Johnson Controls Z2100 User Manual

SINGLE PIECE
INSTALLATION MANUAL
ISO 9001
Management System
VARIABLE SPEED AIR HANDLERS
MODELS: AV*(C) SERIES
LIST OF SECTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ELECTRIC HEATER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .7
LOW VOLTAGE CONTROL CONNECTIONS . . . . . . . . . . . . . . . . . .7
REQUIRED CONTROL SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
LIST OF FIGURES
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Return Duct Attachment & Component Location . . . . . . . . . . . . . . . . .3
Dimensions & Duct Connection Dimensions . . . . . . . . . . . . . . . . . . . .4
Condensate Deflector on Vertical Drain Pan . . . . . . . . . . . . . . . . . . . .4
Condensate Deflecctor on Horizontal Drain Pan Edge . . . . . . . . . . . .5
S-Clip Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Duck Work Transition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Typical Horizontal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
LIST OF TABLES
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Low Voltage Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Heat Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Comfort Setting Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Physical and Electrical Data - Cooling Only (60 Hz) . . . . . . . . . . . . . . . . 12
Electrical Data - Cooling Only (60 Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Conversion Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Electrical Data - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LINE POWER CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AIRFLOW AND COMFORT SETTING SELECTION . . . . . . . . . . . . 12
UNIT DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TXV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Proper Bulb Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Handler Control Board – Communications Connections . . . . . . . . 7
Cooling Models with and without Electric Heat Wiring . . . . . . . . . . . . 8
Two-Stage Heat Pump Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air Handler with Communicating AC or HP . . . . . . . . . . . . . . . . . . . . 9
Line Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical Data - (For Single Source Power Supply) -
Copper Wire - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Data - (For Multi-Source Power Supply) -
Copper Wire - 208/230-1-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Data - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Data - (For Single Source Power Supply) -
Copper Wire - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Data - (For Multi-Source Power Supply) -
Copper Wire - 208/230-3-60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air Handler Air Flow Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION I: GENERAL
The AV single piece air handler provides the flexibility for installation in any upflow, downflow, or horizontal application.
These versatile models may be used for cooling or heat pump operation with or without electric heat.
A BRAND LABEL (available from Distribution) may be applied to the center of the blower access panel on AVG models.
The unit can be positioned for bottom return air in the upflow position, top return air in the downflow position, and right or left return in the hor­izontal position.
Top and side power wiring and control wiring, accessible screw termi­nals for control wiring, easy to install drain connections and electric heaters all combine to make the installation easy, and minimize installa­tion cost.
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. alert against unsafe practices and hazards involving only property dam­age.
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 installation instructions and any applicable local, state, and national codes including, but not limited to building, electrical, and mechanical codes.
FIRE OR ELECTRICAL HAZARD Failure to follow the safety warnings exactly could result in serious
injury, death or property damage. A fire or electrical hazard may result causing property damage, per­sonal injury or loss of life.
It is also used to
536636-UIM-D-1211
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NOTICE
1. Install this air handler only in a location and position as specified in SECTION III of these instructions.
2. Always install the air handler to operate within the air handler’s intended maximum outlet air temperature. Only connect the air handler to a duct system which has an external static pressure within the allowable range, as specified on the air handler rating plate.
3. When an air handler is installed so that supply ducts carry air cir­culated by the air handler to areas outside the space containing the air handler, the return air shall also be handled by duct(s) sealed to the air handler casing and terminating in the space to be cooled/heated.
4. The air handler is not to be used for temporary heating of buildings or structures under construction.
5. The size of the unit should be based on an acceptable heat loss or gain calculation for the structure. ACCA, Manual J or other approved methods may be used.
SAFETY REQUIREMENTS
1. This air handler should be installed in accordance with all national and local building/safety codes and requirements, local plumbing or wastewater codes, and other applicable codes.
2. Refer to the unit rating plate for the air handler model number, and then see the dimensions page of this instruction for supply air ple­num dimensions in Figure 3. The plenum must be installed accord­ing to the instructions.
3. Provide clearances from combustible materials as listed under Clearances to Combustibles.
4. Provide clearances for servicing ensuring that service access is allowed for electric heaters and blower.
5. Failure to carefully read and follow all instructions in this manual can result in air handler malfunction, death, personal injury and/or property damage.
6. Check the rating plate and power supply to be sure that the electri­cal characteristics match.
7. Air handler shall be installed so the electrical components are pro­tected from water.
8. Installing and servicing heating/cooling equipment can be hazard­ous due to the electrical components. Only trained and qualified personnel should install, repair, or service heating/cooling equip­ment. Untrained service personnel can perform basic maintenance functions such as cleaning and replacing the air filters. When working on heating/cooling equipment, observe precautions in the manuals and on the labels attached to the unit and other safety precautions that may apply.
9. These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances these instructions exceed certain local codes and ordinances, especially those who have not kept up with changing residential and non-HUD modular home construction practices. These instructions are required as a minimum for a safe installation.
INSPECTION
As soon as a unit is received, it should be inspected for possible dam­age during transit. If damage is evident, the extent of the damage should be noted on the carrier’s freight bill. A separate request for inspection by the carrier’s agent should be made in writing. Also, before installation the unit should be checked for screws or bolts, which may have loosened in transit. There are no shipping or spacer brackets which need to be removed.
Also check to be sure all accessories such as heater kits, suspension kits, and coils are available. Installation of these accessories or field conversion of the unit should be accomplished before setting the unit in place or connecting any wiring, electric heat, ducts or piping.
LIMITATIONS
These units must be wired and installed in accordance with all national and local safety codes.
Voltage limits are as follows:
1
Air Handler Voltage Voltage code
208/230-1-60 06 187-253
1. Rated in accordance with ARI Standard 110, utilization range “A”.
Airflow must be within the minimum and maximum limits approved for electric heat, evaporator coils and outdoor units.
Entering Air Temperature Limits
Wet Bulb Temp.°F Dry Bulb Temp. °F
Min. Max. Min. Max.
57 72 65 95
Normal Operating
Voltage Range
SECTION III: UNIT INSTALLATION
CLEARANCES
Clearances must be taken into consideration, and provided for as fol­lows:
1. Refrigerant piping and connections - minimum 12” recommended.
2. Maintenance and servicing access - minimum 36” from front of unit recommended for blower motor/coil replacement.
3. Condensate drain lines routed to clear filter and panel access.
4. Filter removal - minimum 36” recommended.
5. The ductwork and plenum connected to this unit are designed for zero clearance to combustible materials.
6. A combustible floor base accessory is available for downflow applications of this unit, if required by local code.
LOCATION
Location is usually predetermined. Check with owner’s or dealer’s installation plans. If location has not been decided, consider the follow­ing in choosing a suitable location:
1. Select a location with adequate structural support, space for ser­vice access, clearance for air return and supply duct connections.
2. Use hanging brackets to wall mount this single piece air handler unit, is not recommended.
3. Normal operating sound levels may be objectionable if the air han­dler is placed directly over some rooms such as bedrooms, study, etc.
4. Select a location that will permit installation of condensate line to an open drain or outdoors allowing condensate to drain away from structure.
The primary and secondary drain line must be trapped to allow proper drainage of condensate water. If the secondary drain line is not used, it must be capped. The coil is provided with a secondary drain. It should be piped to a location that will give the occupant a visual warn­ing that the primary drain is clogged. If the secondary drain is not used it must be capped.
5. Proper electrical supply must be available.
6. If unit is located in an area of high humidity (ie: an unconditioned garage or attic), nuisance sweating of casing may occur. On these installations, unit duct connections and other openings should be properly sealed and a wrap of 2” fiberglass insulation with vinyl vapor barrier should be used.
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NOTICE
UPFLOW DOWNFLOW
HORIZONTAL RIGHT
HORIZONTAL LEFT
NOTICE
FRONT VIEW
SIDE VIEW
BLOWER COMPARTMENT
VERTICAL DRAIN PAN
REFRIGERANT LINE CONNECTIONS
PRIMARY DRAIN UPFLOW 3/4” THREADED
DUCT WORK MAY BE FASTENED CAUTIOUSLY WITH SCREWS TO THE SIDES AND REAR OF UNIT
SECONDARY DRAIN UPFLOW 3/4” THREADED
COIL COMPARTMENT (Access panel removed)
HORIZONTAL DRAIN PAN
HORIZONTAL SECONDARY DRAIN
HORIZONTAL PRIMARY DRAIN
ALTERNATE DRAIN CONNECTIONS UPFLOW/DOWNFLOW
FILTER DOOR
RETURN AIR
DUCT
WHEN ATTACHING DUCT WORK WITH SCREWS - KEEP SCREWS WITHIN 5/8” OF SIDES AND BACK OF AIR HANDLER
When an evaporator coil is installed in an attic or above a finished ceiling, an auxiliary drain pan should be provided under the coil as is specified by most local building codes.
FIGURE 1: Typical Installation
DOWNFLOW AND HORIZONTAL CONVERSION (AV ONLY)
These air handler units are supplied ready to be installed in a upflow and right hand horizontal position. If unit requires left hand positioning, the unit must have the coil assembly repositioned.
1. Remove blower, coil, and filter access panels.
Conversion must be made before brazing the refrigerant connections to the coil.
For downflow and horizontal left installations, follow steps 2 - 8.
2. Remove tubing connection panel.
3. Remove front drain pan, hold down bracket.
4. Slide coil assembly out of air handler.
5. Rotate cabinet 180º so blower outlet is facing down.
In severe high humidity, high temperature indoor unit environments, an accessory insulation blanket is available to supplement the stan­dard cabinet insulation. Insulate with UPG Kit: 1VJ0117 for B cabi­nets, 1VJ0121 for C cabinets or 1VJ0124 on D cabinets or seal completely with adequate fiberglass insulation using vapor barrier on the outside.
6. Re-install coil assembly on downflow bracket.
7. Re-attach front drain pan, hold down bracket.
8. Re-attach tubing connection panel.
9. For horizontal applications, rotate air handler 90º into desired ori-
entation.
10. Re-position drain plugs as necessary based on air handler orienta-
tion.
11. Re-position and replace access panels.
12. For downflow installations, the cladding should be reconfigured so
that the grille and circuit breaker covers having logos and/or black coloring are at the top of the unit on the coil access panel. See below.
13. Apply branding label to air handler in recessed area provided on
blower access panel cladding. This label should be applied after the air handler is placed in its proper orientation so the label is right side up.
FIGURE 2: Return Duct Attachment & Component Location
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536636-UIM-D-1211
NOTICE
10-3/8”
F
CIRCUIT
BREAKER
PANEL
BOTTOM INLET
DIMENSIONS
BLOWER COMPARTMENT
REFRIGERANT
DRAIN CONNECTIONS
FOR UPFLOW AND
DOWNFLOW APPLICATIONS
D
A
E
TOP OUTLET DIMENSIONS
18-9/32”
J
K
CLADDING
CONDENSATE
S-CLIPS (3)
VERTICAL
NOTICE
CLADDING CONFIGURATION FOR DOWNFLOW INSTALLATION (IF USED)
To reconfigure the cladding parts, remove the grille by pulling gently at the top. Once the grille is removed, the circuit breaker cover can also be removed. Remove the gray, non-branded grille and circuit breaker cover from the cladding on the coil access panel. Next, remove the black and/or branded grille and circuit breaker cover from the blower access panel. Install these pieces into the coil access panel cladding so they are at the top of the air handler. Install the gray, non-branded grille and circuit breaker cover in the blower access panel cladding.
If a heat kit with a circuit breaker is installed in the air handler, the cir­cuit breaker cover cladding must be removed to gain access to the sheet metal cover plate. Some local codes may require that the circuit breaker remain visible. If so, do not re-install circuit breaker cover cladding.
FIGURE 3: Dimensions & Duct Connection Dimensions TABLE 1:
Dimensions
Dimensions (Inches)
Models
AV
AB C
Height Width Depth Power Control Liquid Vapor
24B 46 17 1/2 36C 52 21 17-1/8 17-13/32 18-3/32 7/8” 48D 57 24 1/2 22-1/8 20-29/32 21-19/32 7/8” 60D 57 24 1/2 22-1/8 20-29/32 21-19/32 7/8’
1. Actual size (Conduit size).
21-1/2
(w/o cladding)
22-1/2
(with cladding)
SUCTION FEEDER TUBE CONDENSATE DEFLECTOR
UPFLOW OR DOWNFLOW
No action required. See Figure 4.
DEF
12-3/8 13-29/32 14-19/32
Horizontal Left or Right
Use an appropriate tool to pry out water deflector with two or three s­clips from the vertical drain pan. See Figure 4. Relocate the deflector with s-clips on the Horizontal Drain Pan lined up to the coil support brackete. See Figure 5. This positions the deflector below the feeder tubes to channel the condensate to the drain pan.
The condensate deflector should be installed in the s-clip section which is inside the drain pan edge. See Figure 6.
Wiring Knockouts
JK
7/8” (1/2”) 1 3/8” (1”)
7/8” (1/2”) 3/8”
1 23/32” (1 1/4”)
1
Refrigerant
Connections
Line Size
3/4”
FIGURE 4: Condensate Deflector on Vertical Drain Pan
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FIGURE 5: Condensate Deflecctor on Horizontal Drain Pan Edge
S-CLIPS ON HORIZONTAL PAN
FEEDER
TUBES
CONDENSATE
DEFLECTOR
DEFLECTOR
S-CLIP
DRAIN PAN
WALL
SUGGESTED LOCATION OF BLOCK OFF PLATE
RECOMMENDED TRANSITION
536636-UIM-D-1211
ers and never fastened directly to the structure. This unit is not designed for non-ducted (freeblow) applications. Size outlet plenum or transition to discharge opening sizes shown in Figure 3.
Duct work should be fabricated and installed in accordance with local and/or national codes. This includes the standards of the National Fire Protection Association for Installation of Air-Conditioning and Ventilat­ing Systems, NFPA No. 90B.
DUCT WORK TRANSITION
Duct work that is not designed to match the supply air opening can cause turbulence inside the plenum box. This turbulence can change the air flow patterns across the heat kit limit switch. If the factory sug­gested transition can not be fabricated, it is recommended a block off plate (approximately 8” in height and running the full width of the ple­num) be attached to the supply opening Please refer to Figure 7 as a visual aid. The use of this block off plate will keep better air circulation across the limit switch.
FIGURE 6: S-Clip Installation
DUCT CONNECTIONS
Use 1/2" screws to connect ductwork to bottom of unit. Longer screws will pierce the drain pan and cause leakage. If pilot holes are drilled, drill only though field duct and unit bottom flange.
Air supply and return may be handled in one of several ways best suited to the installation. See Figure 3 for dimensions for duct inlet and outlet connections.
The vast majority of problems encountered with combin ation heating and cooling systems can be linked to improperly designed or installed duct systems. It is therefore highly important to the success of an instal­lation that the duct system be properly designed and installed.
Use flexible duct collars to minimize the transmission of vibration/noise into the conditioned space. If electric heat is used, non-flammable material must be used.
Where return air duct is short, or where sound may be a problem, sound absorbing glass fiber should be used inside the duct. Insulation of duct work is a must where it runs through an unheated space during the heating season or through an uncooled space during the cooling season. The use of a vapor barrier is recommended to prevent absorp­tion of moisture from the surrounding air into the insulation.
The supply air duct should be properly sized by use of a transition to match unit opening. All ducts should be suspended using flexible hang-
FIGURE 7: Duck Work Transition The above suggestions will not alleviate problems caused by improper
installation. When receiving intermittent fault codes pertaining to the limit switch, always double check your airflow CFM, motor speed and static pressures.
AIR FILTERS
Air filters must be field supplied. A 1" filter access rack has been built into the unit. See Figure 3. Remove filter access cover shown. Install proper size filter. Standard 1" size permanent or throw away filter may be used, or, permanent washable filters are available using model num­bers: 1PF0601, 602, 603BK. See Table 8 for filter size.
Equipment should never be operated without filters.
HORIZONTAL SUSPENSION (AV ONLY)
For suspension of these units in horizontal applications, it is recom­mended to use angle steel support brackets with threaded rods, sup­porting the units from the bottom, at the locations shown in Figure 8.
When an evaporator coil is installed in an attic or above a finished ceil­ing, an auxiliary drain pan should be provided under the air handler as is specified by most local building codes.
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WW
XX
SUSPENSION SUPPORT LOCATIONS FOR HORIZONTAL APPLICATIONS
2
1-1/2
MIN. 1-1/2” x 1-1/2” Angle Recommended length 26” minimum with 2” clearance on both sides of Air Handler
MIN. 3/8”
THREADED ROD
YY
VAPOR LINE
THERMAL EXPANSION VALVE BULB (Required insulation not shown for clarity)
THERMAL EXPANSION VALV E
DISTRIBUTOR BODY
LIQUID LINE
TXV EQUALIZER LINE
TXV BULB (Cover completely with insulation)
SCREW
CLAMP
NUT
SUCTION LINE
NOTICE
NOTICE
Units
(Nominal Tons)
WW XX 24B 20 46 36C 24 52
AV*48D, 60D 28 57
FIGURE 8: Typical Horizontal Installation
Dimension
TXV METERING DEVICES
If the model (C) number is of the following format: 4F, 4G, 4H, 4J, and 4K will have the coil with R410A TXV metering device installed at the factory.
If the model (C) number is of the 3X model series:
The coil will require an orifice or R410A TXV to be installed in the field. Refer to installation manual with TXV kit. It is recommended to install a orifice or TXV kit prior to brazing line sets.
COIL UNDER PRESSURE. Relieve pressure by depressing schrader core. Coil may have factory
installed TXV or may require orifice or TXV to be added. See outdoor unit documentation for correct orifice or TXV to be used. Refer t o coil nameplate for TXV identification for this unit.
The coil should be open to the air for no more than 2 minutes to keep moisture and contaminates from entering the system. If the coil can­not be installed into the refrigeration system in that time, the ends should be temporarily closed or plugged. For a short term delay, use masking tape over the ends of the copper tubing to close the tube to the air. For a longer term delay, use plugs or caps. There is no need to purge the coil if this procedure is followed.
REFRIGERANT LINE CONNECTION
Coil is under inert gas pressure. Relieve pressure from coil by depressing schrader core.
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.
Connect lines as follows:
FIGURE 9: TXV Please refer to Outdoor Unit Tech Guide to verify which metering device
is installed in this coil and that this is a valid system match for the AC or HP unit installed.
The temperature sensing bulb is attached to the coil suction header line.
FIGURE 10: Proper Bulb Location
Route the refrigerant lines to the coil in a manner that will not obstruct service access to the coil, air handling system, or filter.
1. Suction and liquid line connections are made outside the cabinet. Leave the tubing connection panel attached to the cabinet with the tubes protruding through it. Coil access panel should be removed for brazing. The lines are swedged to receive the field line set tubes.
2. Cut the end of the suction tube using a tube cutter. Place the tube cutter as close as possible to the end of the tube to allow more space for the connection and brazing of the suction line.
3. Remove the heat shield from the Customer Packet, soak in water, and install over coil tubing to prevent overheating of cabinet.
4. Wrap a water soaked rag around the coil connection tubes inside the cabinet to avoid damaging the TXV bulb.
5. Remove grommets where tubes exit the cabinet to prevent burning them during brazing.
6. Purge refrigerant lines with dry nitrogen. Follow outdoor unit braz­ing instructions.
7. Braze the suction and liquid lines.
8. Remove the heat shield.
9. Re-attach the grommets to the lines carefully to prevent air leak­age.
10. Attach the coil access panel to the cabinet.
Refer to Outdoor unit Installation Manual for evacuation, leak check and charging instructions.
Lines should be sound isolated by using appropriate hangers or strap­ping.
All 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.
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