Johnson Controls GHGD, THGD, THJD, YHJD, YHJR Instruction Manual

...

0 (0)

835961-UIM-A-0112

R-410A OUTDOOR SPLIT-SYSTEM HEAT PUMP

MODELS: 13 SEER & 14.5 SEER THG(D,F)/GHGD/THJ(D,F)/YHJ(D, F)/YHJ R/THJR SERIES

1.5 TO 5 TONS – 1 & 3 PHASE

INSTALLATION MANUAL

LIST OF SECTIONS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 ORIFICE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 TXV INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SYSTEM START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSTRUCTING THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

LIST OF FIGURES

Typical Installation with Required Clearances . . . . . . . . . . . . . . . . . . .2 Tubing Hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Orifice Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Outdoor Unit Control Box - Single Phase . . . . . . . . . . . . . . . . . . . . . . .7 Outdoor Unit Control Box - Three Phase . . . . . . . . . . . . . . . . . . . . . . .7 Typical Field Wiring (Air Handler / Electrical Heat) (Single-Phase) . . .7 Typical Field Wiring (Air Handler / Electrical Heat) - (Three Phase) . .8

Heat Pump Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Time/Temp Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Demand Defrost Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Defrost Operation Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Wiring Diagram - Single Phase (Demand Defrost) . . . . . . . . . . . . . . 13 Wiring Diagram - Single Phase (Time-Temp) . . . . . . . . . . . . . . . . . . 14 Wiring Diagram - Three Phase (Demand Defrost) . . . . . . . . . . . . . . 15 Wiring Diagram - Three Phase (Time-Temp) . . . . . . . . . . . . . . . . . . 16

LIST OF TABLES

R-410A Saturation Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 TEST Input Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

X/L Output Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Defrost Initiate Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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 matching indoor coil plus 15 feet of field supplied lines.

Matching indoor coils are available with a thermal expansion valve or an orifice liquid feed sized for the most common usage. The orifice size and/or refrigerant charge may need to be changed for some indoor-outdoor unit combinations, elevation differences, or total line lengths. Refer to Application Data covering “General Piping Recommendations and Refrigerant Line Length” (Part Number 247077).

SECTION II: SAFETY

This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury.

Understand and pay particular attention to the signal words DANGER,

WARNING, or CAUTION. DANGER indicates an imminently hazardous situation, which, if not

avoided, will result in death or serious injury

WARNING indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury

CAUTION indicates a potentially hazardous situation, which, if not avoided may result in minor or moderate injury

. It is also used to alert against unsafe practices and hazards involving only property damage.

INSPECTION

As soon as a unit is received, it should be inspected for possib le damage during transit. If damage is evident, the extent of the damage should be noted on the carrier’s delivery receipt. A separate request for inspection by the carrier’s agent should be made in writing. See Local Distributor for more information.

Improper installation may create a condition where the operation of the product could cause personal injury or property damage.

Improper installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual for assistance or for additional information, consult a qualified contractor, installer, or service agency.

This product must be installed in strict compliance with the enclosed installation instructions and any applicable local, state, and national codes including, but not limited to building, electrical, and mechanical codes.

835961-UIM-A-0112

2 Johnson Controls Unitary Products

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 800 psig high side and 250 psig low side with 550 psig low side restart.

• All hoses must have a 700 psig service pressure rating.

• Leak detectors should be designed to detect HFC refrigerant.

• Recovery equipment (including refrigerant recovery containers) must be specifically designed to handle R-410A.

• Do not use an R-22 TXV.

• A liquid-line filter drier is required on every unit.

LIMITATIONS

The unit should be installed in accordance with all National, State, and Local Safety Codes and the limitations listed below:

1. Limitations for the indoor unit, coil, and appropriate accessories must also be observed.

2. The outdoor unit must not be installed with any duct work in the air stream. The outdoor fan is the propeller type and is not designed to operate against any additional external static pressure.

3. The maximum and minimum conditions for operation must be observed to assure a system that will give maximum performance with minimum service.

4. The maximum allowable line length for this product is 75 feet.

SECTION III: UNIT INSTALLATION

LOCATION

Before starting the installation, select and check the suitability of the location for both the indoor and outdoor unit. Observe all limitations and clearance requirements.

The outdoor unit must have sufficient clearance for air entrance to the condenser coil, for air discharge, and for service access. See Figure 1.

If the unit is to be installed on a hot sun exposed roof or a black-topped ground area, the unit should be raised sufficiently above the roof or ground to avoid taking the accumulated layer of hot air into the outdoor unit.

Provide an adequate structural support.

ADD-ON REPLACEMENT/RETROFIT

When this unit is being used as a replacement for an R-22 unit, it is required that the outdoor unit, indoor coil, and metering device all be replaced. 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/ condensing 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 contaminants, and remove after 50 hours of operation.

4. If the outdoor unit is being replaced due to a compressor burnout, then installation of a 100% activated alumina suction-line filter drier in the suction-line is required, in addition to the factory installed liquid-line drier. Operate the system for 10 hours. Monitor the suction drier pressure drop. If the pressure drop exceeds 3 psig, replace both the suction-line and liquid-line driers. After a total of 10 hours run time where the suction-line pressure drop has not exceeded 3 psig, replace the liquid line drier, and remove the suction-line drier. Never leave a suction-line drier in the system longer than 50 hours of run time.

AIR TEMPERATURE AT

OUTDOOR COIL, °F

AIR TEMPERATURE AT

INDOOR COIL, °F

Min. Max. Min. Max.

Cool

HeatDBCool

Heat

Cool

Heat

Cool

Heat

50 -10 115 75 57

1. Operation below this temperature is permissible for a short period of time, during morning warm-up.

72 80

For multiple unit installations, units must be spaced a minimum of 24 inches apart (coil face to coil face).

NOTICE

FIGURE 1: Typical Installation with Required Clearances

THERMOSTAT

SEAL OPENING(S) WITH PERMAGUM OR EQUIVALENT

TO INDOOR COIL

TO FURNACE OR AIR HANDLER TERMINAL BLOCK

NEC CLASS 2 WIRING

NEC CLASS 1 WIRING

ALL OUTDOOR WIRING MUST BE WEATHERPROOF.

CONTROL ACCESS PANEL

WEATHERPROOF DISCONNECT SWITCH

MINIMUM 18” SERVICE ACCESS CLEARANCE ON ONE SIDE

60” OVERHEAD CLEARANCE

10” CLEARANCE AROUND PERIMETER

NOTE:

835961-UIM-A-0112

Johnson Controls Unitary Products 3

GROUND INSTALLATION

The unit may be installed at ground level on a solid base that will not shift or settle, causing strain on the refrigerant lines and possible leaks. Maintain the clearances shown in Figure 1 and install the unit in a level position.

Normal operating sound levels may be objectionable if the unit is placed directly under windows of certain rooms (bedrooms, study, etc.).

Condensate will drain from beneath the coil of the outdoor unit during the defrost cycle. Normally this condensate may be allowed to drain directly on the ground.

Elevate the unit sufficiently to prevent any blockage of the air entrances by snow in areas where there will be snow accumulation. Check the local weather bureau for the expected snow accumulation in your area.

Isolate the unit from rain gutters to avoid any possible wash out of the foundation.

ROOF INSTALLATION

When installing units on a roof, the structure must be capable of supporting the total weight of the unit, including a pad, lintels, rails, etc., which should be used to minimize the transmission of sound or vibration into the conditioned space.

UNIT PLACEMENT

1. Provide a base in the pre-determined location.

2. Remove the shipping carton and inspect for possible damage.

3. Compressor tie-down bolts should remain tightened.

4. Position the unit on the base provided.

LIQUID LINE FILTER-DRIER

The heat pumps have a solid core bi-flow filter/drier located on the liquid line.

*As listed on the “Energy Guide yellow sticker on the unit.

PIPING CONNECTIONS

The outdoor unit must be connected to the indoor coil using field supplied refrigerant grade copper tubing that is internally clean and dry. Units should be installed only with the tubing sizes for approved system combinations as specified in Tabular Data Sheet. The charge given is applicable for total tubing lengths up to 15 feet. See Application Data Part Number 247077 for installing tubing of longer lengths and elevation differences.

PRECAUTIONS DURING LINE INSTALLATION

1. Install the lines with as few bends as possible. Care must be taken not to damage the couplings or kink the tubing. Use clean hard drawn copper tubing where no appreciable amount of bending around obstruction is necessary. If soft copper must be used, care must be taken to avoid sharp bends which may cause a restriction.

2. The lines should be installed so that they will not obstruct service access to the coil, air handling system, or filter.

3. Care must also be taken to isolate the refrigerant lines to minimize noise transmission from the equipment to the structure.

4. The vapor line must be insulated with a minimum of 1/2" foam rubber insulation (Armaflex or equivalent). Liquid lines that will be exposed to direct sunlight and/or high temperatures must also be insulated.

5. Tape and suspend the refrigerant lines as shown. DO NOT allow tube metal-to-metal contact. See Figure 2.

6. Use PVC piping as a conduit for all underground installations as shown in Figure 3. Buried lines should be kept as short as possible to minimize the build up of liquid refrigerant in the vapor line during long periods of shutdown.

7. Pack fiberglass insulation and a sealing material such as permagum around refrigerant lines where they penetrate a wall to reduce vibration and to retain some flexibility.

8. See Form 247077 for additional piping information.

The outdoor unit should not be installed in an area where mud or ice could cause personal injury. Remember that condensate will drip from the unit coil during heat and defrost cycles and that this condensate will freeze when the temperature of the outdoor air is below 32°F.

Heat pumps will defrost periodically resulting in water drainage. The unit should not be located where water drainage may freeze and create a hazardous condition - such as sidewalks and steps.

Replacements for the liquid line drier must be exactly the same as marked on the original factory drier. See Source 1 for O.E.M. replacement driers.

Failure to do so or using a substitute drier or a granular type may result in damage to the equipment.

Filter-Drier

Source 1 Part No.

Apply with Models

S1-52636219000 All

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 flow. Slope horizontal vapor lines at least 1" every 20 feet toward the outdoor unit to facilitate proper oil return.

FIGURE 2: Tubing Hanger

FIGURE 3: Underground Installation

NOTICE

Liquid Line

Incorrect

Correct

Tape

Sheet Metal Hanger

Insulated Vapor Line

TO INDOOR COIL

TO O UT DO OR UNI T

LIQUID LINE

CAP

PVC

CONDUIT

INSULATED

VAPOR LINE

835961-UIM-A-0112

4 Johnson Controls Unitary Products

PRECAUTION S DUR IN G BRAZING OF LINES

All outdoor unit and evaporator coil connections are copper-to-copper and should be brazed with a phosphorous-copper alloy material such as Silfos-5 or equivalent. DO NOT use soft solder. The outdoor units have reusable service valves on both the liquid and vapor connections. The total system refrigerant charge is retained within the outdoor unit during shipping and installation. The reusable service valves are provided to evacuate and charge per this instruction.

Serious service problems can be avoided by taking adequate precautions to assure an internally clean and dry system.

PRECAUTION S DUR IN G BRAZ I NG SERVICE VALVE

Precautions should be taken to prevent heat damage to service valve by wrapping a wet rag around it as shown in Figure 4. Also, protect all painted surfaces, insulation, and plastic base during brazing. After brazing cool joint with wet rag.

Valve can be opened by removing the plunger cap and fully inserting a hex wrench into the stem and backing out counter-clockwise until valve stem just touches the chamfered retaining wall.

Connect the refrigerant lines using the following procedure:

1. Remove the cap and Schrader core from both the liquid and vapor service valve service ports at the outdoor unit. Connect low pressure nitrogen to the liquid line service port.

2. Braze the liquid line to the liquid valve at the outdoor unit. Be sure to wrap the valve body with a wet rag. Allow the nitrogen to continue flowing. Refer to the Tabular Data Sheet for proper liquid line sizing.

3. Go to “SECTION IV” or “SECTION V” for orifice or TXV Installation depending on application.

4. Braze the liquid line to the evaporator liquid connection. Nitrogen should be flowing through the evaporator coil.

5. Slide the grommet away from the vapor connection at the indoor coil. Braze the vapor line to the evaporator vapor connection. After the connection has cooled, slide the grommet back into original position. Refer to the Tabular Data Sheet for proper vapor line sizing.

6. Protect the vapor valve with a wet rag and braze the vapor line connection to the outdoor unit. The nitrogen flow should be exiting the system from the vapor service port connection. After this connection has cooled, remove the nitrogen source from the liquid fitting service port.

7. Replace the Schrader core in the liquid and vapor valves.

8. 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).

9. Evacuate the vapor line, evaporator, and the liquid line to 500 microns or less.

10. Replace cap on service ports. Do not remove the flare caps from the service ports except when necessary for servicing the system.

11. Release the refrigerant charge into the system. Open both the liquid and vapor valves by removing the plunger cap and with an allen wrench back out counter-clockwise until valve stem just touches the chamfered retaining wall. If the service valve is a ball valve, use a cresent 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”.

12. Replace plunger cap finger tight, then tighten an additional 1/12 turn (1/2 hex flat). Cap must be replaced to prevent leaks.

See "System Charge” section for checking and recording system charge.

Dry nitrogen should always be supplied through the tubing while it is being brazed, because the temperature is high enough to cause oxidation of the copper unless an inert atmosphere is provided. The flow of dry nitrogen should continue until the joint has cooled. Always use a pressure regulator and safety valve to insure that only low pressure dry nitrogen is introduced into the tubing. Only a small flow is necessary to displace air and prevent oxidation.

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.

FIGURE 4: Heat Protection

Do not install any coil in a furnace which is to be operated during the heating season without attaching the refrigerant lines to the coil. The coil is under 30 to 35 psig inert gas pressure which must be released to prevent excessive pressure build-up and possible coil damage.

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.

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.

Never attempt to repair any brazed connections while the system is under pressure. Personal injury could result.

NOTICE

835961-UIM-A-0112

Johnson Controls Unitary Products 5

SECTION IV: ORIFICE INSTALLATION

Install Schrader Valve Core and Orifice as follows:

1. Relieve the holding charge by depressing the Schrader valve stem located in the end of the liquid line. Cut the spundown copper to allow installation of the suction line.

2. Slide indoor coil out of cabinet far enough to gain access to equalizer fitting on the suction line.

3. After holding charge is completely discharged remove black plastic cap on equalizer fitting.

4. Install Schrader Valve Core supplied with the outdoor unit into equalizer fitting using a valve core tool.

5. Loosen and remove the liquid line fitting from the orifice distributor assembly. Note that the fitting has right hand threads

6. Install proper size orifice supplied with outdoor unit. Refer to supplied Tabular Data Sheet for specific orifice size and indoor coil match up.

7. After orifice is installed reinstall the liquid line to the top of the orifice distributor assembly. Hand tighten and turn an additional 1/8 turn to seal. Do not over tighten fittings.

8. Leak test system.

9. Replace black plastic cap on equalizer fitting.

10. Slide indoor coil back into cabinet.

SECTION V: TXV INSTALLATIONS

For installations requiring a TXV, the following are the basic steps for installation. For detailed instructions, refer to the Installation Instructions accompanying the TXV kit.

Install TXV kit as follows:

1. Relieve the holding charge by depressing the Schrader valve stem located in the end of the liquid line. Cut the spundown copper to allow installation of the suction line.

2. After holding charge is completely discharged, loosen and remove the Schrader cap seal.

3. Loosen and remove distributor cap seal.

4. Install the thermal expansion valve to the orifice distributor assembly with supplied fittings. Hand tighten and turn an additional 1/4 turn to seal. Do not overtighten fittings.

5. Install the liquid line to the top of the thermal expansion valve with fitting supplied with the liquid line. Hand modify the liquid line to align with casing opening. Hand tighten the liquid line and an additional 1/4 turn to seal.

6. Install the TXV equalizer line into the vapor line as follows: a. Hand tighten the 1/4” SAE nut to the Schrader fitting and an

additional 1/3 turn to seal.

7. Install the TXV bulb to the vapor line near the equalizer line, using the bulb clamp(s) furnished with the TXV assembly. Ensure the bulb is making maximum contact.

a. Bulb should be installed on a horizontal run of the vapor line if

possible. On lines under 7/8" O.D. the bulb may be installed on top of the line. With 7/8" O.D. and over, the bulb should be installed at the position of about 2 or 10 o'clock.

b. If bulb installation is made on a vertical run, the bulb should

be located at least 16” (40.6 cm) from any bend, and on the tubing sides opposite the plane of the bend. The bulb should be positioned with the bulb tail at the top, so that the bulb acts as a reservoir.

c. Bulb should be insulated using thermal insulation pro vided to

protect it from the effect of the surrounding ambient temperature. Cover completely to insulate from air-stream.

All connections to be brazed are copper-to-copper and should be brazed with a phosphorous-copper alloy material such as Silfos-5 or equivalent. DO NOT use soft solder.

Install the TXV bulb to the vapor line near the equalizer line, using the two bulb clamps furnished with the TXV assembly. Ensure the bulb is making maximum contact. Refer to TXV installation instruction for view of bulb location.

Failure to install Schrader Valve Core on orifice applications could result in total refrigerant loss of the system!

FIGURE 5: Orifice Installation

LIQUID LINE SWIVEL COUPLING (This fitting is a right-hand thread, turn counter-clockwise to remove)

ORIFICE

DISTRIBUTOR

In all cases, mount the TXV bulb after vapor line is brazed and has had sufficient time to cool.

Schrader valve core MUST NOT be installed with TXV installation. Poor system performance or system failure could result.

In all cases, mount the TXV bulb after vapor line is brazed and has had sufficient time to cool.

+ 11 hidden pages