Johnson Controls Duct R-410A User manual

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Johnson Controls Ducted Systems 5782374-UIM-B-0721
R-410A OUTDOOR SPLIT-SYSTEM
HEAT PUMP
MODELS: 14 SEER -
YEE, TE4B, REP14L SERIES
1.5 TONS TO 5 TONS – 1 PHASE
INSTALLATION MANUAL
LIST OF SECTIONS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INDOOR EXPANSION DEVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SYSTEM CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SYSTEM START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTRUCTING THE OWNER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LIST OF FIGURES
Typical installation clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Alternative installation clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Installation of vapor line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Underground installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Heat protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
TXV installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TXV bulb and equalizer line installations . . . . . . . . . . . . . . . . . . . . . . 6
Proper bulb location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Outdoor unit swing away control box . . . . . . . . . . . . . . . . . . . . . . . . .12
Outdoor unit control box (208/230V single phase) . . . . . . . . . . . . . . 12
Outdoor unit control box
(208/230V single phase, (18 and 24 models only) . . . . . . . . . . . . . . 12
Typical field wiring (air handler / electrical heat)
(single and three-phase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Heat pump flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Demand defrost control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Defrost operation curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wiring diagram - single phase - 208/230V (demand defrost) PSC fan
motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
LIST OF TABLES
Maximum / minimum operating limit conditions . . . . . . . . . . . . . . . . . .2
R-410A saturation properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Required subcool adjustment levels for Downflow and
Horizontal-Right Installations for the following equipment . . . . . . . . . .8
1.5 ton subcooling charging chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2 ton subcooling charging chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.5 ton subcooling charging chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3 ton subcooling charging chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.5 ton subcooling charging chart . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4 ton subcooling charging chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5 ton subcooling charging chart - 7/8 in. suction line set . . . . . . . . . 10
5 ton subcooling charging chart - 1 1/8 in. suction line set . . . . . . . .10
1.5 ton heating charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 ton heating charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 ton heating charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3 ton heating charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.5 ton heating charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 ton heating charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 ton heating charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TEST input functionality with Y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TEST input functionality without Y . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Status code display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Defrost jumper pin settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
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 ft of
field-supplied lines.
Matching indoor coils can be used with a thermostatic expansion valve
(TXV). Refer to the Tabular Data Sheet or to the Technical Guide for the
proper selection.
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.
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 assis-
tance or for additional information, consult a qualified contractor,
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 equip-
ment. Service equipment Must Be Rated for R-410A.
!
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5782374-UIM-B-0721
2 Johnson Controls Ducted Systems
INSPECTION
As soon as a unit is received, it must be inspected for possible damage
during transit. If damage is evident, the extent of the damage must be
noted 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/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.
LIMITATIONS
The unit must 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 that will give maximum performance
and service life.
The unit should not be operated in cooling mode at outdoor temperatures below
50°F without an approved low ambient operation accessory kit installed.
The maximum allowable line length for this product is 80 ft. Consult the Piping
Application Guide (P/N 247077) for installations over the maximum allowable
line length. Installation of an accessory crankcase heater is required if not fac-
tory installed for installations over the maximum allowable line length.
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
outdoor coil, air discharge, and service access. See Figures 1 and 2.
If the unit is 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 out-
door 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, refer to the “Optional
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.
ADD-ON REPLACEMENT/RETROFIT
When this unit is being used as a replacement for an R-410A unit, it is
required that the outdoor unit, indoor coil, and metering device all 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/outdoor
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 pre-
cautions 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 possi-
ble.
• Install a suction line filter-drier to trap any remaining contami-
nants, and remove after 50 hrs 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 bi-
flow liquid-line drier. Operate the system for 10 hrs. Monitor the suc-
tion drier pressure drop. If the pressure drop exceeds 3 psig,
replace both the suction-line and liquid-line driers. After a total of 10
hrs 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 hrs of
run time.
Table 1:
Maximum / minimum operating limit conditions
Air temperature at
outdoor coil, °F Air temperature at indoor coil, °F
Minimum Maximum Minimum Maximum
DB
Cool DB Heat DB Cool DB Heat WB Cool DB Heat WB Cool DB Heat
55°F 0°F 125°F 75°F 57°F 50°F 72°F 80°F
Operation below this temperature is permissible for a short period of time,
during morning warm-up.
NOTICE
For multiple unit installations, units must be spaced a minimum of 24
in. (61 cm) apart (coil face to coil face).

5782374-UIM-B-0721
Johnson Controls Ducted Systems 3
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5782374-UIM-B-0721
4 Johnson Controls Ducted Systems
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 main-
taining the clearances shown in Figures 1 and 2.
Normal operating sound levels may be objectionable if the unit is placed
directly under windows of certain rooms (bedrooms, study, etc.).
Condensate will drain from beneath the coil of the outdoor unit during
the defrost cycle. Normally this condensate may be allowed to drain
directly on the ground.
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 sup-
porting the total weight of the unit, including a pad, lintels, rails, etc.,
which should be used to minimize the transmission of sound or vibra-
tion 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 transmis-
sion 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 integ-
rity, safe access and serviceability, as well as the possible sound and
vibration transmission into the structure. These applications are best
served by a properly engineered solution.
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 heat pumps have a solid core bi-flow filter/drier located on the liquid
line.
PIPING CONNECTIONS
The outdoor unit must be connected to the indoor coil using field sup-
plied 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 ft (4.6 m). See Piping
Application Guide (P/N 247077) for installing tubing of longer lengths
and elevation differences.
PRECAUTIONS DURING LINE INSTALLATION
1. 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.
2. The lines should be installed so that they will not obstruct service
access to the coil, air handling system, or filter.
3. Care must also be taken to isolate the refrigerant lines to minimize
noise transmission from the equipment to the structure.
4. The vapor line must be insulated with a minimum of 1/2 in. foam
rubber insulation (Armaflex or equivalent). Liquid lines that will be
exposed to direct sunlight, high temperatures, or excessive humid-
ity must also be insulated.
5. Tape and suspend the refrigerant lines as shown. Do not allow
tube metal-to-metal contact. See Figure 3.
6. 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.
v
7. Pack fiberglass insulation and a sealing material such as perma-
gum around refrigerant lines where they penetrate a wall to reduce
vibration and to retain some flexibility.
WARNING
The outdoor unit must not be installed in an area where mud or ice
could cause personal injury. Remember that condensate will drip from
the unit coil during heat and defrost cycles and that this condensate
will freeze when the temperature of the outdoor air is below 32°F.
NOTICE
Heat pumps will defrost periodically resulting in water drainage. The
unit must not be located where water drainage may freeze and create
a hazardous condition - such as sidewalks and steps.
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. replace-
ment driers.
R-410A filter-drier source 1 Part No. Apply with models
S1-02650625000 All
!
NOTICE
Using a larger than specified line size could result in oil return prob-
lems. 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 out-
door 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
247077).
CAUTION
This system uses R-410A refrigerant which operates at higher pres-
sures 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 equip-
ment 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.
Figure 3: Installation of vapor line
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5782374-UIM-B-0721
Johnson Controls Ducted Systems 5
8. For systems with total line length exceeding 80 ft (22.86 m), see
Piping Application Guide (P/N 247077) for vapor and liquid line
sizing, calibration of liquid line pressure loss or gain, determination
of vapor line velocity, elevation limitations, TXV connections, sys-
tem charging, traps, crankcase heater, etc.
PRECAUTIONS DURING BRAZING OF LINES
All outdoor unit and indoor coil connections are copper-to-copper and
should be brazed with a phosphorous-copper alloy material such as Sil-
fos-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 precau-
tions to assure an internally clean and dry system.
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 braz-
ing, cool joint with wet rag.
The 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.
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 liquid and vapor con-
nections at the indoor coil.
4. Braze the liquid line to the indoor coil liquid connection. Nitrogen
should 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 con-
nection 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.
7. Replace the Schrader core in the liquid and vapor valves.
8. Go to SECTION IV 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 and 60 in. - lbs. maximum).
10.Evacuate the vapor line, indoor coil, and liquid line to 500 microns or
less. See Section V.
Figure 4: Underground installation
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.
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.
TO INDOOR COIL
TO
O UT DO
OR
U
NI T
LIQUID LIN
E
CAP
PVC
COND
U
IT
IN
SULA
TE D
VAPOR LINE
A0152-001
!
!
Figure 5: 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.
NOTICE
Line set and indoor coil can be pressurized to 250 psig with dry nitro-
gen 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.
CAUTION
Do not connect manifold gauges unless trouble is suspected. Approx-
imately 3/4 ounce of refrigerant will be lost each time a standard man-
ifold gauge is connected.
$
:(75$*6
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RUUHIULJHUDQWOLQHV
SULRUWREUD]LQJ
!
!

5782374-UIM-B-0721
6 Johnson Controls Ducted Systems
11. Release the refrigerant charge into the system. Open the liquid line
service valve first. Once system pressures have equalized, open the
vapor line service valve. Valves can be opened by removing the
valve caps and turn the valve counterclockwise using a hex head
wrench. If the service valve is a ball valve, use an adjustable end
wrench to turn valve stem one-quarter turn counterclockwise to
open. Do not overturn or the valve stem may break or become dam-
aged. See “PRECAUTIONS DURING BRAZING SERVICE VALVE”.
12.Replace service valve cap finger tight, then tighten an additional 1/
12 turn (1/2 hex flat). Cap must be replaced to prevent leaks.
13.See “System Charge” section for checking and recording system
charge. See Section VI.
SECTION IV: INDOOR EXPANSION DEVICE
THERMOSTATIC EXPANSION VALVE (TXV)
INSTALLATION
The following are the basic steps for installation. For detailed instruc-
tions, refer to the Installation Instructions accompanying the TXV kit.
Install TXV kit as follows:
1. Relieve the holding charge by depressing Schrader core on the suc-
tion manifold stub out.
2. After holding charge is completely discharged, loosen and remove
the Schrader core.
3. Place a backup wrench on distributor, loosen and remove brass dis-
tributor nut. Retain brass nut for use on liquid line. Keep PTFE
washer in place and discard clear disk.
4. Install the thermal expansion valve to the distributor assembly with
supplied fittings. Ensure PTFE washer is seated in distributor. Hand
tighten and turn an additional 1/4 turn to seal. Do not over-tighten fit-
tings. See Figure 6.
S
5. Slide the nut removed in Step 3 over the supplied liquid line. Place
supplied PTFE washer from TXV kit in place on TXV, and install liq-
uid line to the top of the thermal expansion valve. Adjust assembly
so liquid line aligns with hole in access panel. Hand tighten the liquid
line, and apply an additional 1/4 turn to seal.
6. Install the TXV equalizer line onto the vapor line by hand tightening
the 1/4 in. SAE coupling nut to the equalizer fitting, and apply an
additional 1/3 turn to seal. See Figure 7.
7. Pass the TXV temperature sensing bulb through the suction line
split grommet in the access panel.
8. Install the TXV bulb to the vapor line near the cabinet, using the
bulb clamps furnished with the TXV assembly. Ensure the bulb is
making maximum contact. See Figures 7 and 8.
a. If possible, install the temperature bulb on a horizontal run of
the vapor line. Ensure that the bulb is installed at a 10 o’clock
or 2 o’clock position. See Figure 8.
b. If bulb installation is made on a vertical run, ensure that the
bulb is a minimum of 8 in. (20.3 cm) away from the elbow
coming out of the coil. Position the bulb with the tail of the
bulb at the top, so that the bulb acts as a reservoir.
c. Insulate the bulb using thermal insulation provided to protect
it from the effect of the surrounding ambient temperature.
Cover completely to insulate.
WARNING
Never attempt to repair any brazed connections while the system is
under pressure. Personal injury could result.
IMPORTANT: Refer to the Technical Guide for the unit to determine
the proper TXV kit to be used on this product.
CAUTION
Do not over-torque. Do not use slip joint pliers. This will distort the
aluminum distributor and the brass fitting (potentially causing leaks).
WARNING
Schrader valve core MUST NOT be installed with TXV installation.
Poor system performance or system failure could result.
!
!
!
Figure 6: TXV installation
Figure 7: TXV bulb and equalizer line installations
CAUTION
In all cases, mount the TXV bulb after vapor line is brazed and has
had sufficient time to cool. Failure to use suction line grommet may
result in premature TXV failure.
TXV/distributor coupling
Liquid line/TXV coupling
PTFE washer
TXV
PTFE washer
Distributor
A0281-004
TXV BULB
(Wrap with
insulation.)
VAPOR LINE
LIQUID LINE
TVX
EQUALIZER
LINE
THERMAL EXPANSION
VALVE
(
TXV
)
DISTRIBUTOR
BODY A0279-002
!

5782374-UIM-B-0721
Johnson Controls Ducted Systems 7
9. After line set is installed, leak test the system.
SECTION V: EVACUATION
It will be necessary to 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 vac-
uum pump suction to isolate the pump and hold the system under vac-
uum. 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 con-
tains moisture and may require further evacuation if the reading is
above 500 microns.
SECTION VI: SYSTEM CHARGE
To ensure that your unit performs at the published levels, it is important
that the indoor airflow is determined and refrigerant charge added
accordingly.
MEASURE INDOOR AIR FLOW
To determine rated air flow for a specific match, consult the technical lit-
erature at www.upgnet.com. When attempting to match this air flow,
select the lowest possible speed tap, measure the actual flow, and
adjust as necessary.
To measure actual air flow, it is not an acceptable method to just
check the jumper pin setting tables and is to assume 0.5 in. water
column total external static pressure.
To determine indoor air flow, first measure the static pressure with a
manometer between the filter and return air opening of the indoor
equipment. On a single-piece or modular air handler, take a second
reading in the supply air ductwork leaving the indoor equipment. On a
gas furnace, take the second reading after the heat exchanger, but
before the indoor coil. Add the negative return static to the positive sup-
ply static to determine the system total static pressure. Treat the nega-
tive return static as a positive pressure (even though it is a negative
reading). If there is static pressure on the blower (i.e. -.10) return, add it
to a supply static (.40) which equals a (.50) total system static pressure.
Compare this value to the indoor blower performance charts ensuring
air flow is between 350 CFM to 450 CFM per ton of cooling.
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.
See Tabular Data Sheet provided in unit Customer Booklet for charge
requirements. The “TOTAL SYSTEM CHARGE” must be permanently
marked on the unit data plate.
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 Tabu-
lar Data Sheet if line length is greater than 15 ft (4.6 m).
4. Total system charge = item 1 + item 2 + item 3.
5. Check the unit against the pressure value listed on the cooling chart
on the unit or the appropriate heat charging chart on the following
pages of this Installation Manual. Make any adjustment necessary.
6. Add or subtract refrigerant to obtain the pressure listed on charging
chart. Make sure to adjust the total system charge by the amount
added or removed to obtain charging chart pressures. Permanently
mark the unit data plate with the total amount of refrigerant in the
system.
CHARGING WITH GAUGES
All units include a cooling charging chart for cooling. The heating
charging charts in Table 12 through Table 18 in this document use the
chart corresponding to the installed indoor coil. It can also be obtained
at www.simplygettingthejobdone.com under the Service Application
Data section.
Figure 8: Proper bulb location
CAUTION
If a field installed device is placed in the inner-connecting refrigerant
lines that can store a significant refrigerant charge (ex: refrigerant
mass flow meter, liquid receiver, etc.) the unit may not perform as
designed. If such a performance affecting device is installed and it is
possible to check the unit in heating mode, the unit pressures should
be confirmed in heating mode. Refer to the heating charging charts
located in this installation manual.
CAUTION
Refrigerant charging should only be carried out by a licensed quali-
fied air conditioning contractor.
TXV BULB
(Cover completely
with insulation.)
VAPOR LINE
OF LINE SET
A0269-002
CLAMP
A
DETAIL A
TXV SENSING BULB
(Pass through split hole
in grommet.)
VAPOR
LINE
NUT
NUT
Bulb at
10 o’clock
position.
Bulb at
2 o’clock
position.
SCREW
SCREW
CLAMP
!
!
CAUTION
Always charge in liquid form. Take care not to slug the compressor.
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.
WARNING
Do not attempt to pump “Total System Charge” into outdoor unit for
maintenance, service, etc. This may cause damage to the compres-
sor and/or other components. Recover and weigh “System Charge”
into an appropriate recovery cylinder for any instances requiring
evacuation.
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.
CAUTION
Refrigerant charging should only be carried out by a qualified air con-
ditioning contractor.
!
!
!
!
!
!

5782374-UIM-B-0721
8 Johnson Controls Ducted Systems
Before using gauges, confirm that your gauges are accurate by
comparing the gauges against a calibrated pressure gauge that
has been calibrated against a national standard. If a calibrated
pressure gauge is not available, place a R-410A virgin refrigerant
container in a conditioned space long enough to come to tempera-
ture equilibrium with the surroundings. Then measure the tem-
perature of the air and the pressure of the refrigerant and compare
it to the following table:
:
Before measuring the pressures, use the method above to check the air
flow and then consult the table and match the liquid pressure to that air
flow.
Reference the cooling/heating charging charts in Tables 4 - 18.
SUBCOOLING CHARGING CHARTS
9
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.
Table 2:
R-410A saturation properties
Temp
(°F) Pressure (psig) Temp (°F) Pressure (psig) Temp (°F) Pressure (psig)
40 119 75 218 110 365
45 130 80 236 115 391
50 143 85 255 120 418
55 156 90 274 125 447
60 170 95 295 130 477
65 185 100 317 – –
70 201 105 341 – –
Table 3:
Required subcool adjustment levels for Downflow and
Horizontal-Right Installations for the following equipment
Unit
size Indoor model
Reduce subcooling
value on charging
chart by this amount
18 AE/AVC18B, CF/CM/CU18(A,B),
RFCX18BE 10
24 AE/AVC24B, CF/CM/CU24(B,C),
RFCX24BE 10
30 AE/AVC30B, CF/CM/CU30(A,B,C),
RFCX30BE 6
36 AE/AVC36(B,C), CF/CM/CU36(B,C,D),
RFCX36(B,C)E 6
42 AE/AVC42C, AE/AVC48(C,D), CF/CM/CU48(C,D),
RFCX42C, RFCX48(C,D)E 9
48 AE/AVC48(C,D), CF/CM/CU48(C,D),
RFCX48(C,D)E 4
60 AE60D, AVC60D, CF/CM64D 3
!Table 4:
1.5 ton subcooling charging chart
Outdoor ambient
DB (F)
Indoor wet bulb (°F) at 80°F dry bulb
57 62 67 72
Pressure (psig) and subcooling (°F) at liquid
base value
55 212(12) 215(12) 218(11) 220(10)
60 229(11) 231(12) 234(11) 238(10)
65 247(11) 249(12) 252(11) 256(11)
70 266(11) 269(12) 272(12) 276(11)
75 288(12) 291(13) 294(12) 298(12)
80 311(13) 314(14) 317(13) 321(13)
85 335(13) 338(15) 341(14) 346(14)
90 362(14) 365(15) 368(15) 372(15)
95 390(15) 392(16) 395(16) 400(16)
100 420(15) 422(17) 425(16) 429(16)
105 451(16) 453(17) 456(16) 459(16)
110 484(16) 486(17) 489(17) 491(16)
115 519(16) 521(17) 523(17) 525(16)
120 555(17) 557(18) 559(18) 560(17)
125 593(19) 594(19) 597(19) 596(18)
Table 5:
2 ton subcooling charging chart
Outdoor
ambient DB (F)
Indoor wet bulb (°F) at 80°F dry bulb
57 62 67 72
Pressure (psig) and subcooling (°F) at liquid
base valve
55 217(12) 220(12) 223(12) 226(10)
60 235(12) 238(13) 241(12) 245(11)
65 254(12) 258(13) 261(13) 265(12)
70 275(13) 279(14) 282(13) 286(13)
75 297(14) 301(15) 304(14) 308(14)
80 321(15) 325(16) 328(15) 332(15)
85 346(16) 350(17) 353(16) 357(16)
90 372(17) 376(18) 379(17) 384(16)
95 400(17) 404(18) 407(18) 412(17)
100 430(17) 433(18) 437(18) 441(17)
105 460(18) 464(18) 467(18) 471(17)
110 492(18) 496(18) 499(18) 503(17)
115 526(18) 530(19) 533(18) 536(18)
120 561(18) 564(19) 568(19) 571(19)
125 597(19) 601(20) 604(20) 607(20)

5782374-UIM-B-0721
Johnson Controls Ducted Systems 9
Table 6: 2.5 ton subcooling charging chart
Outdoor
ambient DB (F)
Indoor wet bulb (°F) at 80°F dry bulb
57 62 67 72
Pressure (psig) and subcooling (°F) at liquid
base valve
55 201(7) 204(8) 205(8) 209(8)
60 217(7) 220(8) 222(7) 225(8)
65 234(7) 237(8) 239(7) 242(8)
70 253(7) 256(8) 258(8) 261(8)
75 273(8) 276(8) 278(8) 281(8)
80 294(8) 297(9) 300(9) 303(9)
85 317(9) 320(10) 323(10) 325(10)
90 341(10) 344(10) 347(10) 349(10)
95 366(10) 369(11) 372(11) 375(11)
100 392(10) 395(11) 399(11) 401(11)
105 420(10) 423(11) 427(11) 429(11)
110 449(10) 452(11) 456(11) 459(10)
115 480(10) 482(11) 486(11) 489(10)
120 511(10) 514(10) 518(11) 521(10)
125 544(10) 546(10) 551(11) 554(10)
Table 7:
3 ton subcooling charging chart
Outdoor
ambient DB (F)
Indoor wet bulb (°F) at 80°F dry bulb
57 62 67 72
Pressure (psig) and subcooling (°F) at liquid
base valve
55 195(8) 198(9) 200(10) 207(13)
60 212(8) 214(9) 217(9) 222(11)
65 229(8) 231(8) 234(9) 239(11)
70 248(8) 250(8) 253(9) 257(10)
75 269(9) 270(9) 273(9) 277(10)
80 290(9) 291(9) 294(10) 298(10)
85 313(10) 314(10) 316(10) 320(11)
90 338(11) 337(11) 340(11) 344(11)
95 363(11) 363(11) 366(11) 369(11)
100 390(12) 389(12) 392(12) 395(12)
105 418(12) 417(12) 420(12) 423(12)
110 447(12) 447(12) 449(12) 452(12)
115 478(12) 477(12) 480(12) 483(12)
120 509(12) 509(12) 511(12) 515(12)
125 543(12) 542(12) 544(12) 548(12)
Table 8: 3.5 ton subcooling charging chart
Outdoor
ambient DB (F)
Indoor wet bulb (°F) at 80°F dry bulb
57 62 67 72
Pressure (psig) and subcooling (°F) at liquid
base valve
55 211 (12) 211 (12) 214 (12) 217 (12)
60 230 (12) 231 (12) 234 (12) 236 (12)
65 250 (12) 250 (13) 253 (12) 256 (12)
70 269 (12) 270 (13) 273 (12) 276 (12)
75 288 (13) 290 (13) 293 (13) 296 (12)
80 314 (13) 315 (14) 317 (13) 320 (13)
85 340 (13) 340 (14) 342 (13) 345 (13)
90 366 (14) 365 (14) 367 (14) 370 (14)
95 391 (14) 390 (15) 392 (14) 395 (14)
100 424 (15) 423 (15) 426 (15) 428 (15)
105 457 (15) 456 (16) 459 (15) 461 (15)
110 490 (16) 488 (16) 492 (16) 495 (16)
115 523 (16) 521 (17) 526 (16) 528 (16)
120 555 (17) 553 (17) 559 (17) 561 (17)
125 588 (18) 586 (18) 592 (18) 594 (18)
Table 9: 4 ton subcooling charging chart
Outdoor
ambient DB (F)
Indoor wet bulb (°F) at 80°F dry bulb
57 62 67 72
Pressure (psig) and subcooling (°F) at liquid
base valve
55 199 (8) 202 (9) 204 (9) 206 (9)
60 218 (8) 221 (9) 223 (9) 225 (9)
65 237 (8) 239 (9) 241 (8) 243 (8)
70 256 (8) 257 (9) 259 (8) 262 (8)
75 275 (8) 276 (9) 278 (8) 280 (8)
80 298 (8) 299 (9) 301 (8) 303 (8)
85 322 (8) 323 (9) 325 (8) 327 (8)
90 345 (9) 346 (9) 348 (9) 350 (8)
95 368 (9) 370 (9) 372 (9) 373 (9)
100 399 (9) 400 (9) 402 (9) 404 (9)
105 429 (9) 430 (10) 432 (9) 434 (9)
110 460 (9) 460 (10) 463 (9) 465 (9)
115 490 (9) 489 (10) 493 (10) 495 (9)
120 520 (10) 519 (10) 523 (10) 526 (10)
125 551 (10) 549 (10) 554 (10) 556 (10)

5782374-UIM-B-0721
10 Johnson Controls Ducted Systems
HEAT CHARGING CHARTS
c
Table 10: 5 ton subcooling charging chart - 7/8 in. suction line set
Outdoor
ambient DB (F)
Indoor wet bulb (°F) at 80°F dry bulb
57 62 67 72
Pressure (psig) and subcooling (°F) at liquid
base valve
55 203 (8) 208 (8) 211 (9) 215 (9)
60 223 (8) 227 (8) 230 (8) 234 (9)
65 242 (8) 246 (8) 249 (8) 253 (9)
70 261 (8) 264 (8) 267 (8) 272 (9)
75 280 (8) 283 (8) 286 (8) 291 (9)
80 304 (9) 307 (9) 310 (9) 314 (9)
85 329 (9) 331 (9) 334 (9) 337 (9)
90 353 (9) 355 (9) 359 (9) 360 (9)
95 377 (9) 379 (9) 382 (9) 384 (9)
100 409 (10) 410 (10) 414 (10) 415 (10)
105 440 (10) 442 (10) 445 (10) 447 (10)
110 472 (10) 473 (10) 476 (10) 479 (10)
115 503 (11) 504 (11) 507 (11) 510 (11)
120 535 (11) 536 (11) 539 (11) 542 (11)
125 566 (12) 567 (12) 570 (12) 574 (12)
Table 11: 5 ton subcooling charging chart - 1 1/8 in. suction line set
Outdoor
ambient DB (F)
Indoor wet bulb (°F) at 80°F dry bulb
57 62 67 72
Pressure (psig) and subcooling (°F) at liquid
base valve
55 205 (9) 209 (9) 212 (9) 216 (10)
60 224 (9) 228 (9) 231 (9) 236 (10)
65 244 (9) 247 (9) 250 (9) 255 (10)
70 263 (9) 266 (10) 269 (10) 274 (10)
75 282 (10) 285 (10) 288 (10) 293 (10)
80 307 (10) 309 (10) 313 (10) 316 (10)
85 331 (10) 334 (10) 337 (10) 340 (10)
90 355 (10) 358 (10) 361 (10) 363 (10)
95 380 (10) 382 (10) 385 (10) 386 (10)
100 412 (11) 413 (11) 417 (11) 418 (11)
105 443 (11) 445 (11) 448 (11) 450 (11)
110 475 (12) 476 (12) 480 (12) 482 (12)
115 507 (12) 508 (12) 511 (12) 514 (12)
120 539 (13) 540 (13) 543 (13) 546 (13)
125 571 (13) 571 (13) 574 (13) 578 (13)
Table 12: 1.5 ton heating charts
CFM
Ambient
temperature (°F) 60 47 40 30 17 10
Indoor
temperature (°F) 60 70 80 60 70 80 60 70 80 60 70 80 60 70 80 60 70 80
450 Liquid pressure
(subcool) 348 (18) 390 (17) 432 (17) 318 (21) 361 (21) 405 (21) 301 (22) 346 (23) 391 (23) 278 (23) 324 (25) 370 (26) 248 (25) 296 (27) 344 (29) 232 (26) 280 (28) 329 (31)
600 Liquid pressure
(subcool) 318 (15) 361 (15) 403 (15) 293 (18) 336 (19) 378 (19) 280 (19) 322 (20) 365 (21) 261 (21) 303 (22) 345 (24) 236 (23) 278 (25) 320 (27) 222 (24) 265 (26) 307 (28)
750 Liquid pressure
(subcool) 289 (12) 332 (13) 375 (14) 269 (15) 310 (16) 351 (17) 259 (17) 299 (18) 339 (19) 243 (19) 282 (20) 320 (21) 223 (21) 260 (22) 297 (24) 213 (22) 249 (24) 284 (25)
-Suction pressure 127 107 95 79 59 48
Table 13: 2 ton heating charts
CFM
Ambient
temperature (°F) 60 47 40 30 17 10
Indoor
temperature (°F) 60 70 80 60 70 80 60 70 80 60 70 80 60 70 80 60 70 80
600 Liquid pressure
(subcool) 353 (17) 396 (17) 445 (19) 329 (20) 370 (21) 416 (23) 316 (22) 356 (23) 401 (24) 297 (24) 336 (25) 379 (27) 272 (26) 310 (28) 350 (29) 259 (27) 296 (29) 335 (30)
800 Liquid pressure
(subcool) 321 (15) 362 (16) 408 (17) 301 (18) 341 (19) 385 (21) 290 (19) 330 (21) 373 (22) 275 (21) 314 (23) 355 (25) 255 (24) 293 (26) 332 (27) 245 (25) 281 (27) 320 (28)
1000 Liquid pressure
(subcool) 288 (12) 328 (13) 372 (14) 273 (15) 312 (16) 354 (18) 265 (16) 304 (18) 345 (20) 253 (18) 291 (21) 332 (22) 239 (21) 275 (23) 315 (25) 230 (22) 267 (25) 305 (27)
-Suction pressure 126 101 88 74 59 49
Table 14: 2.5 ton heating charts
CFM
Ambient
temperature (°F) 60 47 40 30 17 10
Indoor
temperature (°F) 60 70 80 60 70 80 60 70 80 60 70 80 60 70 80 60 70 80
750 Liquid pressure
(subcool) 379 (26) 427 (26) 477 (26) 350 (25) 395 (26) 444 (26) 335 (25) 377( 25) 427 (26) 313 (24) 352 (24) 402 (25) 284 (22) 320 (22) 369 (24) 268 (22) 302 (20) 351 (24)
1000 Liquid pressure
(subcool) 345 (24) 394 (26) 441 (25) 321 (23) 366 (24) 414 (25) 308 (23) 351( 24) 399 (24) 290 (21) 330 (22) 377 (23) 266 (20) 302 (19) 350 (22) 253 (19) 287 (18) 335 (21)
1250 Liquid pressure
(subcool) 311 (22) 360 (24) 406 (24) 292 (21) 337 (23) 383 (23) 282 (20) 325( 21) 371 (22) 267 (19) 307 (19) 353 (21) 248 (17) 285 (17) 331 (19) 238 (16) 272 (15) 319 (18)
-Suction pressure 126 103 92 77 60 51