INSTALLATION MANUAL
®
R-410A VARIABLE CAPACITY
OUTDOOR SPLIT-SYSTEM
AIR CONDITIONING
MODELS: 20 SEER
YXV, AC21, AL21 SERIES
2 – 5 TONS – 1 PHASE
LIST OF SECTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
LIST OF FIGURES
Typical Installation Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Alternative Installation Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation of Vapor Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Outdoor Unit Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Typical Communicating Field Wiring (Air Handler / Furnace) . . . . . . .7
Demand Response Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OUTDOOR SCREEN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTRUCTING THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
CHARGING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
System Charging Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Main Outdoor Control and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Outdoor Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Ton Inverter Drive LED Location . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3 & 4 Ton Inverter Drive LED Location . . . . . . . . . . . . . . . . . . . . . . . 19
5 Ton Inverter Drive LED Location . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wiring Diagram - 2 Ton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Wiring Diagram - 3-5 Ton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LIST OF TABLES
Minimum / Maximum Operating Limit Conditions . . . . . . . . . . . . . . . . .2
Allowable Vertical Linesets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TEST Mode Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Same Priority Fault Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Status Code Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Outdoor Display Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
IMPORTANT
It is recommended before starting the system to connect the
thermostat to Wi-Fi using a local network or portable hot-spot
so the thermostat and system receive the latest software
updates to optimize system performance.
!
CAUTION
The EEV is factory installed but shipped in the closed position.
Prior to any brazing, power must be applied to the Indoor Unit. If
installing a coil furnace match or multi-piece air handler system,
the EEV harness must be plugged into the Comm port prior to
applying power to the indoor unit. Allow
open to allow proper nitrogen flow through the coil and lineset. If
you are not able to power the indoor unit before brazing the line
set, a tool to manually open the EEV is available through Source
1 under part number S1-02649686000.
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 a nominal sized matching indoor coil plus 15 feet of
field-supplied lines.
1 minute for the EEV to
Outdoor Control Faults/Status Code Display . . . . . . . . . . . . . . . . . . 12
Inverter Drive Fault/Status Code Display . . . . . . . . . . . . . . . . . . . . . 16
Thermistor Resistance vs Temperature Table . . . . . . . . . . . . . . . . . 21
Sensor Connector Pin Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Low Suction Pressure Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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,
WARNING indicates a potentially hazardous situation, which, if not
avoided,
CAUTION indicates a potentially hazardous situation, which, if not
avoided
alert against unsafe practices and hazards involving only property damage.
will result in death or serious injury.
could result in death or serious injury.
may result in minor or moderate injury. It is also used to
!
WARNING
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.
Johnson Controls Unitary Products 5284792-UIM-D-1017
5284792-UIM-D-1017
!
CAUTION
This product must be installed in strict compliance with the
enclosed installation instructions and any applicable local, state,
and national codes including, but not limited to building, electrical,
and mechanical codes.
!
CAUTION
R-410A systems operate at higher pressures than R-22 systems.
Do not use R-22 service equipment or components on R-410A
equipment. Service equipment
Must Be Rated for R-410A.
INSPECTION
As soon as a unit is received, it should be inspected for possible damage during transit including copper distributor lines that may have shifting during transit, and are touching either copper lines or the cabinet. If
damage is evident, the extent of the damage should be noted on the
carrier’s delivery receipt. A separate request for inspection by the carrier’s agent should be made in writing. See Local Distributor for more
information.
Requirements For Installing/Servicing R-410A Equipment
• Gauge sets, hoses, refrigerant containers, and recovery system
must be designed to handle the POE type oils, and the higher
pressures of R-410A.
• Manifold sets should be high side and low side with low side
retard.
• All hoses must have a 700 psig service pressure rating.
• Leak detectors should be designed to detect HFC refrigerant.
• Recovery equipment (including refrigerant recovery containers)
must be specifically designed to handle R-410A.
LIMITATIONS
The unit should be installed in accordance with all National, State and
Local Safety Codes and the limitations listed below:
1. Limitations for the indoor unit, coil, and appropriate accessories
must also be observed.
2. The outdoor unit must not be installed with any duct work in the air
stream. The outdoor fan is the propeller type and is not designed to
operate against any additional external static pressure.
3. The maximum and minimum conditions for operation must be
observed to ensure a system will give maximum performance with
minimal service.
TABLE 1: Minimum / Maximum Operating
AIR TEMPERATURE AT
OUTDOOR COIL, °F (°C)
Min. Max. Min. Max.
DB Cool DB Cool WB Cool WB Cool
35(2)* 125(52)* 57(14) 72(22)
Limit
Conditions
AIR TEMPERATURE AT
INDOOR COIL, °F (°C)
*Reference the NOTICE under the “Unit Reduced Capacity Conditions”
section.
4. The maximum allowable equivalent line length for this product is 80
feet.
Standard Lineset Applications
Maximum allowable lineset varies depending on the vertical separation
between the evaporator and condenser. See Table 2 for allowable line
set lengths and sizing.
TABLE 2:
Model
Unit Reduced Capacity Conditions
Allowable Vertical Linesets
Liquid
Suction
Line
Line
24
36
48
60
3/4”
3/8”
7/8”
Max Line
Length Units on
Equal Level
80 feet 25 feet 25 feet
Max Suction
Line Riser - If
OD Unit is
Above ID Unit
Max Liquid
Line Riser - If
OD Unit is
Below ID Unit
NOTICE
Inverter Temperature Protection
If excessive inverter temperatures are sensed, the compressor speed
/ capacity is reduced until an acceptable condition is reached.
When the inverter temperature returns to an acceptable level, the
system returns to normal operation.
Over / Under Current Protection: If a low or high Current Condition
is sensed, the compressor speed / capacity is reduced until an
acceptable current level is reached.
When the system reaches an acceptable current level, the compressor and fan return to normal operating conditions.
Over / Under Voltage Protection: If a low or high supply Voltage
Condition is experienced (below 187 VAC or above 265 VAC), the
compressor speed / capacity is automatically reduced until an acceptable voltage level is sensed.
When an acceptable voltage level is sensed, the system automatically returns to a normal state of operation.
High Altitude Protection: If the unit is installed in Altitudes of 6,500
ft / 2,000 m above sea level or higher, the compressor and outdoor
fan reduce speeds to protect the system. It is not recommended
these units be installed at altitudes greater than 6,500 ft / 2,000 m
above sea level.
Low Ambient Protection
Cooling Mode: The unit automatically adjusts to maintain cooling
operation in outdoor ambient conditions down to 35 °F (2 °C). The
unit reduces capacity and Low Ambient Protection (cooling mode) or
cycles off if asked to provide cooling when the outdoor temperature is
at or below these conditions.
SECTION III: UNIT INSTALLATION
LOCATION
Before starting the installation, select and check the suitability of the
location for both the indoor and outdoor unit. Observe all limitations and
clearance requirements.
The outdoor unit must have sufficient clearance for air entrance to the
condenser coil, air discharge, and service access. See Figure 1.
NOTICE
For multiple unit installations, units must be spaced a minimum of 24”
(61 cm) apart (coil face to coil face).
If the unit is to be installed on a hot sun exposed roof or a paved ground
area that is seasonally hot, the unit should be raised sufficiently above
the roof or ground to avoid taking the accumulated layer of hot air into
the outdoor unit (which can cause the unit to derate prematurely).
If the system is being installed during seasonally cold weather of 55°F
or below, the preferred method is to weigh in the charge. For charging
or checking the system charge at 55
Cold Weather Charging” procedures near the end of SECTION VI:
SYSTEM CHARGE. There is an “Optional Cold Weather Charging”
accessory kit to prevent the outdoor unit from taking in cold air below
55°F. The kit part number can be found in the list of accessory kits on
the UPGNET web site.
Provide adequate structural support for the unit.
°F or below, refer to the “Optional
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ADD-ON REPLACEMENT/RETROFIT
When this unit is being used as a replacement for an existing R-410A
unit, these are matched systems and the indoor coil and outdoor unit
must be replaced. The following steps should be performed in order to
insure proper system operation and performance. Line-set change out
is also recommended.
1. Change-out of the indoor coil to an approved R-410A coil / air handling unit combination with the appropriate metering device.
2. Change-out of the line-set when replacing an R-22 unit with an
R410-A unit is highly recommended to reduce cross-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 contami-
nants, and remove after 50 hours of operation.
4. If the outdoor unit is being replaced due to a compressor burnout,
then installation of a 100% activated alumina suction-line filter drier
in the suction-line is required, in addition to the factory installed biflow 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.
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.
The unit must be installed in as level a position as possible while maintaining the clearances shown in Figure 2.
Normal operating sound levels may be objectionable if the unit is placed
directly under windows of certain rooms (bedrooms, study, etc.).
!
WARNING
The outdoor unit should not be installed in an area where mud or ice
could cause personal injury.
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.
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.
WALL MOUNT INSTALLATION
Care must be taken to mount the outdoor unit on a solid base that is
sloped to shed water, secure from settlement, and is isolated from the
structural foundation or walls to prevent sound and vibration transmission into the living space.
On occasion, site conditions may require direct wall mounted brackets
to be used to locate and support the outdoor unit. In these applications,
care must be taken to address unit base pan support, structural integrity, safe access and serviceability, as well as the possible sound and
vibration transmission into the structure. Wall mounting requires 3
mounting brackets and best served by a properly engineered solution.
See price pages for specific part number for your application.
UNIT PLACEMENT
1. Provide a base in the pre-determined location.
2. Remove the shipping carton and inspect for possible damage.
3. Ensure that compressor tie-down bolts 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.
!
CAUTION
Failure to use the same as the original factory drier or using a substitute drier or a granular type may result in damage to the equipment.
NOTICE
Replacements for the liquid line drier must be exactly the same as
marked on the original factory drier. See Source 1 for O.E.M. replacement driers.
R-410A Filter-Drier Source 1 Part No. Apply with Models
S1-02922195000 All
PIPING CONNECTIONS
The outdoor condensing unit must be connected to the indoor evaporator coil using field supplied refrigerant grade (ACR) copper tubing that is
internally clean and dry. Units should be installed only with the tubing
sizes for approved system combinations as specified in tabular data
sheet. The charge given is applicable for total tubing lengths up to 15
feet (4.6 m).
NOTICE
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.
!
WARNING
Never install a suction-line filter drier in the liquid line of an R-410A
system. Failure to follow this warning can cause a fire, injury or death.
!
CAUTION
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 system must
be designed to handle R-410A. If you are unsure, consult the equipment manufacturer.
PRECAUTIONS DURING LINE INSTALLATION
Install the refrigerant 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.
1. The lines should be installed so that they will not obstruct service
access to the coil, air handling system, or filter.
2. Care must also be taken to isolate the refrigerant lines to minimize
noise transmission from the equipment to the structure.
3. 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, high temperatures, or excessive humidity
must also be insulated.
4. Tape and suspend the refrigerant lines as shown. DO NOT allow
tube metal-to-metal contact. See Figure 3.
4 Johnson Controls Unitary Products
5284792-UIM-D-1017
5. Use PVC piping as a conduit for all underground installations as
shown in Figure 4. 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.
Sheet Metal Hanger
Liquid
Line
Incorrect
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A0151-001
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Insulated Vapor Line
FIGURE 3: Installation of Vapor Line
6. 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.
TO IND
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VAPOR LINE
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 5. Also, protect all
painted surfaces, insulation, and plastic base during brazing. After brazing, cool joint with wet rag.
!
WARNING
This is not a backseating valve. The service access port has a valve
core. Opening or closing valve does not close service access port.
If the valve stem is backed out past the chamfered retaining wall, the
O-ring can be damaged causing leakage or system pressure could
force the valve stem out of the valve body possibly causing personal
injury.
Valve can be opened by removing the service valve 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, allow nitrogen to flow.
2. Braze the liquid line to the liquid service valve at the outdoor unit. Be
sure to wrap the valve body with a wet rag. Allow the nitrogen to
continue flowing.
3. Carefully remove the plugs from the evaporator liquid and vapor
connections at the indoor coil.
A0152-001
FIGURE 4: 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, silver solder or equivalent. DO NOT use soft solder. The
outdoor units have reusable service valves on both the liquid and vapor
connections. The system refrigerant charge for 15 feet of lineset 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.
!
CAUTION
Dry nitrogen should always be supplied through the tubing while it is
being brazed, because the temperature required is high enough to
cause oxidation of the copper unless an inert atmosphere is 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.
!
CAUTION
The EEV is factory installed but shipped in the closed position.
Prior to any brazing, power must be applied to the Indoor Unit. If
installing a coil furnace match or multi-piece air handler system,
the EEV harness must be plugged into the Comm port prior to
applying power to the indoor unit. Allow 1 minute for the EEV to
open to allow proper nitrogen flow through the coil and lineset. If
you are not able to power the indoor unit before brazing the line
set, a tool to manually open the EEV is available through Source
1 under part number S1-02649686000.
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FIGURE 5: Heat Protection
!
CAUTION
Do not install any coil with a furnace which is to be operated during
the heating season without attaching the refrigerant lines to the coil.
The coil is under pressure which must be released to prevent excessive pressure build-up and possible coil damage.
4. Power must be applied to the indoor unit.Allow 1 minute for the EEV
to open to allow proper nitrogen flow through the coil and line-set.
5. 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.
6. Braze the liquid line to the evaporator liquid connection. Nitrogen
should be flowing through the evaporator coil.
7. Slide the grommet away from the vapor connection at the indoor coil
and wrap with a wet rag as shown in Figure 5. Braze the vapor line
to the evaporator vapor connection. After the connection has
cooled, slide the grommet back into original position. After this connection has cooled, remove the nitrogen source from the liquid fitting service port.
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Johnson Controls Unitary Products 5
5284792-UIM-D-1017
8. Replace the Schrader core in the liquid and vapor valves.
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).
NOTICE
Line set and indoor coil can be pressurized to 250 psig with dry nitrogen and leak tested with a bubble type leak detector. Then release
the nitrogen charge.
Do not use the system refrigerant in the outdoor unit to purge or leak
test.
10.Evacuate the vapor line, evaporator, and liquid line to 500 microns
or less.
11.Replace cap on service ports. Do not remove the flare caps from the
service ports except when necessary for servicing the system.
!
CAUTION
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 service valve cap and with an
Allen wrench back out counter-clockwise until valve stem just
touches the chamfered retaining wall. If the service valve is a ball
valve, use a Crescent wrench to turn valve stem one-quarter turn
counterclockwise to open. Do not overturn or the valve stem may
break or become damaged. See “PRECAUTIONS DURING BRAZING SERVICE VALVE”.
13.Replace service valve cap finger tight, then tighten an additional 1/2
turn (1/2 hex flat). Cap must be replaced to prevent leaks.
!
WARNING
Never attempt to repair any brazed connections while the system is
under pressure. Personal injury could result.
14.See Section VI “System Charge” section for checking and recording
system charge.
SECTION IV: EVACUATION
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 V: ELECTRICAL CONNECTIONS
GENERAL INFORMATION & GROUNDING
The control box cover is held in place with 5 screws (one screw near
each lower corner, one each at the midpoint of each side and one at top
middle).
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.
!
CAUTION
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. An example of
typical field connections can be found in Figure 7.
FIELD CONNECTIONS POWER WIRING
1. Install the proper size weatherproof disconnect switch outdoors and
within sight of the unit, per local code.
2. Remove the screws at the top and sides of the corner cover. Slide
the control box cover down and remove from unit.
3. Run power wiring from the disconnect switch to the unit.
4. Route wires from disconnect through power wiring exit provided and
into the unit control box as shown in Figure 1 and view the openings
in Figure 6.
5. Make the power supply connections to the supplied terminal block.
DO NOT connect the “R” terminal of unit control board.
MAIN
CONTROL
BOARD
OUTDOOR
DISPLAY
ACCESS PANEL
SWITCH
OUTDOOR
REACTOR/CHOKE
OUTDOOR FILTER
CONTROLLER
(May not be used
on all units)
LOW VOLTAGE
FIELD WIRING BOX
AMBIENT
TEMPERATURE
SENSOR
FIGURE 6: Outdoor Unit Control Box
TRANSFORMER
INVER
DR
TERMINAL
BLOCK
GROUND LUG
FIELD WIRING
HIGH VOLTAGE
CONDUITPLATE
HIGH VOLTAGE
FIELD WIRING
IVE
TER
A0770-001
FIELD CONNECTIONS CONTROL WIRING
1. Route low voltage wiring into bottom of control box through the hole
inside the low voltage box. Connect low voltage wiring inside the low
voltage box by clipping and discarding the connector plug and stripping the low voltage wires. See Figure 6.
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 of the FIELD
CONNECTIONS POWER WIRING procedures.
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. Keep the low voltage wiring 4" or
more away from the high voltage wires that are leaving the control
box. If this isn't possible, install shielded low voltage wiring to
reduce EMI risk.
6 Johnson Controls Unitary Products
5284792-UIM-D-1017
NOTICE
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.
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FIGURE 7: Typical Communicating Field Wiring (Air Handler / Furnace)
Demand Response (Load Shedding)
The main outdoor control has a conventional 24VAC input (DR) for utility demand response signals. When a 24VAC signal is present on the
DR input the HX
point by the user selected setting. For further details on available settings, please refer to the HX
TM
thermostat will adjust the indoor temperature set-
TM
thermostat installation and operation
manual. The DR input terminal location can be found in Figure 10 and
typical wiring is found in Figure 8.
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FIGURE 8: Demand Response Wiring
SECTION VI: SYSTEM CHARGE
After completion of system connections, apply power to the system, it is
recommended before starting the system to connect the thermostat to
Wi-Fi using a local network or portable hot-spot so the thermostat and
system receive the latest software updates to optimize system performance. Utilize the Hx
TM
thermostat to “discover” the system compo-
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nents and identify the Indoor and Outdoor Communicating Equipment.
AVV air handler or MVC modular blower with electric heat. Inputs to air
handler control board come from the thermostat which are communicated from the main control of the outdoor unit. This maintains proper
sensible/latent balance during cooling and proper discharge temperature during heating.
Proper indoor unit airflow is determined by the system and requires no
initial set-up by the installing contractor unless using an AVV or MVC
modular blower air handler with electric heat. If a unit is using electric
heat, the unit must have the electric heat airflow set at the air handler
control board.
After the system is started during the initial set-up process using the
TM
thermostat, additional fine tuning of the airflow is accomplished by
Hx
selecting on of the three operating profiles. The three operating profiles
include: humid, dry or normal. Select the one that best reflects the outdoor environment where the conditioned space is located. This selection adjusts the how the indoor blower and the compressor work
together to manage temperature and humidity. Additional fine tune
adjustments are available using the Hx
TM
thermostat. Refer to the Hx
TM
thermostat manual for additional detail.
The proper airflow is determined by the main outdoor control in the out-
door unit.
!
CAUTION
If the outdoor temperature is below 55°F, an attempt to start the compressor without at least 2 hours of crankcase/stator heat can damage
the compressor.
!
CAUTION
Refrigerant charging should only be carried out by a licensed qualified air conditioning contractor.
To ensure that your unit performs at the published levels, it is important
that the indoor airflow is determined and refrigerant charge added
accordingly.
Johnson Controls Unitary Products 7
5284792-UIM-D-1017
CHARGING THE UNIT
The factory charge in the outdoor unit includes enough charge for the
unit, 15 ft. (4.6 m) of refrigerant piping, and the smallest indoor coil/air
handler match-up. Some indoor coil / air handler matches may require
additional charge.
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FIGURE 9: System Charging Connections
!
CAUTION
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.
!
CAUTION
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.
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TOTAL SYSTEM CHARGE DETERMINED
1. Determine outdoor unit factory charge from Tabular Data Sheet.
2. Determine indoor coil adjustment (if any) from Tabular Data Sheet.
3. Calculate the additional charge for refrigerant piping using the Tabular Data Sheet if line length is greater than 15 feet (4.6 m).
4. Total system charge = item 1 + item 2 + item 3.
5. The manifold gauge set is already installed on the unit for evacuation and charging. Use these gauges to initially charge the system
using system pressures and subcooling. Before charging put the
equipment into “Service Mode” at the outdoor control. You will find
the charging information for charging mode printed on the bottom of
the unit data tag. Charging data for cooling & heating mode is found
on Page 21 of this manual or available in the “Service Data Application Guide”, available online. For subsequent annual maintenance
visits the charge verification display can be used to quickly check
overall system condition and the system charge without attaching a
separate manifold gauge set or temperature sensors.
6. Permanently mark the unit data plate with the total amount of refrigerant in the system.
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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.
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CAUTION
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!
WARNING
DO NOT attempt to pump “Total System Charge” into outdoor unit for
maintenance, service, etc. This may cause damage to the compressor and/or other components. Recover and weigh “System Charge”
into an appropriate recovery cylinder for any instances requiring
evacuation.
8 Johnson Controls Unitary Products
$
FIGURE 10: Main Outdoor Control and Display
5284792-UIM-D-1017
CHARGE VERIFICATION MODE
The outdoor display will assist the installer with charging the system.
Through interaction with the Outdoor Display the system will operate at
predetermined nominal speed values. During this operation the system
will monitor pressures and temperatures. When the subcooling is within
the predetermined values set by the OEM, the outdoor display will indicate SYSTEM CHARGE VALIDATED. This mode is only available
when the ID temperature is within 73 to 83°F and humidity is less than
73% as measured by the Hx
charge will not be verified.
User Interaction/Operation:
1. Press Menu, press Arrow until Modes is displayed, press Select.
Press Arrow until Charge Verification is displayed, press Select.
2. Press Select while in Charge Verification Mode. The system will
detect the Unit Type and Unit Tonnage. The outdoor display will
update and scroll text, see the example below.
Example: 4-TON AC FOUND * VERIFY CHARGE? * 4-TON AC
FOUND * VERIFY CHARGE?
3. Press Select to verify charge, the outdoor display will update and
scroll text, see the example below.
Example: VERIFYING CHARGE * PLEASE WAIT * VERIFYING
CHARGE * PLEASE WAIT
(5 minute wait time during initial charge calculation)
4. ADD CHARGE or REMOVE CHARGE will display on the banner
with the appropriate response dependent upon the OEM's predetermined values, user may press Select when the banner displays
ADD CHARGE or REMOVE CHARGE. The display will indicate
ACCEPTED for 5 seconds and return to the example defined in
Step 1. However, if the system does meet the charge requirements
defined by the OEM, the outdoor display will indicate the below text
example for 5 seconds and return to the text example in Step 2 until
charge verification has fully completed.
Example: SYSTEM CHARGE VALIDATED
The system will repeat steps 1-3 until the subcooling has reached the
predetermined values set by the OEM.
5. Once charge verification is fully complete the outdoor display will
return to the Second Menu Layer.
TABLE 3:
Menu Options Operation
OPERATIONAL MODE (AC - HP) Display current system configuration (AC or HP) and unit capacity stored in memory.
BYPASS ASCD TIMER
TEST Mode Option
TM
thermostat. Operation will continue but
TEST MODE OPTION
Bypass ASCD timer and initiate system operation if a call for space conditioning is present from the HXTM
thermostat.
SECTION VII: SYSTEM OPERATION
SERVICE MODE
Service mode locks the system into maximum capacity operation based
on ambient conditions. The unit will be locked into steady state conditions where operation and performance can be evaluated using the
available service information. This function is outside of the charge verification mode, available for all system component diagnostics and can
only be access from the outdoor control.
ANTI 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 or thermostat signal interruption. The ASCD timer is applied when the control is
first powered 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.
LOW VOLTAGE DETECTION
The control monitors the outdoor transformer secondary (24 VAC) voltage and provides low voltage protection for the heat pump and its components. If the voltage drops below approximately 22 VAC, the control
continues to energize any outputs that are already energized. If the voltage drops below approximately 19 VAC, the control immediately deenergizes the outputs and can no longer energize any outputs until the
voltage level increases above 22VAC. The control stores and displays
the appropriate fault codes when low voltage conditions occur.
TEST MODE OPERATION
Test mode operation provides the features found in Table 3 to assists in
unit commissioning and troubleshooting. TEST MODE is accessed
through the Outdoor Display. Please see Page 11 & Table 6 for detailed
Outdoor Display operation. Test mode can only be accessed from the
outdoor control.
FAULT AND STATUS CODE BEHAVIOR
Fault Code Storage
The main control stores the ten most recent fault codes for review by
the service technician. These codes are stored even when power is
removed from the control and will remain in memory until the control is
powered for 30 consecutive days or manually cleared from the control.
All codes are stored in order of occurrence and time stamped.
The control stores only one identical fault code during the same series
of events. For example, if two or more high pressure switch (HPS) faults
occur sequentially without another fault occurring in between the HPS
faults, the control only stores the HPS fault once.
In addition, the main unit control stores the following unit sensor values
when a fault and/or event occurs.
1. Suction Superheat
2. Liquid Subcooling
3. Liquid Temperature
4. Discharge Pressure
5. Suction Temperature
6. Suction Pressure
Johnson Controls Unitary Products 9
When a fault and/or event is present, the system will indicate the corresponding fault and/or event text on the Outdoor Display status banner.
NOTICE
The display will continue to indicate the above fault (saved) value(s)
on the Outdoor Display with the active Fault and/or Event text, while
the fault and/or event is still present. When the fault and/or event has
cleared, the system will return to the General Display Operation.
Fault Code Display
The system will provide fault and/or event text, using the Outdoor Display when CURRENT and/or STORED SYSTEM FAULT(s) are
selected from the FAULT MODE category. Tables 7 & 8 describe the
fault codes in more detail, giving potential causes and troubleshooting
actions. If multiple faults and/or events are present at the same time,
the Outdoor Display will show the most recent fault and/or event with
the highest priority. In the event that multiple faults and/or events are
populated at the same time, the Outdoor Display will indicate the most
recent system fault and/or event that is stored in memory. The second
system fault will not be displayed, but will be stored in memory. For
example see Table 4.
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