63 178.50 78 228.00 93 286.50 108 355.00
49 139.60 64 181.60 79 231.60 94 290.80 109 360.00
50 142.20 65 184.60 80 235.30 95 295.10 110 365.00
51 144.80 66 187.70 81 239.00 96 299.40 111 370.00
52 147.40 67 190.90 82 242.70 97 303.80 112 375.10
53 150.10 68 194.10 83 246.50 98 308.20 113 380.20
54 152.80 69 197.30 84 250.30 99 312.70 114 385.40
55 155.50 70 200.60 85 254.10 100 317.20 115 390.70
56 158.20 71 203.90 86 258.00 101 321.80 116 396.00
57 161.00 72 207.20 87 262.00 102 326.40 117 401.30
58 163.90 73 210.60 88 266.00 103 331.00 118 406.70
59 166.70 74 214.00 89 270.00 104 335.70 119 412.20
PRESSURE
PSIG
TEMP. °F
PRESSURE
PSIG
TEMP. °F
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.
PRESSURE
PSIG
TEMP. °F
PRESSURE
PSIG
TEMP. °F
PRESSURE
PSIG
ANIT-SHORT CYCLE DELAY
The control includes a five-minute anti-short cycle delay (ASCD) timer
to prevent the compressor from short cycling after a power interruption
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 (Y1 input signal energized).
LOW VOLTAGE DETECTION
The control monitors the transformer secondary (24 VAC) voltage and
provides low voltage protection for the AC unit and its components. In
particular, the control prevents cont actor chatter during low volt age 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. The control will store and display the
appropriate fault codes when low voltage conditions occur.
TEST INPUT
The control includes a TEST input connector that can be used for various testing functions during installation and service. Table 2 summarizes the behavior of the control when the two TEST pins are
connected.
Johnson Controls Unitary Products 15
501562-UIM-A-0909
TABLE 2:
connection (seconds)
Connection not removed Nothing more than previously explained
TEST Input Functionality
Duration of
< 2 No response No response
2 <
Connection removed Resume normal LED display
Control Behavior with no system
master signals present
Display compressor type TS, Ultratech, or
single stage compressor, Ignore LPS
Clear soft lockout Clear soft lockout
Clear hard lockout Clear hard lockout
Reset TS anticipation mode counter
to zero for TS systems.
LED DIAGNOSTIC INDICATORS
The control includes two LED’s that display diagnostic information.
LED1 is red and LED2 is green. These LED’s are used to display operational mode, fault information. A third LED, LED3 is used to display
status information. LED3 is yellow. These LED’s are used to display
operational mode, status, and fault information.
OPERATIONAL MODE DETECTION
The control can be used in a variety of applications including AC units
with multistage compressors. The control uses various inputs to determine the proper mode of operation.
The control senses the connections that are made to M, M1, and M2
terminals and determines the correct operational mode for the control.
This is done each time power to the control is cycled. Therefore, it is
important that no loads be attached to the M1 or M2 terminals of the
control for single-stage compressors, and no loads be attached to the
M1 terminal of the control for a scroll two-stage compressor.
Control behavior with system
master signals present
Bypass ASCD (Reduce timer to zero immediately).
If Y1 (thermostat or communication) is present and the
high-pressure switch is closed, contactors will be energized.
Reset TS anticipation mode counter
to zero for TS systems.
Reduce TS staging delays for TS
systems as described below.
OPERATIONAL MODE DISPLAY
The control will display its active operational mode using the onboard
LED’s when the TEST pins are connected while no thermostat signals
are energized. Table 3 describes the operational modes. The control
will display the operational mode as long as the TEST pins are shorted
and no thermostat signals are energized. When the TEST pin short is
removed, the control will return to normal LED displays.
TABLE 3:
Compressor Type LED1 (Red) LED2 (Green)
Single Stage Compressor 1 flash --TS Compressor 2 flashes --UltraTech Compressor 3 flashes ---
Operational Mode Display
STATUS CODE DISPLAY
The control also provides status codes using the LED’s. Status codes
indicate the state of the operation of the unit but do not represent a
fault. Tables 4 & 5 describes the LED displays during status codes.
Status codes will not be displayed when a fault code is present.
Do not connect any loads to the M1 or M2 terminals of the control
for single-stage compressors, and no loads should be attached to
the M1 terminal of the control for scroll two-stage compressor.
Incorrect system behavior could result.
TABLE 4:
Description Required Condition LED1 (Red) LED2 (Green)
No power to control No power to control OFF OFF
First-stage compressor operation – TS or UltraTech
Second-stage compressor operation - TS, UltraTech, or
Single Stage
Control normal operation – no communication or call for
compressor present
Control normal operation – in ASCD period
TABLE 5:
Description Required Condition LED3 (Yellow)
Control normal operation – with active communication present System is active and presently communicating successfully.
Control powered – without active communication present System has 24 VAC present and the microprocessor is active. 2s ON / 2s OFF
Status Code Display
Status Cod e Display
TS – M & M1 energized,
UltraTech – M energized,
Single Stage - NA
TS and UltraTech – M & M2 energized,
Single Stage – M energized
No faults active, Y1 or Y2 not present OFF 2s ON / 2s OFF
No faults active, Y1 or Y2 present,
ASCD timer not expired
OFF ON
ON ON
OFF
0.1 sec ON /
0.1 sec OFF
0.1 sec ON /
0.1 sec OFF
16 Johnson Controls Unitary Products
501562-UIM-A-0909
FAULT CODE DISPLAY
The control will display any fault code that is currently active using the
LED’s. The control will display the fault code, pause two seconds, and
display the fault again. The control will continue the fault code display
until the condition that caused the fault code no longer exists. If multiple fault codes are present at the same time, the control will display only
the most recent fault.
Table 6 describes the operational faults that the control can detect. The
control displays these types of errors by flashing the LED1 (Red) and/or
LED2 (Green).
TABLE 6:
Description
Control Failure ON OFF
Operational Faults
High-pressure switch fault (not in
lockout yet)
System in high-pressure switch
lockout
System in low-pressure switch
lockout
Low Voltage (<19.2VAC) preventing
further relay outputs
Low Voltage (<16 VAC) stopped
current relay outputs
High-pressure switch fault (with no
communication for compressor
operation and where Y1 and Y2
are not energized)
Operational Fault Codes
LED1 Flash
Code (Red)
1OFF
2OFF
4OFF
5OFF
6OFF
9ON
LED2 Flash
Code (Green)
SENSOR OR SWITCH FAULT CODES
Table 7 describes the faults that the control can detect when a problem
is present with a sensor or switch. The control displays this type of
error by energizing LED1 (Red) constantly and flashing LED2 (Green).
These faults typically occur when an AC unit has been operating and a
problem occurs with a sensor or its wiring. These faults could also
occur during installation as the AC unit is configured.
TABLE 7:
Description
Outdoor ambient temperature
sensor failure (short)
Outdoor ambient temperature
sensor failure (open)
Sensor or Switch Fault Codes
LED1 Flash
Code (Red)
ON 1
ON 2
LED2 Flash
Code (Green)
WIRING RELATED FAUL T CODES
Table 8 describes the faults that the control can detect when a problem
is present with the system wiring or jumper configurations. The control
displays this type of error by flashing LED1 (Red) and energizing LED2
(Green) constantly . These fault s typically occur when the AC unit is first
installed or when a system component such as the room thermostat or
indoor unit is replaced or rewired.
TABLE 8:
Description
Compressor contactor miswire 1 ON
Y2 present without Y1 2 ON
Wiring Related Fault Codes
LED1 Flash
Code (Red)
LED2 Flash
Code (Green)
LOCKOUT MODES
Soft Lockout
The control will cause a soft lockout during the following conditions.
Detailed descriptions of the conditions required for the control to enter
the soft lockout mode are contained in other sections of this document.
1. High-pressure switch
a. Two openings within six hours
2. Low-pressure switch
a. One opening of the switch for more than five seconds except
under certain conditions.
During the soft lockout mode, the control will do the following.
1. De-energize the compressor contactor outputs (M, M1, & M2).
2. Energize the LED’s with the appropriate flash codes as described
elsewhere in this document.
3. In communication applications the fault code will be stored in the
thermostat. (This feature is not available for non communicating
applications)
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 Y1 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.
Hard Lockout
If four soft lockouts occur within a twelve-hour period, the control will
cause a hard lockout condition. These soft lockouts can be caused by
the same or different conditions. The control will function in the same
way during soft and hard lockout conditions. The difference is in the
requirements for resetting the lockout condition. The control will reset
the hard lockout condition when any of the following occur following
removal of the fault condition.
1. Power is removed from the R input of the control.
2. The TEST terminals are shorted for more than two seconds.
A hard lockout condition will not be reset when the thermostat is satisfied or when the thermostat is set to SYSTEM OFF and back to HEAT
or COOL mode. Power (24 VAC) to the control must be removed and
reapplied.
When the hard lockout condition is reset, the control will de-energize
the LED’s and respond to inputs/communication normally.
Wiring or Setting Related Lockouts
The control will not operate the compressor when the following faults
occur. These faults can be reset using the same methods used to reset
a soft lockout. However, two occurrences of these faults will not cause
a hard lockout condition.
1. Presence of Y2 thermostat signal without Y1.
If a compressor wiring error is detected, the control will not operate the
compressor. Once the compressor wiring error has been detected,
power (24 VAC) must be cycled to the control for the control to sense
the wiring change and clear the lockout condition.
Johnson Controls Unitary Products 17
501562-UIM-A-0909
COOLING OPERATION
First-Stage Cooling Operation
During first-stage cooling operation, the control will receive a thermostat
signal at the Y1 terminal. The control will energize the M compressor
output terminal. This signal energizes the coil on the compressor contactor causing the compressor to run.
Second Stage Cooling Operation
During second-stage cooling operation, the control will receive a thermostat signal from Y1 and Y2 inputs. The control will energize both the
M and M2 compressor output terminals. The M signal energizes the
compressor contactor causing the compressor to run. The M2 signal
applies 24VAC to the rectifier plug for the compressor solenoid allowing
the compressor to operate in second stage.
HIGH-PRESSURE SWITCH FAULT
The AC Unit is equipped with a high-pressure switch that is connected
to the control at the HPS terminals. If the high-pressure switch opens
for more than 40 milliseconds, the control will de-energize the compressor and store and display the appropriate fault code. 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. The control will ignore the
high pressure switch for 10 seconds following a call for compressor
operation to avoid nuisance errors. If a call for compressor operation is
initiated while the high-pressure switch is open, the control will use the
logic associated with a high-pressure switch opening during a call for
compressor operation.
When the compressor is started following a high-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 high-pressure
switch before the timer expires, it will cause a soft lockout condition.
The second opening of the high-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 high-pressure switch opening before the six-hour timer
expires, the timer and counter will be reset.
LOW-PRESSURE SWITCH FAULT
The AC unit is equipped with a low-pressure switch which is connected
to the control at the LPS terminals. If the low-pressure switch opens for
more than five seconds, the control will cause a soft lockout condition
and display the appropriate fault codes. If the control experiences multiple soft lockouts the control will enter a hard lockout as described in
another section of this document. However, the control will ignore the
low pressure switch input and not cause a soft lockout condition if it
opens during the following conditions.
• First two minutes of compressor operation.
• While TEST input pins are shorted while any thermostat input Y1
or Y2 signal is being received.
OUTDOOR AMBIENT TEMPERATURE SENSOR
Ambient temperature sensor is used in communication applications
only. It is used to display outdoor temperature to the home owner via
the communicating thermostat.
• Has no effect on operation.
• Not required for operation, but a fault code will be displayed when
sensor is not connected or if sensor is shorted.
18 Johnson Controls Unitary Products
SECTION IX: WIRING DIAGRAM
501562-UIM-A-0909
FIGURE 16: Wiring Diagram
Johnson Controls Unitary Products 19
NOTES
Subject to change without notice. Published in U.S.A. 501562-UIM-A-0909
Copyright © 2009 by Johnson Controls, Inc. All rights reserved. Supersedes: 347269-UIM-A-0108
Johnson Controls Unitary Products
5005 York Drive
Norman, OK 73069
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