Johnson Controls YXV SERIES, 20 SEER SERIES, AL21 SERIES, AC21 SERIES Installation Manual

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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

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

2 Johnson Controls Unitary Products

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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

Tape

A0151-001

OUTDO

Correct

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

OOR C

PVC CO

LIN

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

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

thermostat will adjust the indoor temperature set-

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

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

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

thermostat. Refer to the Hx

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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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

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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

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.

5284792-UIM-D-1017

TABLE 4:

Inverter Control Fault Microelectronic Fault 10:15:00 1

Outdoor Control Fault

Status Code Display TABLE 5:

Description Required Condition LED Color

No power to control No power to control OFF OFF Control Failure System has 24 VAC present and the microprocessor is active. No faults active 2s ON / 2s OFF (“Heartbeat”) Yellow

Control normal operation – in ASCD period

System is active and presently communicating successfully.

Same Priority Fault Storage

Control Description

Inverter Control

Communications Fault

Status Code Display

Time of

Fault

10:15:01 1

Fault

Priority

compressor speed > 0, ASCD

The main control board contains 2 LED’s for status and fault display as shown in Figure 10. The control will provide a status code indicating the state of the system using the Yellow LED as detailed in Table 5. The Red LED indicates a system fault is present. Further details of the fault can be found on the outdoor screen.

Control failure occurs and

can be detected.

No faults/events active,

0.1 sec ON / 0.1 sec OFF Yellow

timer not expired

No faults/events active,

0.5 sec ON / 0.5 sec OFF Yellow

timer not expired

ON Yellow

SECTION VIII: OUTDOOR SCREEN OPERATION

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FIGURE 11: Outdoor Display The system is provided with an advanced screen to assist in unit com-

missioning and troubleshooting. Operating pressures and temperatures from the system sensors are displayed in a format emulating a set of refrigerant gauges. Full description text is scrolled across a banner display to show current system operation and status. A menu structure for the outdoor display can be found in Table 6 and general operation is detailed in the following pages.

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GENERAL DISPLAY OPERATION

1. During an Active Call

A. Display Current system values:

Value

• COMPRESSOR SPEED (RPM)

• OD FAN SPEED (RPM)

• EEV STEP (ID Status)

• EEV STEP (OD Status)

• ID FAN SPEED (CFM)

• INPUT CURRENT (AMPS) -From Inverter Input

• INPUT VOLTAGE (VOLTS) -From Inverter Input

• INPUT WATTS (WATTS) -From Inverter Input

Equipment Status information will scroll sequentially on a continuous loop, example below.

Continuous Loop Example:

COMPRESSOR (RPM) * OD FAN (RPM) * EEV STEP (ID EEV) * EEV STEP (OD EEV) * ID FAN (CFM) * INVERTER (APMS) * INVERTER (VOLTS) * INVERTER (WATTS)

2. No Active Call, High Voltage is applied The control will scroll and display * STANDBY * when there are no active calls for compressor operation.

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10 Johnson Controls Unitary Products

5284792-UIM-D-1017

3. If any of the following conditions exists, do not display current values defined in 1-3 in the banner.

The control will indicate ASCD TIMER (ACTIVE) and display it as the highest priority over all of the below defined active modes, if the ASCD Timer is currently active.

A. Will ONLY Display the Active Condition

• ASCD TIMER (ACTIVE)

-Only present when the ASCD Timer is Active.

• DEMAND RESPONSE (ACTIVE)

• FACTORY RUN TEST (ACTIVE)

• REPAIR HEAT - HP (ACTIVE)

• REPAIR COOL - HP (ACTIVE)

• REPAIR COOL - AC (ACTIVE)

TABLE 6:

EQUIPMENT STATUS

Outdoor Display Menu Structure

MAIN LAYER SECOND LAYER THIRD LAYER BASE LAYER

COMPRESSOR (RPM) OD FAN (RPM) ID EEV (SP) ID FAN (CFM) COMPRESSOR (RPM) OD FAN (RPM) ID EEV (SP) ID FAN (CFM) INPUT CURRENT (AMPS) INPUT VOLTAGE (VOLTS) INPUT WATTS (WATTS) OFF (Default) NORMALY OPEN RELAY NORMALY CLOSED RELAY System will first determine Unit Type (Reversing Valve Presence) and Unit Tonnage

(Inverter Configuration) and will walk the user through the operation, per inverter part number.

2-TON 3-TON 4-TON 5-TON

CURRENT SYSTEM FAULTS STORED SYSTEM FAULTS CLEAR FAULT LOG BYPASS ASCD TIMER OPERATIONAL MODE (AC) System will display Unit Type (Reversing Valve Presence) and Unit Tonnage (Inverter Con-

figuration)

System determines Unit Tonnage (Inverter Configuration) and will walk the user through the operation.

CONFIGURATIONS

MODES

COMMANDED

CURRENT

DEMAND RESPONSE

INVERTER REPAIR PART

SOFT JUMPERS COMFORT - EFFICIENCY

FAULT MODE

TEST MODE

SERVICE MODE COOLING

CHARGE VERIFICATION

• EMERGENCY HEAT (ACTIVE)

• DEFROST CAL (ACTIVE)

• DEFROST DD (ACTIVE)

• DEFROST TT (ACTIVE)

4. No Active Call, No High Voltage

A. Display is OFF

MENU NAVIGATION

Time Duration Response

a. Tap Menu = Back to the second layer string b. Press Menu 2-5 seconds = Back to main layer string

c. Press Menu > 5 seconds

= Exit menu layer string and Return

to the General Display Operation

EFFICIENCY (Default)

COMFORT

MENU NOTES:

Discharge Pressure, Liquid Temperature, Suction Pressure, Suction Temperature, Calculated Superheat, and Calculated Subcool. On the high gauge display, the control shall toggle at a rate of 10 seconds between the Liquid Temperature and the Subcool calculated value. On the low gauge display, the control shall toggle at a rate of 10 seconds between the Suction Temperature and the Superheat calculated value.

Time out period: While in the Menu Structure if the display does not sense a navigational response within 5 minutes, the outdoor display will return to General Display Operation.

Johnson Controls Unitary Products 11

Door Switch: If the outdoor display is in the Menu Structure and the door switch is de-activated, the system will de-energizing the outdoor screen. Upon re-energizing the outdoor screen, the display will return to the General Display Operation.

Saved Configuration/Selection: The system will save all individual configuration selections made on the Outdoor Display. Upon returning to a previously saved configuration the system shall display the previously saved configuration setting(s). Not the Default setting(s), unless the saved selection was in fact the default selection.

Operational Mode: The system will display (Inverter profile and reversing valve dependent) unit tonnage when the user selects Operational Mode (AC).

5284792-UIM-D-1017

FAULT/STATUS CODE OUTDOOR SYSTEM TROUBLE SHOOTING

TABLE 7:

Operational Faults

System in high-pressure

mode of operation was

System in high-pressure

mode of operation was

match the stored value

Inverter Model Number

Outdoor Control Faults/Status Code Display

Outdoor Control

Description

High-pressure

switch fault

(not in lockout yet)

switch lockout (last

normal compressor)

switch lockout (last

normal compressor)

Low Voltage

(<19 VAC)

Inverter Control

Communications

Fault

JCI RS-485

Communications

Lost

Repair part tonnage

selection does not

programmed in the

JCI factory

installed does not

match the stored

tonnage in EEPROM

LED

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

Outdoor

Display Text

HPS – OPEN

HPS SOFT

LOCKOUT – NORMAL

HPS HARD

LOCKOUT – NORMAL

LOW VOLTAGE –

BELOW 19VAC

COMMUNICATIONS

LOST –

INVERTER DRIVE

COMMUNICATIONS

LOST –

SYSTEM MASTER

INVERTER

CONFIGURATION

ERROR

INVERTER MODEL

INSTALLATION

ERROR –

HARD LOCKOUT

Possible

Causes

Reduced or no

OD airflow

Reduced or no

OD airflow due to

motor limits OD air temp

out of range.

Pressure switch is disconnected

from OD unit

control board.

Pressure

switch faulty.

Faulty EEV or

restriction

System

overcharged.

See HPS fault. See HPS fault. – X

Under Voltage

Bad wiring

Damaged OD Control Board

Damaged

Inverter Board

Bad wiring

System out

of phase.

Correct model

number of drive

not installed

Correct model

number of drive

not installed

Verify outdoor coil is clean.

Verify fan is functioning. Verify

there is airflow through the coil.

Check motor current against limits.

Verify the outdoor ambient

Check high pressure switch

connection on the outdoor board.

Ohm out the switch to confirm

continuity when the system

pressure is below 650 PSIG.

Verify the system has the correct

amount of refrigerant charge.

Refer to the tables from the

Check input power supply wires.

Check input power supply and

24VAC circuit before and during

operation to verify voltage is

within range given in manual

Check 24Vac transformer

tap for correct input power

Remove power to system for

2 minutes. Reapply power.

If problem remains, replace

Remove power to system for

2 minutes. Reapply power.

If problem remains, replace drive.

Check wiring from OD to ID

unit as well as to thermostat.

Check ground and phasing on the

low and high voltage side.

Verify the replacement part

model number with the list

Verify the replacement part

model number with the list

Solution

Check input voltage to

ensure within range.

temperature is within the

range listed in the IOM.

Check EEV operation as

superheat and/or

subcooling will be high.

product technical guide.

(197-252Vac and >19).

supply voltage selection.

Check wiring from

OD control to Inverter.

OD Control Board.

supplied by Source-1.

Left Triangle

Indication

(OD Screen)

Right Triangle

Indication

(OD Screen)

–X

––

12 Johnson Controls Unitary Products

5284792-UIM-D-1017

TABLE 7:

Required Sensor or Switch Faults

sensor failure (short)

sensor failure (open)

(short) not in lockout yet

(open) not in lockout yet

Coil sensor failure (open)

Liquid line temperature

sensor failure (short)

Liquid line temperature

sensor failure (short)

Liquid line temperature

sensor failure (open)

Liquid line temperature

sensor failure (open)

Discharge temperature

sensor failure (short)

Discharge temperature

sensor failure (open)

Discharge temperature

sensor failure (open)

sensor failure (short)

Outdoor Control Faults/Status Code Display

Outdoor Control

Description

Outdoor ambient

Coil sensor failure

Coil sensor

failure (short)

Coil sensor failure

not in lockout yet

Suction temperature

not in lockout yet

Suction temperature

LED

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

Outdoor

Display Text

OUTDOOR AMBIENT

SENSOR - SHORT –

SOFT LOCKOUT

OUTDOOR AMBIENT

SENSOR - SHORT –

HARD LOCKOUT

OUTDOOR AMBIENT

SENSOR – OPEN –

SOFT LOCKOUT

OUTDOOR AMBIENT

SENSOR – OPEN –

HARD LOCKOUT

COIL TEMP

SENSOR – SHORT

COIL TEMP

SENSOR – SHORT –

SOFT LOCKOUT

COIL TEMP

SENSOR – SHORT –

HARD LOCKOUT

COIL TEMP

SENSOR – OPEN

COIL TEMP

SENSOR – OPEN –

SOFT LOCKOUT

COIL TEMP

SENSOR – OPEN –

HARD LOCKOUT

LIQUID TEMP

SENSOR – SHORT

LIQUID TEMP

SENSOR – SHORT –

SOFT LOCKOUT

LIQUID TEMP

SENSOR – OPEN

LIQUID TEMP

SENSOR – OPEN –

SOFT LOCKOUT

DISCHARGE TEMP SENSOR – SHORT

DISCHARGE TEMP

SENSOR – OPEN

DISCHARGE TEMP

SENSOR – OPEN –

SOFT LOCKOUT

SUCTION TEMP

SENSOR – SHORT

SUCTION TEMP

SENSOR – SHORT –

SOFT LOCKOUT

Possible

Causes

Bad thermistor

Bad main OD

control board.

Bad thermistor

Bad main OD

control board.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

See Ambient

Sensor failure.

Left Triangle

Solution

Check temperature vs.

resistance curve per Table 9.

Check wiring lead from

sensor to board.

If leads and sensor are fine, board

is bad and needs to be replaced.

Check temperature vs.

resistance curve per Table 9.

Check wiring lead

from sensor to board.

If leads and sensor are fine, board

is bad and needs to be replaced.

See Ambient Sensor failure. – –

See Ambient Sensor failure. – X

See Ambient Sensor failure.

See Ambient Sensor failure. – X

See Ambient Sensor failure. X –

Indication

(OD Screen)

Right Triangle

––Bad wiring leads

– X

Indication

(OD Screen)

Johnson Controls Unitary Products 13

5284792-UIM-D-1017

TABLE 7:

Outdoor Control Faults/Status Code Display

Outdoor Control

Description

Suction temperature sensor failure (open)

not in lockout yet

Suction temperature sensor failure (open)

Discharge pressure

sensor failure

(low voltage) not in

lockout yet

Discharge pressure

sensor failure

(low voltage)

Discharge pressure

sensor failure

(high voltage) not

in lockout yet

Discharge pressure

sensor failure

(high voltage)

Suction pressure

sensor failure

(low voltage)

Suction pressure

sensor failure (high voltage)

LED

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

RED

(Solid)

Outdoor

Display Text

SUCTION TEMP

SENSOR – OPEN

SUCTION TEMP

SENSOR – OPEN –

SOFT LOCKOUT

DISCHARGE

PRESSURE SENSOR –

LOW VOLTAGE

DISCHARGE

PRESSURE SENSOR –

LOW VOLTAGE –

SOFT LOCKOUT

DISCHARGE

PRESSURE SENSOR –

HIGH VOLTAGE

DISCHARGE

PRESSURE SENSOR –

HIGH VOLTAGE –

SOFT LOCKOUT

SUCTION PRESSURE

SENSOR –

LOW VOLTAGE –

SOFT LOCKOUT

SUCTION PRESSURE

SENSOR –

HIGH VOLTAGE –

SOFT LOCKOUT

Possible

Causes

See Ambient

Sensor failure.

See Ambient

Sensor failure.

Bad wiring

harness Bad OD

control board

Bad transducer

Bad OD

control board

See Discharge

Pressure

Sensor Fault

See Discharge

Pressure

Sensor Fault

See Discharge

Pressure

Sensor Fault

Bad wiring

harness Bad OD

control board

Bad transducer

Bad OD

control board

Bad wiring

harness Bad OD

control board

Bad transducer

Bad OD

control board

Left Triangle

Solution

See Ambient Sensor failure. X –

Check harness for continuity.

If supply voltage across BLK and

RED/WHT doesn't read 4.5-5.5

VDC replace OD control board.

If voltage across BLK and RED/WHT

is within a tolerance of 4.5-5.5 VDC

and the voltage across WHT and RED/WHT doesn't read between

0.5-4.5 VDC replace sensor.

If voltage across WHT and RED/WHT

reads between 0.5-4.5 VDC but fault still exists, replace OD control board.

See Discharge

Pressure Sensor Fault

See Discharge

Pressure Sensor Fault

See Discharge

Pressure Sensor Fault

Check harness for continuity.

If supply voltage across BLK and

BLU/WHT doesn't read 4.5-5.5 VDC

replace OD control board.

If voltage across BLK and BLU/WHT

is within a tolerance of 4.5-5.5 VDC

and the voltage across WHT and BLU/WHT doesn't read between

0.5-4.5 VDC replace sensor.

If voltage across WHT and BLU/WHT

reads between 0.5-4.5 VDC but fault still exists, replace OD control board.

Check harness for continuity.

If supply voltage across BLK and

BLU/WHT doesn't read 4.5-5.5 VDC

replace OD control board.

If voltage across BLK and BLU/WHT

is within a tolerance of 4.5-5.5 VDC

and the voltage across WHT and BLU/WHT doesn't read between

0.5-4.5 VDC replace sensor.

If voltage across WHT and BLU/WHT

reads between 0.5-4.5 VDC but fault still exists, replace OD control board.

Indication

(OD Screen)

–X

X–

Right Triangle

Indication

(OD Screen)

14 Johnson Controls Unitary Products

5284792-UIM-D-1017

TABLE 7:

Outdoor Control Faults/Status Code Display

Outdoor Control

Description

LED

Outdoor

Display Text

Discharge Temp Faults

High discharge

temperature (not in

lockout yet)

High discharge

temperature

High discharge

temperature

RED

(Solid)

RED

(Solid)

RED

(Solid)

HIGH DISCHARGE

TEMP –

SOFT LOCKOUT

HIGH DISCHARGE

TEMP –

HARD LOCKOUT

Suction Pressure Faults

Low suction

pressure (not in

lockout yet)

Low suction pressure

1. Refer to Figure 10 for Outdoor Control LED location.

RED

(Solid)

RED

(Solid)

RED

(Solid)

LOW SUCTION

PRESSURE

LOW SUCTION

PRESSURE –

SOFT LOCKOUT

LOW SUCTION

PRESSURE –

HARD LOCKOUT

TEMP

Possible

Causes

Insufficient

charge

Faulty sensor

Faulty EEV or

restriction

ID and OD

temperature

out of range.

See High

Discharge Temp.

See High

Discharge Temp.

Reduced or no

ID airflow

ID air temp

out of range.

Reduced or no

ID airflow due

to motor limits.

Insufficient

charge

Faulty suction

transducer Restriction

after the EEV

See Low Suction

Pressure

See Low Suction

Pressure

Left Triangle

Solution

Indication

(OD Screen)

Check refrigerant charge

Check discharge sensor with proce-

dure found in

discharge sensor faults.

Check EEV operation as

–X

superheat will be high.

Bring the temperature within design

parameters found in the IOM.

See High Discharge Temp. – X

Check for dirty filter -

clean or replace

Check blower motor operation

and airflow restrictions.

Dirty ID coil.

External static is too high -

correct duct work.

Verify the ID ambient temperature

is with the range listed in the

IOM/design parameters.

Check motor current against limits.

X–

Check input voltage to

ensure within range.

Check refrigerant charge

compared to tech service guide.

Check transducer

Check for temperature drop at various

section along the refrigerant circuit,

i.e., across filter drier, etc.

See Low Suction Pressure X –

See Low Suction Pressure

X –

Right Triangle

Indication

(OD Screen)

Johnson Controls Unitary Products 15

5284792-UIM-D-1017

TABLE 8:

Inverter - Faults

Phase Over Current

Compressor Phase

Inverter Drive Fault/Status Code Display

Inverter Drive

Description

C+B6:H16

Compressor

Current Foldback

Timeout

AC Input

Over Current

AC Input Current

Sampling Fault

DC Bus

Over Voltage

DC Bus

Under Voltage

AC Input

Over Voltage

AC Input

Under Voltage

Power Module

Over Temp

PFC-IGBT

Over Temp

LED

LED604 / LED2 1 or 3

LED 603 / LED3 4

LED604 / LED2 16

LED604 / LED2

LED 603 / LED3 5

LED604 / LED2 7

LED604 / LED2 8

LED604 / LED2 10

LED604 / LED2 9

LED604 / LED2 4

LED604 / LED2 5

Codes

14 Distorted input voltage

15 High compressor load.

Blink

OD Display Text

COMPRESSOR

PHASE OVER CURRENT –

INVERTER DRIVE

COMPRESSOR PHASE

CURRENT FOLDBACK –

INVERTER DRIVE

AC INPUT OVER

CURRENT –

INVERTER DRIVE

DC BUS OVER

VOLTAGE –

INVERTER DRIVE

DC BUS UNDER

VOLTAGE –

INVERTER DRIVE

AC INPUT OVER

VOLTAGE –

INVERTER DRIVE

AC INPUT UNDER

VOLTAGE –

INVERTER DRIVE

POWER MODULE

OVER TEMP –

INVERTER DRIVE

PFC-IGBT OVER TEMP –

INVERTER DRIVE

Possible

Causes

Check lead to the compressor

Loose or incorrect

wire connections

Check compressor winding resistance

Phase imbalance or shorted compressor

windings.

High compressor load.

High compressor load

caused by

internal damage.

Sensor on drive not

reading properly

See Compressor

Phase Over Current.

Reduced input voltage Check the line voltage if it is < 187VAC.

Drive component issue. Replace drive.

Sensor on drive not

reading properly.

High input voltage

Damaged Inverter Board Replace drive.

Low input voltage

Damaged Inverter Board Replace drive.

High input voltage

Damaged Inverter Board

Low input voltage

Damaged Inverter Board Replace drive.

Outdoor airflow is

too low or off.

Inverter component

damage.

Outdoor airflow is

too low or off.

Inverter component

damage.

Check compressor and if all looks normal and

Check the DC bus voltage if it is < 385VDC. Use

Check the DC bus voltage if it is > 385VDC. Use

Check the DC bus voltage if it is < 385VDC. Use

at the compressor terminals.

Verify system is within operating

conditions as outlined in IOM.

problems still persist when all other solutions

have been vetted, replace compressor.

See Compressor Phase Over Current.

Check the line voltage for noise.

Call an electrician or the power

company if noise is found.

Check the compressor is operating

Check the DC bus voltage if it is

> 385 VDC. Use bus voltage terminals

Check the line voltage if it is > 265VAC.

(If high, contact utility provider.)

bus voltage terminals found in Figures 12-14.

Check the line voltage if it is < 187VAC.

(If low, contact utility provider.)

Check the line voltage if it is > 265VAC.

(If high, contact utility provider.)

bus voltage terminals found in Figures 12-14.

Check the line voltage if it is < 187VAC.

(If low, contact utility provider.)

bus voltage terminals found in Figures 12-14.

Verify proper airflow over the drive heat sink.

Solution

plug and at inverter drive.

W: Black Wire (BLK).

V: Red Wire (RED).

U: Brown Wire (BRN).

2 Ton - 0.681 3 Ton - 0.203 4 Ton - 0.203 5 Ton - 0.203

Replace drive.

with in specified limits.

Replace drive.

found in Figures 12-14.

Replace drive.

16 Johnson Controls Unitary Products

5284792-UIM-D-1017

TABLE 8:

Compressor Phase

Current Imbalance

Power Module Temp

Communication Lost

Inverter Drive Fault/Status Code Display

Inverter Drive

Description

Lost Rotor

Position

Microelectronic

Fault

EEPROM Fault LED 603 / LED3 12

Low or Sensor

Open Fault

DC Bus

Under Voltage

AC Input Current

Foldback Timeout

Modbus

LED604 / LED2 2

LED 603 / LED3 14

LED 603 / LED3 13

LED 603 / LED3 2

LED604 / LED2 17 NA

LED 603 / LED3 15

LED 603 / LED3

LED

Blink

Codes

OD Display Text

LOST ROTOR POSITION –

INVERTER DRIVE

COMPRESSOR PHASE

CURRENT IMBALANCE –

INVERTER DRIVE

MICROELECTRONIC

FAULT –

INVERTER DRIVE

POWER MODULE TEMP LOW / SENSOR OPEN –

INVERTER DRIVE

AC INPUT CURRENT

FOLDBACK –

INVERTER DRIVE

MODBUS COMM LOST –

INVERTER DRIVE

Possible

Causes

Check lead to the compressor plug

Loose or incorrect

wire connections

Check compressor winding resistance

Phase imbalance or

shorted compressor

windings.

Inverter component

damage.

Internal compressor

damage.

Loose or incorrect

wire connections

Phase imbalance or shorted compressor

windings

Inverter component

damage.

Internal compressor

damage.

Digital Signal

Processor self-check.

Digital Signal

Processor self-check.

Temperature sensor on the drive is potentially faulty.

Low input voltage

Damaged Inverter Board Replace drive.

Reduced input voltage Check the line voltage if it is < 187VAC.

Distorted input voltage

High compressor load.

Drive component issue. Replace drive.

Sensor on drive not

reading properly.

Loose or

disconnected

communication

harness.

Broken or damaged

communication

harness.

Damaged OD

Control Board

Damaged

Inverter Board

Remove power to drive for 2 minutes. Reapply

Check the DC bus voltage if it is < 385VDC. Use

Check continuity of harness wires. If an problem

Remove power to drive for 2 minutes. Reapply

at the compressor terminals.

Check lead to the compressor plug

Check compressor winding resistance

at the compressor terminals.

power. If problem remains, replace drive.

bus voltage terminals found in Figures 12-14.

Check the line voltage if it is < 187VAC.

(If low, contact utility provider.)

Check the line voltage for noise.

Call an electrician or the power

company if noise is found.

Check the compressor is operating

Validate harness connection.

is found, replace communication harness.

Remove power to system for 2 minutes.

Reapply power. If problem remains,

replace OD Control Board.

power. If problem remains, replace drive.

Solution

and at inverter drive. W: Red Wire (RED). V: Black Wire (BLK).

U: Brown Wire (BRN).

2 Ton - 0.681 3 Ton - 0.203 4 Ton - 0.203 5 Ton - 0.203

Replace drive.

Replace compressor.

and at inverter drive.

W: Black Wire (BLK).

V: Red Wire (RED).

U: Brown Wire (BRN).

2 Ton - 0.681 3 Ton - 0.203 4 Ton - 0.203 5 Ton - 0.203

Replace drive.

Replace compressor.

with in specified limits.

Replace drive.

Johnson Controls Unitary Products 17

5284792-UIM-D-1017

TABLE 8:

PFC MCU and DSP

Communication Lost

COM MCU and DSP Communication Lost

PFC-IGBT Temp Low or Sensor Open Fault

Power Module Temp.

Compressor Model Configuration Error

Configuration Error

Inverter Drive Fault/Status Code Display

Inverter Drive

Description

Power Module

Temp High

PFC-IGBT

High Temp

LED

LED604 / LED2 18

LED604 / LED2 19

LED 603 9

LED 603 8

LED 603 1

Foldback Timeout

LED604 / LED2 21

LED 604 / LED2 22

High Pressure

Sensor Type

DLT Low Temp

or Open

AC Input Voltage

Sampling Fault

DC BUS Voltage

Sampling Fault

LED 604 / LED2

LED 603 / LED3

LED 603 / LED3 6 NA

LED 603 / LED3 7 NA

Blink

Codes

OD Display Text

POWER MODULE HIGH

INVERTER DRIVE

PFC-IGBT HIGH TEMP –

INVERTER DRIVE

PFC MCU /

DSP COMM ERROR –

INVERTER DRIVE

COM MCU / DSP COMM ERROR –

INVERTER DRIVE

PFC-IGBT LOW TEMP /

SENSOR OPEN –

INVERTER DRIVE POWER MODULE

TEMP FOLDBACK –

INVERTER DRIVE

COMPRESSOR MODEL

CONFIGURATION ERROR –

INVERTER DRIVE

HPS CONFIGURATION

INVERTER DRIVE

DLT CONFIGURATION

INVERTER DRIVE

Auto Configuration

Communication

LED 603 / LED3 17 NA

Fault Timeout

Compressor AA5

Phase Over Current

LED 2 27 NA NA NA

(Intermediate)

Board Temp High LED 2 26 NA

1. Refer to Figures 12-14 for LED inverter drive locations.

TEMP –

ERROR –

Possible

Causes

Outdoor airflow is

too low or off.

Inverter component

damage.

Outdoor airflow is

too low or off.

Inverter component

damage.

Loose or disconnected

communication harness.

Broken or damaged

communication harness.

Damaged OD Control Board

Damaged

Inverter Board

Loose or disconnected

communication harness.

Broken or damaged

communication harness.

Damaged OD Control Board

Damaged

Inverter Board

Temperature sensor on

the drive is

potentially faulty.

Outdoor airflow is too

low or off.

Inverter component

damage.

Compressor model

and configuration

code do not match.

Pressure sensor and

configuration code

do not match.

System configuration

not set properly.

Sensor on drive

not reading properly.

Sensor on drive

not reading properly.

Baud rate or parity of

the system controller

not matching with drive.

Outdoor airflow is too

low or off.

Inverter component

damage.

Solution

Verify proper airflow over the drive heat sink.

Replace drive.

Verify proper airflow over the drive heat sink.

Replace drive.

Validate harness connection.

Check continuity of harness wires. If an problem

is found, replace communication harness.

Remove power to drive for 2 minutes.

Reapply power if problem remains,

replace OD Control Board.

Remove power to drive for 2 minutes. Reapply

power. If problem remains, replace drive.

Validate harness connection.

Check continuity of harness wires. If an problem

is found, replace communication harness.

Remove power to drive for 2 minutes.

Reapply power. If problem remains,

replace OD Control Board.

Remove power to drive for 2 minutes. Reapply

power. If problem remains, replace drive.

Remove power to drive for 2 minutes. Reapply

power. If problem remains, replace drive.

Verify proper airflow over the drive heat sink.

Replace drive.

Check system configuration and select

proper system tonnage in repair part menu.

If proper option is not available the correct

drive has not been installed, replace drive.

Check system configuration and select

proper system tonnage in repair part menu.

If proper option is not available the correct

drive has not been installed, replace drive.

Check system configuration and select

proper system tonnage in repair part menu.

If proper option is not available the correct

drive has not been installed, replace drive.

Remove power to drive for 2 minutes. Reapply

power. If problem remains, replace drive.

Remove power to drive for 2 minutes. Reapply

power. If problem remains, replace drive.

Remove power to drive for 2 minutes. Reapply

power. If problem remains, replace drive.

Verify proper airflow over the drive heat sink.

Replace drive.

18 Johnson Controls Unitary Products

FIGURE 12: 2 Ton Inverter Drive LED Location

5284792-UIM-D-1017

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FIGURE 13: 3 & 4 Ton Inverter Drive LED Location

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FIGURE 14: 5 Ton Inverter Drive LED Location

Johnson Controls Unitary Products 19

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5284792-UIM-D-1017

INVERTER DRIVE TROUBLE SHOOTING

ELECTRICAL SHOCK HAZARD

WARNING

CAUTION

Safety Statements

• Only qualified and authorized HVAC or refrigeration personnel are permitted to install, commission and maintain this equipment.

• Electrical connections must be made by qualified electrical personnel.

• All valid standards and codes for installing, servicing, and maintaining electrical and refrigeration equipment must be observed.

• Disconnect and lock out power before servicing.

• Wait 2 minutes to ensure that drive capacitors are discharged before servicing.

• Use compressor with grounded system only.

• Molded electrical plug must be used for connection to compressor.

BURN HAZARD

• Failure to follow these warnings could result in serious personal injury or property damage.

• Ensure that materials and wiring do not touch high temperature areas of the compressor.

• Personal safety equipment must be used.

RCD PROTECTION

• Be sure to install a Residual Current protective Device (RCD) in accordance with the applicable legislation. Failure to do so may cause electric shock or fire.

• Be sure to use a dedicated power circuit, never use a power supply shared by another appliance.

• When installing the RCD be sure that it is compatible with the inverter (resistant to high frequency electric noise and to higher harmonics) to avoid unnecessary opening of the RCD.

The RCD must be a high speed type breaker of 30 mA (<0.1 seconds).

DRIVE HANDLING

• Caution must be used when lifting and installing the drive. Failure to use caution may result in bodily injury.

• Personal safety equipment must be used.

• Failure to follow these warnings could result in personal injury or property damage.

INVERTER DRIVE LED

There are three control chips on the drive board and all of them have their own LED status display as detailed below. The location of each LED can be found in Figures 12-14.

Operation Indicating LED (Green - 1 or 605) - When the drive is in normal or standby state with no protection or fault condition the LED will flash at 0.5 sec ON / 0.5 sec OFF. If the compressor is running the LED will be solid.

Protection Indicating LED (Yellow - 2 or 604) - When the drive is under protection, the yellow LED will flash. Refer to the fault status and troubleshooting section of this bulletin for more information.

Hardware Fault Indicating LED (Red - 3 or 603) - When the drive is under hardware fault, the red LED will flash. Refer to the fault status and troubleshooting section of this bulletin for more information.

LED for Drive Control (Green - 4 or 602) - When the drive is in normal state, whether the compressor is running or standby, the LED will flash at 1 sec ON / 1 sec OFF. When the drive is under protection or hardware fault, the LED will flash at 8 sec ON/ 8 sec OFF.

LED for Power Factor Correction (Green-601) - When the drive PFC is not in operation, the LED will blink at 1 sec ON / 1 sec OFF. When the PFC is in operation, the LED will be solid.

20 Johnson Controls Unitary Products

5284792-UIM-D-1017

TABLE 9:

Thermistor Resistance vs Temperature Table

TEMP °C TEMP °F

-40 -40.0 336000 22 71.6 11418 84 183.2 1104

-39 -38.2 314490 23 73.4 10921 85 185.0 1070

-38 -36.4 294520 24 75.2 10449 86 186.8 1037

-37 -34.6 275970 25 77.0 10000 87 188.6 1005

-36 -32.8 258730 26 78.8 9571 88 190.4 974

-35 -31.0 242700 27 80.6 9164 89 192.2 944

-34 -29.2 227610 28 82.4 8776 90 194.0 915

-33 -27.4 213570 29 84.2 8407 91 195.8 889

-32 -25.6 200510 30 86.0 8056 92 197.6 861

-31 -23.8 188340 31 87.8 7720 93 199.4 836

-30 -22.0 177000 32 89.6 7401 94 201.2 811

-29 -20.2 166342 33 91.4 7096 95 203.0 787

-28 -18.4 156404 34 93.2 6806 96 204.8 764

-27 -16.6 147134 35 95.0 6530 97 206.6 742

-26 -14.8 138482 36 96.8 6266 98 208.4 721

-25 -13.0 130402 37 98.6 6014 99 210.2 700

-24 -11.2 122807 38 100.4 5774 100 212.0 680

-23 -9.4 115710 39 102.2 5546 101 213.8 661

-22 -7.6 109075 40 104.0 5327 102 215.6 643

-21 -5.8 102868 41 105.8 5117 103 217.4 626

-20 -4.0 97060 42 107.6 4918 104 219.2 609

-19 -2.2 91588 43 109.4 4727 105 221.0 592

-18 -0.4 86463 44 111.2 4544 106 222.8 576

-17 1.4 81662 45 113.0 4370 107 224.6 561

-16 3.2 77162 46 114.8 4203 108 226.4 546

-15 5.0 72940 47 116.6 4042 109 228.2 531

-14 6.8 68957 48 118.4 3889 110 230.0 517

-13 8.6 65219 49 120.2 3743 111 231.8 503

-12 10.4 61711 50 122.0 3603 112 233.6 489

-11 12.2 58415 51 123.8 3469 113 235.4 476

-10 14.0 55319 52 125.6 3340 114 237.2 463

-9 15.8 52392 53 127.4 3217 115 239.0 450

-8 17.6 49640 54 129.2 3099 116 240.8 437

-7 19.4 47052 55 131.0 2986 117 242.6 425

-6 21.2 44617 56 132.8 2878 118 244.4 413

-5 23.0 42324 57 134.6 2774 119 246.2 401

-4 24.8 40153 58 136.4 2675 120 248.0 390

-3 26.6 38109 59 138.2 2579 121 249.8 379

-2 28.4 36182 60 140.0 2488 122 251.6 369

-1 30.2 34367 61 141.8 2400 123 253.4 359 0 32.0 32654 62 143.6 2315 124 255.2 349 1 33.8 31030 63 145.4 2235 125 257.0 340 2 35.6 29498 64 147.2 2157 126 258.8 332 3 37.4 28052 65 149.0 2083 127 260.6 323 4 39.2 26686 66 150.8 2011 128 262.4 315 5 41.0 25396 67 152.6 1943 129 264.2 308 6 42.8 24171 68 154.4 1876 130 266.0 300 7 44.6 23013 69 156.2 1813 131 267.8 293 8 46.4 21918 70 158.0 1752 132 269.6 285 9 48.2 20883 71 159.8 1693 133 271.4 278

10 50.0 19903 72 161.6 1637 134 273.2 272 11 51.8 18972 73 163.4 1582 135 275.0 265 12 53.6 18090 74 165.2 1530 136 276.8 259 13 55.4 17255 75 167.0 1480 137 278.6 253 14 57.2 16464 76 168.8 1431 138 280.4 247 15 59.0 15714 77 170.6 1385 139 282.2 241 16 60.8 15000 78 172.4 1340 140 284.0 235 17 62.6 14323 79 174.2 1297 141 285.8 230 18 64.4 13681 80 176.0 1255 142 287.6 224 19 66.2 13071 81 177.8 1215 143 289.4 219 20 68.0 12493 82 179.6 1177 144 291.2 214 21 69.8 11942 83 181.4 1140 145 293.0 209

Resistance

TEMP °C TEMP °F

Resistance

TEMP °C TEMP °F

Resistance

Johnson Controls Unitary Products 21

5284792-UIM-D-1017

TABLE 10:

Sensor Connector Pin Definition

A1 High Pressure Signal A2 3.3VDC

$

$

$

PRESSURE SWITCH FAULT & LOCKOUT

HIGH PRESSURE SWITCH (HPS) FAULT

If the compressor is operating and the high pressure switch is recognized as open, the control de-energizes the compressor output. The 5 minute ASCD timer starts when the compressor speed reaches 0. The compressor contactor remains off until the high pressure switch has reclosed and the 5 minute ASCD timer has been satisfied.

HIGH PRESSURE SWITCH LOCKOUT

If the system recognizes two HPS faults within six hours of accumulated compressor run-time, the system will enter the HPS lockout. During the lockout period, the defrost and compressor relays remain de-energized. While the system is locked out, the Outdoor Display will represent the appropriate fault message as described elsewhere in this document. The system will differentiate between PS faults that occur in heating or defrost modes. This is only for the system to decide which fault code to display. This may help the service person in troubleshooting issues with the unit when this lockout occurs. Otherwise it shouldn't differentiate between heating or defrost modes when counting PS faults.

The six hour timing starts after the ASCD has expired following the first PS fault. The timer only accumulates when the compressor is running. If the system recognizes a second opening of the PS before the six hour timer expires, the system will enter the PS soft lockout. If the system does not recognize a second opening of the PS before the six hour timer expires, the six hour timer is cleared and the PS fault counter is reset.

SUCTION PRESSURE SENSOR FAULT

The system will monitor the suction pressure during operation. If the suction pressure value falls below the trending limit point and is not increasing, the low suction pressure fault is recognized. The suction pressure must remain below the trending limit for 360 seconds in cool operation. The low suction pressure fault is bypassed for 120 seconds upon system startup. If the fault limit value is ever reached for > 5 seconds a low suction pressure fault is recognized regardless of a bypass time.

TABLE 11:

Low Suction Pressure Limits

Mode of Operation Trending Limit Fault Limit

Cool < 90psi < 5psi

SECTION IX: INSTRUCTING THE OWNER

Assist the owner with registering the unit warranty using the warranty card included with the unit, or preferably online at

www.upgproductregistration.com. It is strongly recommended to com-

plete a startup sheet showing the critical readings of the unit at the time of commissioning, which can be uploaded as part of the online registration process.

When applicable, instruct the owner that the compressor is equipped with a crankcase heater to prevent the migration of refrigerant to the compressor during the OFF cycle. The heater is energized only when the unit is not running. If the main switch is disconnected for long periods of shut down, do not attempt to start the unit until 2 hours after the switch has been connected. This will allow sufficient time for all liquid refrigerant to be driven out of the compressor.

The installer should also instruct the owner on proper operation and maintenance of all other system components.

MAINTENANCE

1. Dirt should not be allowed to accumulate on the outdoor coils or other parts in the air circuit. Clean as often as necessary to keep the unit clean. Use a brush, vacuum cleaner attachment, or other suitable means.

2. The outdoor fan motor bearings are permanently lubricated and do not require periodic oiling.

3. If the coil needs to be cleaned, it should be washed with water or a PH neutral detergent. Allow solution to remain on coil for several minutes before rinsing with clean water. Solution should not be permitted to come in contact with painted surfaces.

4. Refer to the furnace or air handler instructions for filter and blower motor maintenance.

5. The indoor coil and drain pan should be inspected and cleaned regularly to prevent odors and assure proper drainage.

CAUTION

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.

COOLING CHARGE TABLE IS ON THE UNIT CODE PLATE ATTACHED TO THE OUTSIDE OF THE CONTROL BOX COVER.

22 Johnson Controls Unitary Products

SECTION X: WIRING DIAGRAM

LEGEND

AMB - AMBIENT TEMP SENSOR DPT - DISCHARGE PRESSURE DR - DEMAND RESPONSE DS - DISPLAY SWITCH DTS - DISCHARGE TEMP SENSOR HPS - HIGH PRESS SWITCH LTS - LIQUID TEMP SENSOR SPT - SUCTION PRESSURE STS - SUCTION TEMP SENSOR TB - TERMINAL BLOCK XFMR - TRANSFORMER

VS CONTROL

LED DIAGNOSTIC CODES

LAMP

COLOR

NO LAMP YELLOW YELLOW YELLOW YELLOW

RED

LAMP

CONDITION

N/A 2 sec ON/2 sec OFF .1 sec ON/.1sec OFF

.5 sec ON/.5 sec OFF

DPTSPT AMBSTS LTSDTS

DESCRIPTION

No power to the control System has 24 VAC present No Active Call Active Call; Active ASCD Timer Active Call; Successful Communications Controlled Event; Active Foldback Condition Controlled Fault; Active Fault Condition

COLOR CODES

BLK - BLACK BLU - BLUE BLU/WHT - BLUE w/WHITE STRIPE BRN - BROWN GRN - GREEN PUR - PURPLE RED - RED RED/WHT - RED w/WHITE STRIPE WHT - WHITE YEL - YELLOW YEL/PINK - YELLOW w/PINK STRIPE

WHT

BLK

DRAIN WIRE

RED

5284792-UIM-D-1017

DANGER - SHOCK HAZARD

TURN OFF ELECTRICAL POWER BEFORE SERVICING TO PREVENT POSSIBLE DAMAGE TO THE EQUIPMENT AND POSSIBLE PERSONAL INJURY.

WAIT 2 MINUTES - ELECTRICAL COMPONENTS MAY HOLD CHARGE. DO NOT REMOVE THIS COVER OR SERVICE THIS FOR 2 MINUTES AFTER THE POWER HAS BEEN REMOVED.

CAUTION

TO PREVENT ELECTRICAL SHOCK OPEN REMOTE DISCONNECT SO ELECTRICAL SUPPLY TO AC UNIT IS SHUT OFF.

WIRING MUST CONFORM TO

NATIONAL AND LOCAL CODES.

IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED, IT

MUST BE REPLACED WITH 105 C THERMOPLASTIC OR ITS EQUIVALENT.

HIGH VOLTAGE FACTORY WIRING HIGH VOLTAGE FIELD WIRING LOW VOLTAGE FACTORY WIRING LOW VOLTAGE FIELD WIRING FERRITE RING/CHOKE

HPS

BLK

GRN

BLK

WHT

SEE UNIT

INSTALLATION

INSTRUCTIONS FOR

LOW VOLTAGE

TERMINATIONS

WHT

BLU/WHT

COMMRS485 COMM

COMM

RS485

WHT

P10

EEV

FIGURE 15: Wiring Diagram - 2 Ton

RED/WHT

DRCO

CONV.

INPUTS

DPT

SPT

OD FAN

DTS

STS

STATUS

FAULT

OD FAN MOTOR

TTTT

BLK

BLU/WHT

RED/WHT

AMB

LTS

CTS

BLK

RED

BLU/WHT

PWM

TEST PAD

CONTROL

BOARD

PUR

YEL

BRN

BLK

OD FAN

CONTROLLER

PUR

BLU

RED

24V SEC

40VA

XFMR

230V

208V

REACTOR

WHT

BLK

L1 L2

GND

208-230 VAC 60 Hz

1 PHASE SUPPLY

USE COPPER

CONDUCTORS

ONLY

GRN

BLK

WHT

BLK

GRN

YEL/PINK

INVERTER

DRIVE

GND

HPS

W(R)

COMPRESSOR

5295812-UWD-C-0217

U(S)

V(C)

3 2 1

RS485

COMM

6 5 4

BRN

RED

BLK

Johnson Controls Unitary Products 23

5284792-UIM-D-1017

LEGEND

VS CONTROL

LED DIAGNOSTIC CODES

LAMP

COLOR

NO LAMP YELLOW

YELLOW YELLOW YELLOW

RED

LAMP

CONDITION

N/A

2 sec ON/2 sec OFF

.1 sec ON/.1sec OFF

.5 sec ON/.5 sec OFF

ON ON

DPTSPT AMBSTS LTSDTS

DESCRIPTION

COLOR CODES

BLK - BLACK BLU - BLUE BLU/WHT - BLUE w/WHITE STRIPE BRN - BROWN GRN - GREEN PUR - PURPLE RED - RED RED/WHT - RED w/WHITE STRIPE WHT - WHITE YEL - YELLOW YEL/PINK - YELLOW w/PINK STRIPE

WHT

BLK

DRAIN WIRE

TTTT

DANGER - SHOCK HAZARD

TURN OFF ELECTRICAL POWER BEFORE SERVICING TO PREVENT POSSIBLE DAMAGE TO THE EQUIPMENT AND POSSIBLE PERSONAL INJURY.

WAIT 2 MINUTES - ELECTRICAL COMPONENTS MAY HOLD CHARGE. DO NOT REMOVE THIS COVER OR SERVICE THIS FOR 2 MINUTES AFTER THE POWER HAS BEEN REMOVED.

CAUTION

TO PREVENT ELECTRICAL SHOCK OPEN REMOTE DISCONNECT SO ELECTRICAL SUPPLY TO AC UNIT IS SHUT OFF.

WIRING MUST CONFORM TO

NATIONAL AND LOCAL CODES.

IF ANY OF THE ORIGINAL WIRE SUPPLIED

WITH THIS UNIT MUST BE REPLACED, IT MUST BE REPLACED WITH 105 THERMOPLASTIC OR ITS EQUIVALENT.

RED

HIGH VOLTAGE FACTORY WIRING HIGH VOLTAGE FIELD WIRING LOW VOLTAGE FACTORY WIRING LOW VOLTAGE FIELD WIRING FERRITE RING/CHOKE

HPS

BLK

GRN

BLK

WHT

SEE UNIT

INSTALLATION

INSTRUCTIONS FOR

LOW VOLTAGE

TERMINATIONS

WHT

BLU/WHT

RS485 COMM

COMM

EEV

RS485

P10

WHT

RED/WHT

FIGURE 16: Wiring Diagram - 3-5 Ton

RED/WHT

DRCO

CONV.

INPUTS

DPT

SPT

OD FAN

DTS

STS

STATUS

FAULT

OD FAN MOTOR

BLU/WHT

RED/WHT

BLU/WHT

AMB

LTS

CTS

TEST PAD

BLK

CONTROL

BOARD

RED

OD FAN

CONTROLLER

BLK

PWM

BLK

PUR

YEL/PINK

BLU

RED

24V SEC

40VA

XFMR

YEL

BRN

BLK

230V

208V

1 PH.

FILTER

BOARD

BLK

WHT

BLK

L1 L2

GND

USE COPPER

CONDUCTORS

ONLY

208-230 VAC 60 Hz

1 PHASE SUPPLY

WHT

GRN

BLK

WHT

GRN

REACTOR

INVERTER

DRIVE

GND

WHT

COMPRESSOR

5286847-UWD-C-0217

U(S)

W(R)

V(C)

3 2 1

RS485

COMM

HPS

6 5

BRN

RED

BLK

24 Johnson Controls Unitary Products

SECTION XI: CHARGING CHARTS

5284792-UIM-D-1017

YXV24B21S HIGH SPEED COOLING

SUBCOOLING CHARGING CHART

OUTDOOR

AMBIENT

DB (°F)

INDOOR WET BULB (°F)AT 80°F DRY BULB

57 62 67 72

PRESSURE (PSIG)& SUBCOOLING (°F)

AT LIQUID BASE VALVE

55 189(6) 207(8) 212(9) 211(4) 60 202(6) 215(8) 220(9) 219(4) 65 216(7) 226(8) 230(8) 228(5) 70 232(7) 239(8) 242(8) 240(5) 75 249(7) 254(8) 256(8) 255(5) 80 269(7) 271(8) 272(7) 271(5) 85 290(8) 290(8) 291(7) 290(6) 90 313(8) 311(8) 312(7) 311(6)

95 337(8) 334(8) 335(7) 334(6) 100 363(9) 360(8) 360(8) 360(7) 105 391(9) 387(9) 388(8) 387(7) 110 420(9) 417(9) 418(8) 417(8) 115 451(10) 449(10) 450(9) 450(8) 120 484(10) 483(10) 484(10) 484(9) 125 518(11) 518(11) 520(10) 521(10)

Charging chart is for use in Service mode only. Charging chart is for use in Cooling mode only.

YXV36B21S HIGH SPEED COOLING

SUBCOOLING CHARGING CHART

OUTDOOR

AMBIENT

DB (°F)

INDOOR WET BULB (°F)AT 80°F DRY BULB

57 62 67 72

PRESSURE (PSIG)& SUBCOOLING (°F)

AT LIQUID BASE VALVE

55 182(7) 183(7) 188(9) 191(11)

60 197(7) 198(7) 202(9) 204(9)

65 214(7) 215(7) 217(8) 218(8)

70 232(7) 233(7) 235(8) 235(7)

75 251(7) 252(8) 253(7) 252(6)

80 272(7) 273(8) 273(7) 272(6)

85 294(8) 295(8) 295(7) 293(6)

90 318(8) 319(8) 318(7) 316(5)

95 343(8) 344(9) 343(7) 341(5) 100 370(9) 371(9) 370(7) 367(5) 105 398(9) 399(9) 398(8) 395(6) 110 428(9) 429(10) 427(8) 425(6) 115 459(10) 460(10) 458(9) 457(7) 120 491(10) 492(10) 491(9) 490(8) 125 525(11) 526(11) 525(10) 525(9)

Charging chart is for use in Service mode only. Charging chart is for use in Cooling mode only.

YXV48B21S HIGH SPEED COOLING

SUBCOOLING CHARGING CHART

OUTDOOR

AMBIENT

DB (°F)

INDOOR WET BULB (°F)AT 80°F DRY BULB

57 62 67 72

PRESSURE (PSIG)& SUBCOOLING (°F)

AT LIQUID BASE VALVE

55 191(10) 192(10) 194(11) 194(12) 60 207(10) 208(10) 210(11) 211(11) 65 224(10) 225(10) 227(11) 229(11) 70 242(10) 244(10) 246(11) 248(11) 75 262(10) 263(10) 266(11) 268(11) 80 282(10) 284(10) 287(11) 290(11) 85 304(10) 306(10) 309(11) 312(11) 90 327(10) 329(10) 332(11) 335(11)

95 352(10) 353(10) 356(11) 360(11) 100 377(10) 378(10) 382(11) 386(11) 105 403(10) 405(10) 408(11) 412(11) 110 431(10) 432(10) 436(11) 440(11) 115 460(10) 461(11) 465(11) 469(11) 120 490(11) 491(11) 494(11) 499(11) 125 521(11) 522(11) 526(11) 530(11)

Charging chart is for use in Service mode only. Charging chart is for use in Cooling mode only.

YXV60B21S HIGH SPEED COOLING

SUBCOOLING CHARGING CHART

OUTDOOR

AMBIENT

DB (°F)

INDOOR WET BULB (°F)AT 80°F DRY BULB

57 62 67 72

PRESSURE (PSIG)& SUBCOOLING (°F)

AT LIQUID BASE VALVE

55 194(9) 194(9) 196(10) 197(11)

60 210(9) 210(10) 212(10) 214(11)

65 227(10) 227(10) 229(10) 231(11)

70 245(10) 246(10) 248(10) 250(10)

75 264(10) 265(10) 268(10) 270(10)

80 285(10) 286(10) 288(10) 291(10)

85 307(10) 308(10) 311(10) 313(10)

90 330(10) 331(10) 334(10) 337(10)

95 354(10) 356(10) 358(10) 362(10) 100 379(10) 381(10) 384(10) 388(10) 105 406(10) 408(10) 411(10) 415(10) 110 434(10) 436(10) 439(10) 443(10) 115 463(10) 465(11) 469(11) 473(11) 120 494(10) 496(11) 499(11) 503(11) 125 525(10) 527(11) 531(11) 535(11)

Charging chart is for use in Service mode only. Charging chart is for use in Cooling mode only.

Johnson Controls Unitary Products 25

5284792-UIM-D-1017

NOTES

26 Johnson Controls Unitary Products

SECTION XII: START UP SHEET

Residential Split Variable Capacity System Unit Cooling With Electric Heat Start-Up Sheet

Proper start-up is critical to customer comfort and equipment longevity

5284792-UIM-D-1017

Start-Up Date

Dealer Training Certication Number

Start-Up TechnicianCompany Name

Owner Information

Name Address

City State or Province Zip or Postal Code

Daytime Phone

Equipment Data

Outdoor Model # Unit Serial #

Indoor Model # Unit Serial #

General Information

New Construction

Unit Location and Connections

Unit is level and installed on:

Condensate drain properly connected per the installation instructions Condensate trap has been primed with water

(Check all that apply)

Roof level

Grade level

(Check all that apply)

Slab Roof curb Supply Return

Horizontal

Upow

Duct connections are complete:

Filters

Filters installed Filter located inside Filter located outside

Filter size

Electrical Connections & Inspection

208 volts AC 230 volt AC

Inspect wires and electrical connections

Low voltage present at control board "R & C"

Line voltage present at disconnect

(Check all that apply)

Transformer wired properly for primary supply voltage

Measured voltage "R" and "C" outdoor unit control board

Measured voltage "L1 to L2"

Total amperes "L1" "L2"Compressor amperes "L1" "L2"

Air Flow Setup / Cooling

Blower Type

ECM

Set-Up

Supply static (inches of water column) Supply air dry bulb temperature

Return static (inches of water column)

Total external static pressure

COOL

ADJUST

DELAY

Return air dry bulb temperature

Temperature drop

A B C D

Ground connected

Supply air wet bulb temperature

Return air wet bulb temperature

Outside air dry bulb temperature

C D

Page 1 of 2 (3/14/17)

Johnson Controls Unitary Products 27

Refrigerant Charge and Metering Device

R-410A

Data plate - lbs / Oz

Discharge line temperature

Suction line temperature

Suction pressure

Superheat

Discharge pressure

Liquid line temperature

Subcooling

Electric Heat

Electric heat kit - Model number

Single Phase

Number

of elements

Heating return air

dry bulb temperature

Measured Amperage

Measured Voltage

Heater 1

Heater 4

Heater 1

Heater 4

Heating supply air

dry bulb temperature

Serial number Rated KW

Heater 2

Heater 5

Heater 2

Heater 5

Air temperature rise

Clean Up Job Site

Job site has been cleaned, indoor and outdoor debris removed from job site

Tools have been removed from unit

All panels have been installed

Unit Operation and Cycle Test

Operate the unit through continuous fan cycles from the thermostat, noting and correcting any problems

Operate the unit through cooling cycles from the thermostat, noting and correcting any problems

Heater 3

Heater 6

Heater 3

Heater 6

Owner Education

Provide owner with the owner's manual

Explain operation of system to equipment owner

Explain thermostat use and programming (if applicable) to owner

Explain the importance of regular lter replacement and equipment maintenance

Setup

WiFi enabled:

Demand response enabled: Fan Prole:

Yes No

Normal Arid

Yes

Humid

Comments and Additional Job Details

Page 2 of 2 (3/14/17)

York International Corp.

5005 York Drive

Norman, OK 73069

Johnson Controls YXV SERIES, 20 SEER SERIES, AL21 SERIES, AC21 SERIES Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual