Johnson Controls YC2E User manual

Johnson Controls Ducted Systems
R-410A Outdoor Split-System Air
Conditioning
York International Corporation, 5005 York
Drive, Norman, OK 73069
2022-01-10
6158110-UIM-A-0122
Supersedes: nothing
A

2 R-410A Outdoor Split-System Air Conditioning
Johnson Controls Ducted Systems

Contents
ContentsGeneral......................................................................................5
Certification.............................................................................. 5
Safety.........................................................................................5
Inspection........................................................................... 5
Limitations.......................................................................... 5
Unit installation........................................................................ 6
Location...............................................................................6
Liquid line filter-drier.........................................................8
Filter-drier installation at outdoor unit......................8
Filter-drier installation at indoor coil......................... 8
Piping connections.............................................................9
Precautions during line installation.................................9
Precautions during brazing of lines...............................10
Precautions during brazing of service valve.................10
Connecting the refrigerant lines.............................. 10
Coil metering devices............................................................ 11
Installing a thermostatic expansion valve (TXV).......... 12
Evacuation...............................................................................13
System charge........................................................................13
Measuring indoor airflow............................................... 13
Charging the system........................................................14
Subcooling charging - TXV indoor................................. 15
R-410A saturation properties..........................................15
Optional cold weather charging.................................... 16
Electrical connections............................................................16
General information and grounding............................. 16
Field connections power wiring..................................... 17
Field connections control wiring....................................17
Field wiring..................................................................18
Instructing the user...............................................................19
Maintenance.....................................................................19
Wiring diagrams.....................................................................20
Start-up sheet.........................................................................21
Johnson Controls Ducted Systems
R-410A Outdoor Split-System Air Conditioning 3

4 R-410A Outdoor Split-System Air Conditioning
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 equipped
with a filter-drier located in the liquid line.
Units with quick-connect coupling connections are
factory charged with refrigerant to be matched with the
appropriate pre-charged line set 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, you must inspect it for
possible damage during transit. If damage is evident,
you must 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. See 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 the unit is to be installed 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 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°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.
R-410A Outdoor Split-System Air Conditioning6
Johnson Controls Ducted Systems

Figure 1: Typical installation clearances
Figure 2: Alternative installation clearances
R-410A Outdoor Split-System Air Conditioning 7
Johnson Controls Ducted Systems

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.
Filter-drier installation 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.
Figure 3: Liquid line filter-drier installation at outdoor
unit
Filter-drier installation 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
R-410A Outdoor Split-System Air Conditioning8
Johnson Controls Ducted Systems

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 will result
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 proper oil return. If more
than the 80 ft line length is necessary, facilitate proper
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. 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.
• The lines must be installed so that they do not
obstruct service access to the coil, air handling
system, or filter.
• Care must also be taken to isolate the refrigerant
lines to minimize noise transmission from the
equipment to the structure.
• The vapor line must be insulated with a minimum
of 3/8 in. foam rubber insulation (Armaflex or
equivalent). Liquid lines that are exposed to direct
sunlight, high temperatures, or excessive humidity
must also be insulated.
• 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. Buried lines must
be kept 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.
R-410A Outdoor Split-System Air Conditioning 9
Johnson Controls Ducted Systems

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
About this task:
Connect the refrigerant lines using the following
procedure:
1. Remove the cap and Schrader core from both the
liquid and vapor service valve service ports at the
outdoor unit. Connect low pressure nitrogen to the
liquid line service port.
2. Braze the liquid line to the liquid valve at the
outdoor unit. Be sure to wrap the valve body with a
wet rag. Allow the nitrogen to continue flowing.
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.
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Johnson Controls Ducted Systems