Johnson Controls TCE2 Series User manual

Johnson Controls Ducted Systems
Installation Manual: R-410A Outdoor Split-
System Air Conditioner
YC2E, TCE2 and RAC143 Series
York International Corporation, 5005 York
Drive, Norman, OK 73069
2023-11-01
6158110-UIM-B-1123
Supersedes: 6158110-UIM-A-0122
B

2 Installation Manual: R-410A Outdoor Split-System Air Conditioner
Johnson Controls Ducted Systems

Contents
ContentsGeneral......................................................................................5
Certification.............................................................................. 5
Safety.........................................................................................5
Inspection........................................................................... 5
Limitations.......................................................................... 5
Unit installation........................................................................ 6
Location...............................................................................6
Liquid line filter-drier.........................................................7
Installing the filter-drier at outdoor unit...................7
Installing the filter-drier at indoor coil...................... 8
Piping connections.............................................................8
Precautions during line installation.................................8
Precautions during brazing of lines.................................9
Precautions during brazing of service valve...................9
Connecting the refrigerant lines................................ 9
Coil metering devices............................................................ 11
Installing a thermostatic expansion valve (TXV).......... 11
Evacuation...............................................................................12
System charge........................................................................12
Measuring indoor airflow............................................... 12
Charging the system........................................................13
Subcooling charging - TXV indoor................................. 14
R-410A saturation properties..........................................15
Optional cold weather charging.................................... 15
............................................................................................15
Electrical connections............................................................15
General information and grounding............................. 15
Field connections power wiring..................................... 16
Field connections control wiring....................................17
Field wiring..................................................................17
Instructing the user...............................................................18
Maintenance.....................................................................18
............................................................................................18
Wiring diagrams.....................................................................19
Start-up sheet.........................................................................20
Johnson Controls Ducted Systems
Installation Manual: R-410A Outdoor Split-System Air Conditioner 3

4 Installation Manual: R-410A Outdoor Split-System Air Conditioner
Johnson Controls Ducted Systems

General
Read all sections of this manual and keep the manual for
future reference.
These outdoor condensing units are designed to be
connected to a matching indoor coil. They are shipped
with a filter-drier that must be installed in the liquid line.
Units with quick-connect coupling connections are
factory-charged with refrigerant to be matched with the
appropriate pre-charged refrigeration piping and indoor
coil.
Certification
Safety
This is a safety alert symbol. When you see this
symbol on labels or in manuals, be alert to the
potential for personal injury.
Understand and pay particular attention to the signal
words DANGER, WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation,
which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation,
which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation,
which, if not avoided may result in minor or moderate
injury. It is also used to alert against unsafe practices and
hazards involving only property damage.
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.
For additional information, consult a qualified installer
or service agency.
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, inspect it for possible
damage during transit. If damage is evident, note the
extent of the damage on the carrier’s delivery receipt.
A separate request for inspection by the carrier’s agent
must be made in writing. Contact your Local Distributor
for more information.
Requirements for installing or servicing R-410A
equipment
• Gauge sets, hoses, refrigerant containers, and the
recovery system must be designed to handle the POE
type oils and the higher pressures of R-410A.
• Manifold sets must be high side and low side with low
side retard.
• All hoses must have a 700 psig service pressure rating.
• Leak detectors must 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.
Limitations
You must install the unit in accordance with all national,
state, and local safety codes, and the following limitations:
• Limitations for the indoor unit, coil, and appropriate
accessories must also be observed.
• 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.
• The maximum and minimum conditions for operation
must be observed to ensure a system that gives
maximum performance with minimum service.
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Johnson Controls Ducted Systems

Table 1: Application limitations
Ambient air temperature on outdoor coil (°F) Air temperature on indoor coil (°F)
Model Minimum DB Maximum DB Minimum DB Maximum DB
YC2E/TCE2B/RAC143 55 125 57 72
• The unit must not be operated at outdoor
temperatures below 55°F without an approved low
ambient operation accessory kit installed.
• The maximum allowable line length for this product
is 80 ft. To install more than the maximum allowable
line length, consult the Piping Application Guide (P/N
247077).
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 and Figure 2.
NOTICE
For multiple unit installations, units must be spaced a
minimum of 24 in. (61 cm) apart (coil face to coil face).
If installing the unit on a hot sun-exposed roof or a paved
ground area that is seasonally hot, the unit must be raised
sufficiently above the roof or ground to avoid taking the
accumulated layer of hot air into the outdoor unit.
If installing the system during seasonally cold weather
of 55°F or below, weigh in the charge. For charging or
checking the system charge at 55°F or below, see the
Optional cold weather charging procedures near the
end of the System charge section. 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 at
www.simplygettingthejobdone.com.
Provide adequate structural support for the unit.
Figure 1: Typical installation clearances
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Johnson Controls Ducted Systems

Figure 2: Alternative installation clearances
Liquid line filter-drier
The filter-drier is packaged and shipped along with the
outdoor unit. It is located outside the unit next to the
service valves.
CAUTION
Filter-drier is required to be installed in liquid line. The
recommended location is at the indoor coil before the
refrigerant metering device. It can be installed at the
outdoor unit if desired.
CAUTION
Using a granular type drier may result in damage to
the equipment.
CAUTION
Filter-drier must be wrapped in wet rag while brazing.
Filter-drier Source 1 part S1-401021 applies to all AC
models.
Installing the filter-drier at outdoor unit
About this task:
Complete the following steps and see Figure 3 to install a
filter-drier at the outdoor unit:
1. Connect low pressure nitrogen to the liquid line
service port.
2. Insert a short piece of 3/8 in. tubing into the liquid
line service valve piping connection. Install filter
drier (direction arrow toward indoor coil) on the
short piece of tubing and insert the liquid line
going to the indoor coil into the opposite end of
the filter drier.
3. Wrap a wet rag around the liquid line base valve
and filter drier.
4. Braze the liquid line connections.
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Johnson Controls Ducted Systems

Figure 3: Liquid line filter-drier installation at outdoor
unit
Installing the filter-drier at indoor coil
About this task:
Complete the following steps and see Figure 4 to install a
filter-drier at the indoor coil:
1. Connect low pressure nitrogen to the liquid line
indoor coil.
2. Insert a short piece of 3/8 in. tubing into the liquid
line indoor coil. Install filter drier (direction arrow
toward indoor coil) on the short piece of tubing
and insert the liquid line going to the indoor coil
into the opposite end of the filter drier.
3. Wrap a wet rag around the filter drier.
4. Braze the liquid line connections.
Figure 4: Liquid line filter-drier installation at indoor
coil
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 must be installed only with the tubing sizes for
approved system combinations as specified in the Tabular
Data Sheet. The charge given is applicable for total tubing
lengths up to 15 ft (4.6 m). Refer to the Piping Application
Guide (P/N 24077) for installing tubing of longer lengths
and elevation differences.
NOTICE
Using a larger than specified line size could result
in oil return problems. Using too small a line results
in loss of capacity and other problems caused by
insufficient refrigerant flow. Slope horizontal vapor
lines at least 1 in. (2.5 cm) every 20 ft (6.1 m) toward
the outdoor unit to facilitate adequate oil return. If
more than the 80 ft line length is necessary, facilitate
correct refrigerant velocity with adjusted line diameter
in accordance with the Piping Application Guide (P/N
24077).
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 the recovery system must
be designed to handle R-410A. If you are unsure,
consult the equipment manufacturer.
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.
Precautions during line installation
• Install the lines with as few bends as possible. Be
careful 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, be careful to
avoid sharp bends, which may cause a restriction.
• Install the lines so that they do not obstruct service
access to the coil, air handling system, or filter.
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Johnson Controls Ducted Systems

• Isolate the refrigerant lines to minimize noise
transmission from the equipment to the structure.
• Insulate the vapor line with a minimum of 3/8 in.
foam rubber insulation (Armaflex or equivalent).
Also insulate liquid lines that are exposed to direct
sunlight, high temperatures, or excessive humidity.
• Tape and suspend the refrigerant lines as shown in
Figure 5. Do not allow tube metal-to-metal contact.
• Use PVC piping as a conduit for all underground
installations as shown in Figure 6. Keep buried lines
as short as possible to minimize the build up of liquid
refrigerant in the vapor line during long periods of
shutdown.
Figure 5: Installation of vapor line
Figure 6: Underground installation
• 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.
• For systems with total line length exceeding 75 ft
(22.86 m), refer to the Piping Application Guide (P/
N 24077) for vapor and liquid line sizing, calibration
of liquid line pressure loss or gain, determination
of vapor line velocity, elevation limitations, TXV
connections, system charging or traps.
Precautions during brazing of lines
All outdoor unit and indoor coil connections are copper-
to-copper and must be brazed with a phosphorous-
copper alloy material such as Silfos-5 or equivalent. Do
not use soft solder. The outdoor units have reusable
service valves on both the liquid and vapor connections.
The total system refrigerant charge is retained within
the outdoor unit during shipping and installation. The
reusable service valves are provided to evacuate and
charge per this instruction.
Serious service problems can be avoided by taking
adequate precautions to assure an internally clean and
dry system.
CAUTION
Dry nitrogen must 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 must 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.
Precautions during brazing of service
valve
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.
Precautions must be taken to prevent heat damage to
service valve by wrapping a wet rag around it as shown in
Figure 7. Protect all painted surfaces, insulation, and the
plastic base during brazing. After brazing, cool the joint
with a wet rag.
Open the valve by removing the service valve cap, fully
inserting a hex wrench into the stem, and backing out
counterclockwise until the valve stem just touches the
chamfered retaining wall.
Connecting the refrigerant lines
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.
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2. Braze the liquid line to the liquid valve at the
outdoor unit. Be sure to wrap the valve body with a
wet rag. Allow the nitrogen to continue flowing.
3. Carefully remove the plugs from the indoor coil
liquid and vapor connections at the indoor coil.
Figure 7: Heat protection
CAUTION
Do not install any coil in a furnace which is to
be operated during the heating season without
attaching the refrigerant lines to the coil. The
coil is under pressure which must be released
to prevent excessive pressure build-up and
possible coil damage.
4. Braze the liquid line to the indoor coil liquid
connection. Nitrogen must be flowing through the
indoor coil.
5. Slide the grommet away from the vapor connection
at the indoor coil. Braze the vapor line to the
indoor coil vapor connection. After the connection
has cooled, slide the grommet back into original
position.
6. Protect the vapor valve with a wet rag and braze
the vapor line connection to the outdoor unit. The
nitrogen flow must be exiting the system from the
vapor service port connection. After this connection
cools, remove the nitrogen source from the liquid
fitting service port.
7. Replace the Schrader core in the liquid and vapor
valves.
8. Go to the section for TXV installation.
9. Leak test all refrigerant piping connections,
including the service port flare caps, to be sure they
are leak tight. Do not over-tighten (between 40 in.
lb and 60 in. lb 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, indoor coil, 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 oz
of refrigerant is lost each time a standard
manifold gauge is connected.
12. Release the refrigerant charge into the system
by opening the liquid line valve first. After a few
minutes, the suction line valve may be opened.
Open both the liquid and vapor valves by removing
the plunger cap and with an hex wrench, back out
counterclockwise until the valve stem just touches
the chamfered retaining wall. If the service valve
is a ball valve, use a adjustable wrench to turn the
valve stem 1/4 turn counterclockwise to open.
Do not overturn or the valve stem may break or
become damaged. See Precautions during brazing
of service valve.
13. Replace the plunger cap finger tight, then tighten
an additional 1/12 turn (1/2 hex flat). The 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.
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Johnson Controls Ducted Systems