Johnson Controls NH-07 Series, NH-10 Series, NH-15 Series, NH-20 Series, NJ-10 Series Installation Manual
...
R-410A
MODELS: NH-07 Thru -20, 2-Pipe
NJ-10 Thru -20, 4-Pipe
7.5 - 20 Ton, 60 Hertz
TABLE OF CONTENTS
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Renewal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Unit Application Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Physical Data Indoor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air Discharge Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LIST OF TABLES
1 Unit Application Data Indoor . . . . . . . . . . . . . . . . . . . . . . . 4
2 Physical Data Indoor Unit . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Minimum Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4 Corner Weights & Center of Gravity NH/NJ Unit . . . . . . . 9
5 Accessory Operating Weight Distribution (Lbs) . . . . . . . 10
6 Electrical Data - Electric Heat . . . . . . . . . . . . . . . . . . . . . 16
7 Altitude/Temperature Correction Factors . . . . . . . . . . . . 19
8 Example Supply Air Blower Performance . . . . . . . . . . . . 20
9 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 NH-07 Upflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11 NH-07 Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Duct Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Refrigerant Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Expansion Valve Bulb Installation. . . . . . . . . . . . . . . . . . . 13
Air System Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Airflow Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Twin Belt Drive Adjustment. . . . . . . . . . . . . . . . . . . . . . . . 29
Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Air Handling Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
12 NH/NJ-10 Upflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
13 NH/NJ-10 Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
14 NH/NJ-15 Upflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
15 NH/NJ-15 Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
16 NH/NJ-20 Upflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
17 NH/NJ-20 Horizontal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
18 RPM Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
19 Additional Static Resistance . . . . . . . . . . . . . . . . . . . . . . 26
20 Blower Motor And Drive Data . . . . . . . . . . . . . . . . . . . . . 27
21 Unit Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
LIST OF FIGURES
1 Vertical Airflow Arrangements . . . . . . . . . . . . . . . . . . . . . 6
2 Horizontal Airflow Arrangements . . . . . . . . . . . . . . . . . . . 6
3 Typical Cabinet Clamp Assembly . . . . . . . . . . . . . . . . . . 6
4 Typical Suspension of AHU’s From Ceiling . . . . . . . . . . . 8
5 Suggested Method For Connecting Ductwork . . . . . . . . 10
6 Recommended Drain Piping . . . . . . . . . . . . . . . . . . . . . 11
7 Typical Field Wiring Diagram - NH-07 Unit . . . . . . . . . . 14
8 Typical Field Wiring Diagram - NH/NJ-10 Thru -20 Unit 15
9 NH/NJ-10 Thru -20 Liquid Line Solenoid Wiring . . . . . . 15
10 Altitude/Temperature Correction Factors . . . . . . . . . . . . 19
11 Hole Location For Pressure Drop Reading . . . . . . . . . . 27
12 Pressure Drop Across A Dry Indoor Coil vs. Supply
Air CFM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
13 Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
14 Double Groove Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . 29
15 Unit Dimensions NH-07 Thru -10 & NJ-10 . . . . . . . . . . 31
16 Unit Dimensions NH/NJ-15 . . . . . . . . . . . . . . . . . . . . . . 32
17 Unit Dimensions NH/NJ-20 . . . . . . . . . . . . . . . . . . . . . . 33
18 Typical Horizontal Configuration . . . . . . . . . . . . . . . . . . 34
520413-BIM-A-0209
520413-BIM-A-0209
General
These completely assembled 7-1/2 thru 20 ton evaporator
blower units include a well insulated cabinet, a DX cooling coil
with copper tubes and aluminum fins, expansion valve(s), a distributor(s), throwaway filters, centrifugal blower(s), a blower
motor, and a small holding charge of dry nitrogen. Blower
motors and adjustable drives are factory-installed on all units.
Supplemental resistance heaters, a supply air plenum, a return
air grill, hot water coils, non-freeze steam coils, and a base are
available as accessories for field installation.
The units are shipped in the vertical position ready for field
installation.
Safety Considerations
Installer should pay particular attention to the words: NOTE,
CAUTION, and WARNING. Notes
make the installation easier. Cautions are given to prevent
equipment damage. Warnings are given to alert installer that
personal injury and/or equipment damage may result if installation procedure is not handled properly.
are intended to clarify or
Additional information on the design, installation, operation and
service of this equipment is available in the Technical Guide -
505430.
Renewal Parts
Contact your local UP Parts Distribution Center for authorized
replacement parts.
Agency Approvals
Design certified by CSA as follows:
1. For use as a (cooling coil, heat pump coil/air handler) only
with or without supplemental electric heat.
2. For indoor installation only.
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 freight bill. A separate
request for inspection by the carrier’s agent should be made in
writing.
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 system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system. Gage sets, hoses, refrigerant
containers and recovery systems must be designed to
handle R-410A. If you are unsure, consult the
equipment manufacturer. Failure to use R-410A
compatible servicing equipment may result in property
damage or injury.
Reference
This instruction covers the installation and operation of evaporator blower units. For information on the operation of matching
condensing units, refer to Installation Manual - 430646 for cool
ing units and Installation Manual - 430647 for heat pumps.
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.
Wear safety glasses and gloves when handling
refrigerants. Failure to follow this warning can cause
serious personal injury.
-
2 Johnson Controls Unitary Products
Nomenclature
Configured Split Air Handler Model Number Nomenclature
520413-BIM-A-0209
Product Category
N = Split System, Air Handler, AC & HP, R-410A
Product Identifier
H = Standard Efficiency, 2-Pipe, R-410A
J = Standard Efficiency, 4-Pipe, R-410A
Nominal Cooling Capacity - MBH
-07 = 7.5 Ton
-10 = 10 Ton
-15 = 15 Ton
-20 = 20 Ton
Heat Type & Nominal Heat Capacity
C00 = Cooling Only
N
H
-20
C00 B
S
A
A = None
Voltage
S = 208/230/460-3-60
X = 575-3-60
B = 1.5 HP Motor
C = 2.0 HP Motor
D = 3 HP Motor
E = 5 HP Motor
F = 7.5 HP Motor
2
AA
Installation Options
Airflow
A
Product Style
A = Style A
Product Generation
1 = First Generation
Product Options
AA = None
Johnson Controls Unitary Products 3
520413-BIM-A-0209
Unit Application Data
Table 1: Unit Application Data Indoor
Entering Air Temperature Degrees °F
Model Power Supply Voltage
208/230-3-60 187 253 2,250 3,750 65/57 90/77 40 80
NH-07
NH-10
NJ-10
NH-15
NJ-15
NH-20
NJ-20
1. Heating Min/Max temperatures apply to steam and hot water coils. NOTE: Do not apply steam to hot water coils.
460-3-60 414 506 2,250 3,750 65/57 90/77 40 80
575-3-60 540 630 2,250 3,750 65/57 90/77 40 80
208/230-3-60 187 253 3,000 5,000 65/57 90/77 40 80
460-3-60 414 506 3,000 5,000 65/57 90/77 40 80
575-3-60 540 630 3,000 5,000 65/57 90/77 40 80
208/230-3-60 187 253 3,000 5,000 65/57 90/77 40 80
460-3-60 414 506 3,000 5,000 65/57 90/77 40 80
575-3-60 540 630 3,000 5,000 65/57 90/77 40 80
208/230-3-60 187 253 4,500 7,500 65/57 90/77 40 80
460-3-60 414 506 4,500 7,500 65/57 90/77 40 80
575-3-60 540 630 4,500 7,500 65/57 90/77 40 80
208/230-3-60 187 253 4,500 7,500 65/57 90/77 40 80
460-3-60 414 506 4,500 7,500 65/57 90/77 40 80
575-3-60 540 630 4,500 7,500 65/57 90/77 40 80
208/230-3-60 187 253 6,000 10,000 65/57 90/77 40 80
460-3-60 414 506 6,000 10,000 65/57 90/77 40 80
575-3-60 540 630 6,000 10,000 65/57 90/77 40 80
208/230-3-60 187 253 6,000 10,000 65/57 90/77 40 80
460-3-60 414 506 6,000 10,000 65/57 90/77 40 80
575-3-60 540 630 6,000 10,000 65/57 90/77 40 80
Voltage Variation Supply Air Range CFM
Min. Max. Min. Max. Min. Max. Min. Max.
Cooling
DB/WB
Heating DB
1
4 Johnson Controls Unitary Products
520413-BIM-A-0209
Physical Data Indoor Unit
Table 2: Physical Data Indoor Unit
Component
Nominal Tonnage 7 1/2 10 10 15 15 20 20
DIMENSIONS (inches)
Length
Width
Height
WEIGHTS (lb)
Unit Shipping
Unit Operating With
Standard Motor and Drive
High Static Motor and Drive
INDOOR BLOWER (Forward Curve)
Diameter x Width 12 x 12 15 x 15 15 x 15 18 x 18 18 x 18 15 x 15 15 x 15
Quantity 1111122
NH-07 NH-10 NJ-10 NH-15 NJ-15 NH-20 NJ-20
56.0 56.0 56.0 74.5 74.5 98.5 98.5
30.0 30.0 30.0 33.0 33.0 30.0 30.0
65.0 65.0 65.0 75.0 75.0 65.0 65.0
405 512 512 681 681 874 874
381 468 468 632 632 816 816
385 492 492 661 661 854 854
INDOOR COIL
Face area (Sq. Ft.) 10.6 10.6 10.6 18.3 18.3 20.0 20.0
Rows 3443443
Fins per inch 15 15 15 15 15 15 15
Tube diameter 3/8 3/8 3/8 3/8 3/8 3/8 3/8
Circuitry Type Interfaced Interfaced Interfaced Interfaced Interfaced Interfaced Interfaced
Refrigerant Control TXV TXV TXV TXV TXV TXV TXV
Operating Charge (lb) 4 6 6 10 10 10 10
SYSTEM DATA
No. Refrigeration Circuits 1121212
Suction Line OD (in.) 1 1/8 1 3/8 1 1/8 1 5/8 1 1/8 1 5/8 1 3/8
Liquid Line OD (in.) 5/8 7/8 5/8 7/8 5/8 7/8 7/8
FILTERS
Size and Quantity Per Model (In.) 16 x 25 x 2 4 4 4 --- --- 8 8
20 x 24 x 2 --- --- --- 6 6 --- --Face area (Sq. Ft.) 11.1 11.1 11.1 20.0 20.0 22.2 22.2
Size and Quantity Per Model (In.) 16 x 25 x 4 4 4 4 --- --- 8 8
18 x 24 x 4 --- --- --- 6 6 --- ---
Face area (Sq. Ft.) 11.1 11.1 11.1 18.0 18.0 22.2 22.2
Models
Air Discharge Conversion
6. Rotate the blower section and mate it to the hole left when
the panel was removed in Step 5.
These units are shipped for Vertical Airflow operation as seen in
Figure 1 Positions 1 thru 4, but may be converted for Horizontal
Airflow operation illustrated in Figure 2 Positions 1 thru 4.
Conversion Example:
7. Bolt and clamp the two sections together.
8. Place the panel remove
1. d in Step 5 on top of the evaporator section and screw
together.
Convert Vertical Airflow Position 1 to Horizontal Airflow Position
1 as follows:
NOTE: 1 inch blower duct flange shipped with air handler.
1. Remove the front blower panel from the blower section and
set aside. This allows access to the clamps that hold the
blower section to the evaporator section.
2. Remove the bolts and clamp angles that hold the coil
section and blower section together.
3. Place the panel removed in Step 1 on top of the blower
section and screw together.
4. Set the blower section aside.
5. Remove the evaporator section rear panel and set aside.
Johnson Controls Unitary Products 5
520413-BIM-A-0209
BLOWER
EVAPORATOR
COIL
POSITION
1
Figure 1: Vertical Airflow Arrangements
POSITION
2
POSITION
3
POSITION
4
POSITION
POSITION
Figure 2: Horizontal Airflow Arrangements
1
2
3
POSITION
4
3/8” x 1 1/4” Bolt
Clamp
See Detail A
Detail A
POSITION
Bolt
Lock
Flat
Washer
Detail B
Cabinet Clamp Assembly
Typical Cabinet Clamp Assembly
Figure 3: Typical Cabinet Clamp Assembly
6 Johnson Controls Unitary Products
Unit Installation
Location
These evaporator blowers are not designed for outdoor
installation. They must be located inside a building structure,
either inside or outside the conditioned space where they are
protected from rain and other moisture.
The unit should be located as close to the condensing unit as
practical and positioned to minimize bends in the refrigerant
piping.
Units being installed vertically or horizontally can be set directly
on a floor or platform, or supported by metal or wooden beams.
Rigging
Care must be taken when moving the unit. Do not remove any
packaging until the unit is near the place of installation.
SPREADER BARS SHOULD BE USED BETWEEN THE
SLINGS TO PREVENT CRUSHING THE UNIT FRAME OR
PANELS. When preparing to move the unit, always determine
the center of gravity of the unit in order to equally distribute the
weight. Rig the unit by attaching chain or cable slings around
the bottom skid. A lift truck may be used to raise a unit to a
suspended location. Refer to Table 4 for unit weights.
520413-BIM-A-0209
Clearances
Table 3: Minimum Clearances
Minimum Clearances
Top with Supply Air Opening
Front with Return Air Opening 24”
Right Side with Access for Piping, Power &
Control Wiring Connections
Left Side 24”
3
Rear
4
Bottom
1. This dimension will vary if an electric heater, a supply air plenum or a
base is used.
2. This dimension is required for normal installation and service.
3. Although no clearance is required for service and operation, some
clearance may be required for routing the power and control wiring.
4. Allow enough clearance to trap the condensate drain line.
NOTE: If the coil has t o be removed, the blowe r section can be unbolted
and set aside and the coil can be lifted out the top of the
evaporator section.
A 24-inch clearance is required on the end with the piping
connections and the supply air blower motor to properly service
and maintain the unit.
Some clearance will also be required for the duct and power
wire connections.
1
2
24”
24”
N/A
N/A
Johnson Controls Unitary Products 7
520413-BIM-A-0209
Mounting
The split air handling units can be applied in various horizontal
positions. Figure 4 shows recommended suspension rigging
using properly sized all-thread and metal c-channel. All
END VIEW
components to suspend an AHU must be field supplied. Please
refer to the units total weight, center of gravity and corner
weights (Horizontal position) shown in the appropriate table for
proper support sizing.
MOUNTING DETAIL
All Thread
Steel Rod
Mounting
Bracket
Flat Washer /
Lock Washer
and Nut
Steel Cchannel
SIDE VIEW
Figure 4: Typical Suspension of AHU’s From Ceiling
8 Johnson Controls Unitary Products
Table 4: Corner Weights & Center of Gravity NH/NJ Unit
Model Options
Vertical Airflow
NH-07
NH/NJ-10
NH/NJ-15
NH/NJ-20
Std. Mtr. and Drv. 357 381 30 30 102 102 88 88 68 68 68 59 59 59
High Static Mtr. and Drv. 357 385 30 30 103 103 89 89 69 69 69 60 60 60
Std. Mtr. and Drv. 422 468 30 30 125 125 109 109 84 84 84 72 72 72
High Static Mtr. and Drv. 422 492 31 29 123 132 123 115 81 85 89 83 79 76
Std. Mtr. and Drv. 560 632 36 36 139 167 178 148 90 101 115 122 108 96
High Static Mtr. and Drv. 560 661 36 35.5 143 172 189 157 93 104 118 130 114 102
Std. Mtr. and Drv. 715 816 32 48 186 212 223 195 121 132 145 152 139 127
High Static Mtr. and Drv. 715 854 32 47 190 217 238 208 124 135 148 162 148 136
Horizontal Airflow
NH-07
NH/NJ-10
NH/NJ-15
NH/NJ-20
Std. Mtr. and Drv. 357 381 15 30 102 102 88 88 68 68 68 59 59 59
High Static Mtr. and Drv. 357 385 15 30 103 103 89 89 69 69 69 60 60 60
Std. Mtr. and Drv. 422 468 15 30 125 125 109 109 84 84 84 72 72 72
High Static Mtr. and Drv. 422 492 15.5 29 123 132 123 115 81 85 89 83 79 76
Std. Mtr. and Drv. 560 632 18 36 139 167 178 148 90 101 115 122 108 96
High Static Mtr. and Drv. 560 661 18 35.5 143 172 189 157 93 104 118 130 114 102
Std. Mtr. and Drv. 715 816 16 48 186 212 223 195 121 132 145 152 139 127
High Static Mtr. and Drv. 715 854 16 47 190 217 238 208 124 135 148 162 148 136
Weight (lbs.) Center of Gravity (in.) 4 Point Load Location (lbs.) 6 Point Load Location (lbs.)
Shipping Operating X Y A B C D A B C D E F
520413-BIM-A-0209
FRONT
WIDTH
LEFT
A
A
DIM Y
F
D
DIM X
VERTICAL POSITION
B
E
LENGTH
RIGHT
CG
LEFT
B
C
WIDTH
REAR
FRONT
D
C
DIM Y
A
A
F
D
DIM X
HORIZONTAL POSITION
B
E
LENGTH
RIGHT
CG
B
C
REAR
D
C
Johnson Controls Unitary Products 9
520413-BIM-A-0209
Table 5: Accessory Operating Weight Distribution (Lbs)
ACCESSORY
2
BASE
HOT WATER COIL
STEAM COIL
1.These weights should be added to each point load in table 4.
2.This accessory can only be applied on units installed in the vertical position.
NH-07 NH/NJ-10 NH/NJ-15 NH/NJ-20
1
25 25 30 45
35 35 45 35
30 30 35 50
Duct Connections
Ductwork should always be suspended with hangers or
supported by legs. It should never be fastened directly to the
building structure.
Allow clearance around ducts for safety in the handling of
heated air and for insulation when required.
Insulation
Ductwork insulation should meet the following criteria:
• Be used when ducts pass through an unconditioned
space in the cooling season or through an unheated
space during the heating season.
• Include a vapor barrier around the outside to prevent the
absorption of moisture.
• Be no less than 2 inches thick with a weatherproof coating
when applied to ducts exposed to outdoor conditions.
Supply Air Ducts
See Figure 5 for suggested method of connecting supply air
ductwork. Non-flammable material collars should be used to
minimize the transmission of noise and/or vibration.
DUCT
NON-FLAMMABLE
COLLAR
24"
AIR
OUTLET
BLOWER
GASKETS
(BY INSTALLER)
TRANSITION
DUCT
FLANGED DUCT
CONNECTION
(Factory Furnished,
Field Installed )
Figure 5: Suggested Method For Co nn e cti ng Ductw ork
10 Johnson Controls Unitary Products
520413-BIM-A-0209
Drain Connections
All drain lines MUST be trapped and located so they will not be
exposed to freezing temperatures.
All evaporator blower units have a 3/4” PVC condensate stub at
the end of a double sloped drain pan. The drain pan is
removable and reversible, It can be unscrewed and slid out
from one side of the evaporator section and installed in the
other end.
Drain piping should be constructed as shown in Figure 6. The
3-inch dimension must equal or exceed the negative static
pressure developed by the supply air blowers. If it does not, the
condensate will not drain properly and may overflow the drain
pan.
¾” PVC
STUB
3" MINIMUM
Line Sizing
When sizing refrigerant pipe for a split-system air conditioner,
check the following:
1. Suction line pressure drop due to friction.
2. Liquid line pressure drop due to friction.
3. Suction line velocity for oil return.
4. Liquid line pressure drop due to vertical rise. For certain
piping arrangements, different sizes of suction line pipe
may have to be used. The velocity of the refrigerant vapor
must always be great enough to carry the oil back to the
compressor.
5. Evaporator Located Below Condenser - On a split
system where the evaporator blower is located below the
condenser, the suction line must be sized for both pressure
drop and for oil return.
6. Condenser Located Below Evaporator - When the
condenser is located below the evaporator blower, the
liquid line must be designed for the pressure drop due to
both friction loss and vertical rise. If the pressure drop due
to vertical rise and friction exceeds 40 psi, some refrigerant
will flash before it reaches the thermal expansion valve.
Flash gas
:
FIELD SUPPLIED
Figure 6: Recommended Drain Piping
Refrigerant Mains
This Split-System (Air Condensing / Heat Pump / Air
Handling) unit is one component of an entire system. As
such it requires specific application considerations with
regard to the rest of the system (air handling unit, duct
design, condensing unit, refrigerant piping and control
scheme).
Failure to properly apply this equipment with the rest of
the system may result in premature failure and/or
reduced performance / increased costs. Warranty
coverage specifically excludes failures due to improper
application and Unitary Products specifically disclaims
any liability resulting from improper application.
Please refer to the equipment Technical Guide,
Installation Manual and the piping applications bulletin
247077 or call the applications department for Unitary
Products @ 1-877-UPG-SERV for guidance.
1. Increases the liquid line pressure loss due to friction that in
turn causes further flashing.
2. Reduces the capacity of the refrigerant control device
which starves the evaporator.
3. Erodes the seat of the refrigerant control device.
4. Causes erratic control of the refrigerant entering the
evaporator.
Take Adequate Precautions
Many service problems can be avoided by taking adequate
precautions to provide an internally clean and dry system and
by using procedures and materials that conform to established
standards.
Use hard drawn copper tubing where no appreciable amount of
bending around pipes or other obstructions is necessary. If soft
copper is used, care should be taken to avoid sharp bends that
may cause a restriction. Pack fiberglass insulation and a
sealing material such as permagum around refrigerant lines
where they penetrate a wall to reduce vibrations and to retain
some flexibility.
Support all tubing at minimum intervals with suitable hangers,
brackets or clamps.
Braze all copper-to-copper joints with Silfos-5 or equivalent
brazing material. Do not use soft solder. Insulate all suction
lines with a minimum of 1/2" ARMAFLEX or equivalent. Liquid
lines exposed to direct sunlight and/or high temperatures must
also be insulated. Never solder suction and liquid lines
together. They can be taped together for convenience and
Johnson Controls Unitary Products 11
520413-BIM-A-0209
support purposes, but they must be completely insulated from
each other.
The liquid and suction service ports on the condenser section
permit leak testing, evacuation, and partial charging of the field
piping and the evaporator without disturbing refrigerant stored
in the condenser during initial installation.
Before beginning installation of the main lines, be sure that the
evaporator section has not developed a leak in transit. Check
pressure at the Schrader valve located on the header of each
coil. If pressure still exists in the system, it can be assumed to
be leak free. If pressure DOES NOT exist the section will need
to be repaired before evacuation and charging is performed.
A filter-drier MUST be field-installed in the liquid line of every
system to prevent dirt and moisture from damaging the system.
Properly sized filter-driers are shipped with each condensing
section.
NOTE: Installing a filter-drier does not eliminate the need for
the proper evacuation of a system before it is charged.
A field-installed moisture indicating sight-glass should be
installed in the liquid line(s) between the filter-drier and the
evaporator coil. The moisture indicating sight-glass can be used
to check for excess moisture in the system or used as a visual
means to verify refrigerant charge.
Both condenser and evaporator sections have copper sealing
disks brazed over the end of liquid and suction connections.
The temperature required to make or break a brazed joint is
high enough to cause oxidation of the copper unless an inert
atmosphere is provided.
connections of the main lines. Repeat for the liquid line valve
body.
Never remove a cap from an access port unless the
valve is fully back-seated with its valve stem in the
maximum counter-clockwise position because the
refrigerant charge will be lost. Always use a refrigeration
valve wrench to open and close these service valves.
Connect the main liquid line to the liquid line connection on the
condenser section, while maintaining a flow of Nitrogen. Cool
the valve body and replace the Schraded valve stem on the
service port of the liquid line service valve.
Install the liquid line from the condensing unit to the evaporator
liquid connection, maintaining a flow of nitrogen during all
brazing operations.
The filter-drier and sight glass must be located in this line, close
to the evaporator.
Connect a low-pressure nitrogen source to the Schrader valve
located on the evaporator section coil headers. Drill a small
hole in the sealing disks, the flow of Nitrogen will prevent any
debris from entering the system. Unbraze both liquid and
suction sealing disks and prepare the joints for connections of
the main lines.
Connect the main liquid line to the liquid line connection on the
evaporator section, while maintaining a flow of Nitrogen.
NOTE: Dry Nitrogen should flow through the system at all
times when heat is being applied and until the joint has
cooled. The flow of Nitrogen will prevent oxidation of
the copper lines during installation.
Always drill a small hole in sealing disks before unbrazing to
prevent the pressure in the line from blowing them off.
NOTE: Solenoid and hot gas bypass valves (if used) should be
opened manually or electrically duri ng brazing or
evacuating.
NOTE: Schrader valves located on unit service valves should
have their stem removed during brazing to prevent
damage to the valve.
Start Installation
Start Installation of main lines at the condensing section. Verify
the service valves are fully seated by screwing the stem of both
valves down into the valve body until it stops. Remove the
Schraded valve stem and connect a low-pressure nitrogen
source to the service port on the suction line valve body. Drill a
small hole in the sealing disk; the flow of Nitrogen will prevent
any debris from entering the system. Wrap the valve body with
a wet rag to prevent overheating during the brazing process.
Overheating the valve will damage the valve seals. Unbraze the
sealing disk, cool the valve body and prepare the joint for
Make the suction line connection at the evaporator and run the
line to the condensing unit. Connect the main suction line to the
suction line connection on the condenser section, while
maintaining a flow of Nitrogen. Cool the valve body and replace
the Schraded valve stem on the service port of the liquid line
service valve.
Once the brazing process is complete, leak testing should be
done on all interconnecting piping and the evaporator befo re
proper evacuation to 500 microns is performed. Once the line
set and evaporator section is properly evacuated the service
valves can be opened and the condensing unit is now ready to
charge with the appropriate weight of refrigerant.
The correct refrigerant pressures are indicated as shown in
Figures 10 through 13.
12 Johnson Controls Unitary Products
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