Johnson Controls SA PC090, SA PD 180 User Manual

0 (0)

R-410A MODELS:

7.5 - 20 Ton 60 Hertz

Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Renewal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Agency Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Phasing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 PC090 - 240 and PD180 - 240 Physical Data . . . . . . . . . . 4

2 Unit Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 Corner Weights & Center of Gravity . . . . . . . . . . . . . . . . . 6

4 Minimum Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5 Electrical Data - Outdoor Unit - HP Without Powered

Convenience Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

6 Electrical Data - Outdoor Unit - HP With Powered

Convenience Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

PC090 Thru 240 PD180 Thru 240

TABLE OF CONTENTS

LIST OF TABLES

Electrical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Refrigerant Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Piping And Electrical Connections . . . . . . . . . . . . . . . . . . 17

Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Crankcase Heaters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Sequence of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Cooling Sequence Of Operation. . . . . . . . . . . . . . . . . . . . 18

Heating Sequence of Operation . . . . . . . . . . . . . . . . . . . . 20

Unit Control Board Option Setup. . . . . . . . . . . . . . . . . . . . 23

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Typical Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7 PC090, PC120 Unit Height Dimensions . . . . . . . . . . . . . 15

8 PC/PD180 & PC/PD240 Unit Height Dimensions . . . . . . 16

9 Piping and Electrical Connection Sizes . . . . . . . . . . . . . 17

10 PC090 thru 240 Unit Control Board Flash Codes . . . . . . 21

11 PD180 thru 240 Unit Control Board Flash Codes . . . . . . 22



LIST OF FIGURES

1 Corner Weights & Center Of Gravity . . . . . . . . . . . . . . . . 6

2 Typical Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Typical Field Wiring Diagram - NC090 Air Handling Unit

With PC090 Heat Pump . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 Typical Field Wiring Diagram - NC120 thru 240 Evaporator

Unit with PC120 thru 240 Heat Pump . . . . . . . . . . . . . . 13

5 NC120 - 240 Liquid Line Solenoid Wiring . . . . . . . . . . . 13

6 Typical Field Wiring Diagram - ND180 thru 240

Evaporator Unit with PD180 thru 240 Heat Pump . . . . . 14

7 PC090, PC120 Unit Dimensions . . . . . . . . . . . . . . . . . . 15

8 PC/PD180 & PC/PD240 Unit Dimensions and Piping

& Electrical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . 16

9 Fan Orientation, Control Box End . . . . . . . . . . . . . . . . . 21

10 Unit Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

11 PC090 Charging Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 27

12 PC120 Charging Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 27

13 PC180 Charging Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 28

14 PD180 Charging Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 28

15 PC240 Charging Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 29

16 PD240 Charging Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 29

17 Typical PC090 Heat Pump Wiring Diagram . . . . . . . . . . 30

18 Typical PC120 Heat Pump Wiring Diagram . . . . . . . . . . 31

19 Typical PC180 - 240 Heat Pump Wiring Diagram . . . . . 32

20 Typical PD180 - 240 Heat Pump Wiring Diagram . . . . . 33

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Product Category

P = Split System, Condenser, HP, R-410A

Product Identifier

C = Standard Efficiency, 2-Pipe, R-410A D = Standard Efficiency, 4-Pipe, R-410A

Nominal Cooling Capacity - MBH

090 = 7.5 Ton 120 = 10 Ton 150 = 12.5 Ton 180 = 15 Ton 240 = 20 Ton

C00 = Cooling Only

Product Options

AA = None AB = Phase Monitor AC = Coil Guard AE = Phase Monitor + Coil Guard LA = Low Ambient LB = Low Ambient + Phase Monitor LC = Low Ambient + Coil Guard LD = Low Ambient + Phase Monitor + Coil Guard LE = Low Ambient + Technicoat Cond. Coil LF = Low Ambient + Technicoat Cond. Coil + Phase Monitor LG = Low Ambient + Technicoat Cond. Coil + Coil Guard LH = Low Ambient + Technicoat Cond. Coil + Phase Monitor + Coil Guard TA = Technicoat Condenser Coil TB = Technicoat Condenser Coil + Phase Monitor TC = Technicoat Condenser Coil + Coil Guard TE = Technicoat Condenser Coil + Coil Guard + Phase Monitor

Installation Options

A = None

2 = 208/230-3-60 4 = 460-3-60 5 = 575-3-60 7 = 380/415-3-50

Configured Split Condenser Model Number Nomenclature

A = Standard Motor

Airflow

Product Generation

1 = First Generation 2 = Second Generation

Voltage

Heat Type & Nominal Heat Capacity

240

C00 A

Product Style

A = Style A

2 = Non Pwr’d Conv Outlet

1 = Disconnect

T = Options 1 & 5

S = Options 5

D = Options 1 & 2

C = Option 2

B = Option 1

Options

5 = Pwr’d Conv Outlet

Nomenclature

General

These condensing units are designed for outdoor installation on a roof or at ground level. Every unit is completely piped and wired at the factory and is shipped ready for immediate installation. Only the liquid and suction lines to the evaporator coil, the filter drier, the thermostat wiring and the main power wiring are required to complete the installation. Each unit is dehydrated, evacuated, leak tested and pressure tested at 450 psig before being pressurized with a holding charge of refrigerant R-410A for shipment and/or storage.

All controls are located in the front of the unit and are readily accessible for maintenance, adjustment and service. All wiring (power and control) can be made through the front of the unit.

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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.

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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.

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.

Before performing service or maintenance operations on unit, turn off main power switch to unit. Electrical shock could cause personal injury. Improper installation, adjustment, alteration, service or maintenance can cause injury or property damage. Refer to this manual. For assistance or additional information consult a qualified installer, service agency or the gas supplier.

are intended to clarify or

Reference

This instruction covers the installation and operation of the basic condensing unit. For refrigerant piping installation instructions refer to document 247077 “Application Data General Piping Recommendations for Split System Air Conditioning and Heat Pumps”. For information on the installation and operation of the evaporator blower units, refer to Instruction Manual No. 508526.

All accessories come with a separate Installation Manual.

Renewal Parts

Contact your local Source 1 Center for authorized replacement parts.

Agency Approvals

Design certified by CSA as follows:

1. For use as a cooling/heating uni t.

2. For outdoor 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.

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.

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.

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Physical Data

Table 1: PC090 - 240 and PD180 - 240 Physical Data

Component

Nominal Tonnage 7.5 10 15 15 20 20

Refrigerant type R-410A R-410A R-410A R-410A R-410A R-410A Holding charge (lb)

Operating Charge (lb)

Length 59.1 59.1 59.1 59.1 59.1 59.1 Width 31.9 31.9 64.1 64.1 64.1 64.1 Height 44.5 50.0 44.5 44.5 50.0 50.0

Shipping 421 543 947 921 1116 1090 Operating 430 574 968 942 1152 1126

Type Single Scroll Tandem Scroll Tandem Scroll Single Scroll Tandem Scroll Single Scroll Quantity 1 1 1212

Cooling

Nominal Capacity (Tons)

Capacity Stages

Heating

Nominal Capacity (Tons) System #1 & #2 7.5 10 15 15 20 20 Capacity Stages System #1 & #2 1 1 1111

No. Refrigeration Circuits 111212 Suction Line OD (in.) 1 1/8 1 3/8 1 5/8 1 3/8 1 5/8 1 3/8 Liquid Line OD (in.) 5/8 7/8 7/8 5/8 7/8 7/8

Face area (Sq. Ft.) 23.8 29.0 47.5 47.5 58.1 58.1 Rows 222222 Fins per inch 20 20 20 20 20 20 Tube diameter (in./MM) 0.38 / 10 0.38 / 10 0.38 / 10 0.38 / 10 0.38 / 10 0.38 / 10 Circuitry Type Interlaced Interlaced Interlaced Interlaced Interlaced Interlaced Refrigerant Control TXV TXV TXV TXV TXV TXV

No. Fans / Diameter (in.) 2/24 2/24 4/24 4/24 4/24 4/24 Type Axial Axial Axial Axial Axial Axial Drive type Direct Direct Direct Direct Direct Direct No. speeds 1 1 1111

Number of motors Motor HP (ea.) 1/3 3/4 1/3 1/3 3/4 3/4

Rotation RPM 850 1100 850 850 1100 1100

Nominal CFM

REFRIGERANT

DIMENSIONS (inches)

WEIGHTS (lb)

COMPRESSORS

SYSTEM DATA

OUTDOOR COIL DATA

CONDENSER FAN DATA

System #1 23.9 27.5 54.0 27.0 60.0 34.0 System #2 --- --- --- 27.0 --- 34.0

System #1 7.5 10 15 7.5 20 10 System #2 --- --- --- 7.5 --- 10 System #1122121 System #2 --- --- --- 1 --- 1

System #1224242 System #2 --- --- --- 2 --- 2

System #1 7500 9800 15000 7500 19600 9800 System #2 --- --- --- 7500 --- 9800

PC090 PC120 PC180 PD180 PC240 PD240

1.0 1.0 1.0 1.0 1.0 1.0

CW CW CW CW CW CW

1. Holding Charge is the amount in the unit as shipped from the factory.

2. Includes matched evaporator unit with 25 ft of piping.

3. All Compressors include crankcase heater.

4. When viewing the shaft end of the motor.

Models

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Table 2: Unit Application Data

208/230-3-60 187/252

Voltage Variation

Min. / Max.

460-3-60 432/504 575-3-60 540/630

Ambient Air on Condenser Coil

Min. /Max.

Suction Pressure at Compressor and

Corresponding Temp. at Saturation

Min. / Max.

1.Utilization range “A” in accordance with ARI Standard 110.

2.These units can operate in an ambient temperature of 125°F providing the wet bulb temperature of the air entering the evaporator coil does not exceed 67°F. Unit can operate to 0°F if equipped with a low ambient kit.

40°F/125°F

101.6 psig / 156.6 psig

32.0 ºF / 55.0 ºF

Installation

Limitations

These units must be installed in accordance with all national and local safety codes. If no local codes apply, installation must conform to the appropriate national codes. Units are designed to meet National Safety Code Standards. If components are to be added to a unit to meet local codes, they are to be installed at the dealer's and/or the customer's expense.

3. The heat pump and the evaporator should be positioned to minimize the number of bends in the refrigerant piping.

4. The heat pump should be as close to the evaporator as practical.

5. The heat pump should not be installed where normal operating sounds may be objectionable.

6. The evaporator should be located within the building, either outside or inside the conditioned space.

Rooftop Locations

Be careful not to damage the roof. Consult the building contractor or architect if the roof is bonded. Choose a location with adequate structural strength to support the unit.

The heat pump must be mounted on level supports. The supports can be channel iron beams or wooden beams treated to reduce deterioration.

Minimums of two (2) beams are required to support each unit. The beams should: (1) be positioned perpendicular to the roof joists. (2) Extend beyond the dimensions of the section to distribute the load on the roof. (3) Be capable of adequately supporting the concentrated loads at the corners. These beams can usually be set directly on the roof. Flashing is not required.

NOTE: On bonded roofs, check for special installation

requirements.

Location

Use the following guidelines to select a suitable location for both the condensing unit and the evaporator.

1. The heat pump is designed for outdoor installation only.

2. The condenser fans are the propeller type and are not suitable for use with ductwork in the condenser air stream.

Ground Level Locations

It is important that the units be installed on a substantial base that will not settle, causing strain on the refrigerant lines and possible leaks. A one-piece concrete slab with footers that extend below the frost line is recommended. The slab should not be tied to the building foundation, as noise will telegraph through the slab.

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DIM X

DIM Y

LENGTH

WIDTH

FRONT

RIGHT

REAR

LEFT

DIM X

DIM Y

LENGTH

WIDTH

FRONT

REAR

LEFT

RIGHT

PC090, PC120

PC180, PD180, PC240, PD240

Table 3: Corner Weights & Center of Gravity

Model

PC090 421 430 17.3 33 110 130 103 87 PC120 543 574 16.4 32.3 153 161 134 127 PC180 947 968 32.5 33 266 274 217 211 PD180 921 942 34 32.5 243 275 225 199 PC240 1116 1152 32.1 30.8 300 301 276 275 PD240 1090 1126 31.2 31.8 311 295 253 267

Weight (lbs.) Center of Gravity (in.) 4 Point Load Location (lbs.)

Shipping Operating X Y A B C D

Figure 1: Corner Weights & Center Of Gravity NOTE: Front of unit is considered the side having the control

box.

Concrete piers can also support ground level units. These piers should (1) extend below the frost line, (2) be located under each of the section's four corners, and (3) be sized to carry the load of the corner it supports.

On either rooftop or ground level installations, rubber padding can be applied under the unit to lessen any transmission of

Holes are provided in the base rails for bolting the unit to its foundation.

For ground level installations, precautions should be taken to protect the unit from tampering and unauthorized persons from injury. Screws on access panels will prevent casual tampering. Further safety precautions such as a fenced enclosure or locking devices on the panels may be advisable. Check local authorities for safety regulations.

vibration.

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Clearances

The unit must be installed with sufficient clearance for air to enter the condenser coils, for air discharge and for servicing access. See Table Table 4 for clearances.

NOTE: Additional clearance is required to remove the

compressors out the back of the unit.

Table 4: Minimum Clearances

Clearance Description Distance in Inches

Overhead (Top) 120

Front 36

Rear 36

Left Side 30

Right Side 30

Bottom

1.In all installations where snow ac cu mulates and winter oper-

ation is expected, additional height mus t be prov id ed to insure normal condenser airflow.

LENGTH OF FORKS MUST BE A MINIMUM OF 60 INCHES.

Spreaders, longer than the largest dimension across the unit must be used across the top of the unit.

Before lifting a unit, make sure that its weight is distributed equally on the cables so that it will lift evenly.

Do not permit overhanging structures or shrubs to obstruct condenser air discharge.

Rigging

Exercise care when moving the unit. Do not remove any packaging until the unit is near the place of install ation. Rig the unit by attaching chain or cable slings to the lifting holes provided in the base rails. Spreader bars, whose length exceeds the largest dimension across the unit, MUST be used across the top of the unit.

The unit may be moved or lifted with a forklift. Slotted openings in the base rails are provided for this purpose.

Figure 2: Typical Rigging

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Power Wiring

Check the available power and the unit nameplate for correct voltage. Run the necessary number of properly sized wires to the unit. Provide a disconnect switch (if not included with the unit) and fusing as required (Factory disconnect is a fused disconnect /breaker). Route the conduit through the large knockout located near the electrical box. See Table 5 for Electrical Data.

The disconnect switch may be bolted to the side of the unit but not to any of the removable panels; which would interfere with access to the unit. Make sure that no refrigerant lines will be punctured when mounting the disconnect switch, and note that it must be suitable for outdoor installation.

All power and control wiring must be in accordance with National and Local electrical codes.

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

POE (polyolester) compressor lubricants are known to cause long term damage to some synthetic roofing materials.

Exposure, even if immediately cleaned up, may cause embrittlement (leading to cracking) to occur in one year or more. When performing any service that may risk exposure of compressor oil to the roof, take precautions to protect roofing.

Control Wiring

Route the necessary low voltage control wires from the Simplicity™ control board to the thermostat and also between the terminal blocks inside the heat pump and evaporator control boxes. Refer to Figures 3 thru 6 for field wiring diagrams.

Compressors

The scroll compressors used in this product are specifically designed to operate with R-410A Refrigerant and cannot be interchanged.

This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system.

The compressor also uses a polyolester (POE oil), Mobil 3MA POE. This oil is extremely hydroscopic, meaning it absorbs water readily. POE oil can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the oil to the atmosphere.

Procedures which risk oil leakage include, but are not limited to, compressor replacement, repairing refrigerant leaks, replacing refrigerant components such as filter drier, pressure switch, metering device or coil.

The unit is shipped with compressor mounting bolts which are factory adjusted and ready for operation.

Do not loosen compressor mounting bolts.

Phasing

Three-phase, scroll compressors operate in only one direction. If the scroll is drawing low amperage, has similar suction and discharge pressures, or is producing a high noise level, the scroll is misphased. Change the incoming line connection phasing to obtain the proper rotation.

Scroll compressors require proper rotation to operate properly. Failure to check and correct rotation may result in property damage.

8 Johnson Controls Unitary Products

Electrical Data

Table 5: Electrical Data - Outdoor Unit - HP Without Powered Convenience Outlet

Model

PC090

PC120

PC180

PD180

PC240

PD240

Power

Supply

208/230-3-60 1 25.0 39 164 208/230-1-60 1/3 2 2.1 - 3 5.5 45

460-3-60 1 12.2 19 100 460-1-60 1/3 2 1.2 - 1 7.6 25 575-3-60 1 9.0 14 78 575-1-60 1/3 2 0.9 - 13.1 20

208/230-3-60 2 18.1 28.3 137 208/230-1-60 3/4 2 3.0 - 46.8 60

460-3-60 2 9.0 14.0 62 460-1-60 3/4 2 1.6 - 2 3.5 30 575-3-60 2 6.8 10.6 50 575-1-60 3/4 2 1.4 - 1 8.0 20

208/230-3-60 2 25.0 39 164 208/230-1-60 1/3 4 2.1 - 6 4.7 80

460-3-60 2 12.2 19 100 460-1-60 1/3 4 1.2 - 3 2.2 40 575-3-60 2 9.0 14 78 575-1-60 1/3 4 0.9 - 24.0 30

208/230-3-60 2 25.0 39 164 208/230-1-60 1/3 4 2.1 - 6 4.7 80

460-3-60 2 12.2 19 100 460-1-60 1/3 4 1.2 - 3 2.2 40 575-3-60 2 9.0 14 78 575-1-60 1/3 4 0.9 - 24.0 30

208/230-3-60 2 30.1 47 225 208/230-1-60 3/4 4 3.0 - 7 9.8 100

460-3-60 2 16.7 26 114 460-1-60 3/4 4 1.6 - 4 4.0 60 575-3-60 2 12.2 19 80 575-1-60 3/4 4 1.4 - 32.9 45

208/230-3-60 2 30.1 47 225 208/230-1-60 3/4 4 3.0 - 7 9.8 100

460-3-60 2 16.7 26 114 460-1-60 3/4 4 1.6 - 4 4.0 60 575-3-60 2 12.2 19 80 575-1-60 3/4 4 1.4 - 32.9 45

1. Based on three, 75°C insulated copper conductors in conduit and ambient of 30°C.

2. Maximum fuse or maximum circuit breaker (HACR type per NEC). Refer to NEC/NFPA No. 70, Articles 440-11, 12 for information on minimum disconnect sizing.

Compressors Outdoor Fan Motor Pwr Conv Outlet Qty

RLA

(each)

MCC

(each)

LRA

(each)

Power

Supply

HP Qty

FLA

(each)

FLA

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Minimum

Circuit

Ampacity

Maximum Fuse Size

(A)

Table 6: Electrical Data - Outdoor Unit - HP With Powered Convenience Outlet

Compressors Outdoor Fan Motor Pwr Conv Outlet

Model

PC090

PC120

PC180

PD180

PC240

PD240

Power

Supply

208/230-3-60 1 25.0 39 164 208/230-1-60 1/3 2 2.1 10.0 45.5 60

460-3-60 1 12.2 19 100 460-1-60 1/3 2 1.2 5.0 22.6 30 575-3-60 1 9.0 14 78 575-1-60 1/3 2 0.9 4.0 17.1 25

208/230-3-60 2 18.1 28.3 137 208/230-1-60 3/4 2 3.0 10.0 56.8 70

460-3-60 2 9.0 14.0 62 460-1-60 3/4 2 1.6 5.0 28.5 35 575-3-60 2 6.8 10.6 50 575-1-60 3/4 2 1.4 4.0 22.0 25

208/230-3-60 2 25.0 39 164 208/230-1-60 1/3 4 2.1 10.0 74.7 90

460-3-60 2 12.2 19 100 460-1-60 1/3 4 1.2 5.0 37.2 45 575-3-60 2 9.0 14 78 575-1-60 1/3 4 0.9 4.0 28.0 35

208/230-3-60 2 25.0 39 164 208/230-1-60 1/3 4 2.1 10.0 74.7 90

460-3-60 2 12.2 19 100 460-1-60 1/3 4 1.2 5.0 37.2 45 575-3-60 2 9.0 14 78 575-1-60 1/3 4 0.9 4.0 28.0 35

208/230-3-60 2 30.1 47 225 208/230-1-60 3/4 4 3.0 10.0 89.8 110

460-3-60 2 16.7 26 114 460-1-60 3/4 4 1.6 5.0 49.0 60 575-3-60 2 12.2 19 80 575-1-60 3/4 4 1.4 4.0 36.9 45

208/230-3-60 2 30.1 47 225 208/230-1-60 3/4 4 3.0 10.0 89.8 110

460-3-60 2 16.7 26 114 460-1-60 3/4 4 1.6 5.0 49.0 60 575-3-60 2 12.2 19 80 575-1-60 3/4 4 1.4 4.0 36.9 45

Qty

RLA

(each)

MCC

(each)

LRA

(each)

Power

Supply

HP Qty

1. Based on three, 75°C insulated copper conductors in conduit and ambient of 30°C.

2. Maximum fuse or maximum circuit breaker (HACR type per NEC). Refer to NEC/NFPA No. 70, Articles 440-11, 12 for information on minimum disconnect sizing.

FLA

(each)

FLA

Minimum

Circuit

Ampacity

Maximum Fuse Size

(A)

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Refrigerant Mains

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.

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 Evapora tor - 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 60 psi, some refrigerant will flash before it reaches the thermal expansion valve.

Flash gas

1. Increases the liquid line pressure loss due to friction that in

2. Reduces the capacity of the refrigerant control device

3. Erodes the seat of the refrigerant control device.

4. Causes erratic control of the refrigerant entering the

turn causes further flashing.

which starves the evaporator.

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 that meets local codes. 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 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 bi-flow solid core 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.

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.

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.

10 Johnson Controls Unitary Products

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