Johnson Controls r-410a - Manual

Johnson Controls Unitary Products

835964-UIM-A-0112

R-410A
OUTDOOR SPLIT-SYSTEM
AIR CONDITIONING

MODELS: 13 & 14.5 SEER -
TCG(D,F)/GCGD/TCJ(D,F)/YCJ(D,F) SERIES

1.5 TO 5 TONS – 1 & 3 PHASE

INSTALLATION MANUAL

®

LIST OF SECTIONS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ‘1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ORIFICE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TXV INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTRUCTING THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

LIST OF FIGURES

Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Installation of Vapor Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Underground Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Orifice Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Outdoor Unit Control Box (Single Phase) . . . . . . . . . . . . . . . . . . . . . . 7
Outdoor Unit Control Box (Three Phase) . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Field Wiring (Air Handler / Electrical Heat) (Single-Phase) . . . 8

Typical Field Wiring (Air Handler / Electrical Heat) (Three-Phase) . . . 8
Thermostat Chart - Single Stage AC with PSC Air Handler . . . . . . . . 9
Thermostat Chart - Single Stage AC with PSC Air Handler . . . . . . . 10
Thermostat Chart - Single Stage AC with PSC Furnace . . . . . . . . . 11
Thermostat Chart - Single Stage AC with PSC Furnace . . . . . . . . . 12
Wiring Diagram - Single Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Diagram - Three Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

LIST OF TABLES

Application Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

R-410A Saturation Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION I: GENERAL

The outdoor units are designed to be connected to a matching indoor
coil with sweat connect lines. Sweat connect units are factory charged
with refrigerant for a matching indoor coil plus 15 feet of field-supplied
lines.

The refrigerant charge may need to be changed for some indoor-out-
door unit combinations, elevation differences or total line lengths. Refer
to Application Data covering “General Piping Recommendations and
Refrigerant Line Length” (Part Number 247077).

SECTION II: SAFETY

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

Understand and pay particular attention to the signal words

DANGER

,

WARNING

, or

CAUTION

.

DANGER

indicates an

imminently

hazardous situation, which, if not

avoided,

will result in death or serious injury

.

WARNING

indicates a

potentially

hazardous situation, which, if not

avoided,

could result in death or serious injury

.

CAUTION

indicates a potentially hazardous situation, which, if not

avoided

may result in minor or moderate injury

. It is also used to

alert against unsafe practices and hazards involving only property dam-
age.

INSPECTION

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

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.

•

Do not use an R-22 TXV.

•

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

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.

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.

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 mainte-
nance can cause injury or property damage. Refer to this manual
for assistance or for additional information, consult a qualified con-
tractor, installer or service agency.