Johnson Controls RL Series Owner's manual

RL SERIES
VERTICAL AND HORIZONTAL CABINETS
7–25 TONS
Issue Date:
January 2015
WATER SOURCE HEAT PUMPS
INSTALLATION, OPERATION, MAINTENANCE Supercedes: 146.00-NOM3 (310) Form 146.00-NOM3 (115)
LD20072

This equipment is a relatively complicated apparatus.
During rigging, installation, operation, maintenance,
or service, individuals may be exposed to certain com-
ponents or conditions including, but not limited to:
heavy objects, refrigerants, materials under pressure,
rotating components, and both high and low voltage.
Each of these items has the potential, if misused or
handled improperly, to cause bodily injury or death. It
is the obligation and responsibility of rigging, instal-
lation, and operating/service personnel to identify and
recognize these inherent hazards, protect themselves,
and proceed safely in completing their tasks. Failure
to comply with any of these requirements could result
in serious damage to the equipment and the property in
IMPORTANT!
READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or
death to themselves and people at the site.
This document is intended for use by owner-authorized
rigging, installation, and operating/service personnel. It
is expected that these individuals possess independent
training that will enable them to perform their assigned
tasks properly and safely. It is essential that, prior to
performing any task on this equipment, this individual
shall have read and understood the on-product labels,
this document and any referenced materials. This in-
dividual shall also be familiar with and comply with
all applicable industry and governmental standards and
regulations pertaining to the task in question.
SAFETY SYMBOLS
The following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation
which will result in death or serious injury
if proper care is not taken.
Indicates a potentially hazardous situa-
tion which will result in possible injuries
or damage to equipment if proper care is
not taken.
Identies a hazard which could lead to
damage to the machine, damage to other
equipment and/or environmental pollu-
tion if proper care is not taken or instruc-
tions and are not followed.
Highlights additional information useful
to the technician in completing the work
being performed properly.
External wiring, unless specied as an optional connection in the manufacturer’s product line, is not
to be connected inside the control cabinet. Devices such as relays, switches, transducers and controls
and any external wiring must not be installed inside the micro panel. All wiring must be in accor-
dance with Johnson Controls’ published specications and must be performed only by a qualied
electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper
connections to the controls or application of improper control signals. Failure to follow this warn-
ing will void the manufacturer’s warranty and cause serious damage to property or personal injury.
JOHNSON CONTROLS
2
RL SERIES INSTALLATION MANUAL

CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-
tinuous product improvement, the information con-
tained in this document is subject to change without
notice. Johnson Controls makes no commitment to
update or provide current information automatically
to the manual or product owner. Updated manuals, if
applicable, can be obtained by contacting the nearest
Johnson Controls Service office or accessing the John-
son Controls QuickLIT website at http://cgproducts.
johnsoncontrols.com.
It is the responsibility of rigging, lifting, and operating/
service personnel to verify the applicability of these
documents to the equipment. If there is any question
regarding the applicability of these documents, rig-
ging, lifting, and operating/service personnel should
verify whether the equipment has been modified and
if current literature is available from the owner of the
equipment prior to performing any work on the chiller.
CHANGE BARS
Revisions made to this document are indicated with a
line along the left or right hand column in the area the
revision was made. These revisions are to technical in-
formation and any other changes in spelling, grammar
or formatting are not included.
JOHNSON CONTROLS
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RL SERIES INSTALLATION MANUAL

RL SERIES INSTALLATION MANUAL
Table of Contents
Model Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vertical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horizontal Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Horizontal Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Vertical Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Cleaning and Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional FX10 Microprocessor Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Drive Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Drop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup/Troubleshooting Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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5
6
7
9
10
12
13
14
15
16
17
27
29
39
40
41
41
42
43
43

RL SERIES INSTALLATION MANUAL
Model Nomenclature
RLX
1-3 4 5-7 8 9 10
Model Type
RLL –RL Low Temp
RLX –RL Extended Range
Cabinet Configuration
V–Vertical
H - Horizontal
Unit Capacity (MBTUH)
080, 095, 120, 160
180, 240, 300
Discharge Configuration
T–Top (Vertical)
E–End (Horizontal)
S–Side (Horizontal)
Return Air Configuration
L–Left
R–Right
Voltage
3–208-230/60/3
4–460/60/3
5–575/60/3
Future Option
0–Future
Blower Options
A–Standard Static, Standard Motor
B–Low Static, Standard Motor1
C–High Static, Standard Motor2
D–Standard Static, Large Motor2,3
E–High Static, Large Motor3
Water Coil Option
C–Copper
N–CuproNickel
Vintage
* - Factory Use Only
Non-Standard Options
SS –Standard
QP –2" MERV 13 Filter
SF –Stainless Steel Drain Pan4
SG –2" MERV 13 Filter, Stainless Steel Drain Pan4
Air Coil/Insulation Option
3–Uncoated
4–AlumiSealTM
Control Option
4–FX10 Standard without Communication
5–FX10 with Open N2 Communication
6–FX10 with Lonworks Communication
7–FX10 with BacNet Communication
8–FX10 Standard with User Interface
9–FX10 with Open N2 & User Interface
0–FX10 with Lonworks & User Interface
3–FX10 with BacNet & User Interface
Water Control Option
N–None
Hot Gas Bypass/Reheat Option
N–None
G–Hot Gas Bypass
R–Hot Gas Reheat
B–Hot Gas Bypass w/Hot Gas Reheat
Sound Kit Option
A–None
B–Sound Kit
Rev.: 14 August 2014D
11 12 13 15
V 120 T L 3 0 A C A N
14
N
16
4
17
3
18
SS
19-20
*
21
Notes:
1–Not available on RLXV/RLLV095, 180, RLXH/RLLH080
2–Not available on RLXV/RLLV080, 160
3–Not available on RLXH/RLLH120, RLXV/RLLV300
4–Not available on RLXV/RLLV160-300. Stainless steel is standard on RLXV/RLLV160-300
JOHNSON CONTROLS
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RL SERIES INSTALLATION MANUAL
WARNING: Before performing service or maintenance operations on a system, turn off main power switches to the
indoor unit. If applicable, turn off the accessory heater power switch. Electrical shock could cause personal injury.
Installing and servicing heating and air conditioning equipment can be hazardous due to system pressure and electrical components. Only
trained and qualified service personnel should install, repair or service heating and air conditioning equipment. Untrained personnel can
perform the basic maintenance functions of cleaning coils and cleaning and replacing filters. All other operations should be performed by
trained service personnel. When working on heating and air conditioning equipment, observe precautions in the literature, tags and labels
attached to the unit and other safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work gloves. Use a quenching cloth for brazing operations and have a fire extinguisher
available.
Moving and Storage
Move units in the normal “up” orientation. Horizontal units may be moved and stored per the information on the packaging. Do not stack
more than three units in total height. Vertical units may be stored one upon another to a maximum height of two units. Do not attempt to
move units while stacked. When the equipment is received, all items should be carefully checked against the bill of lading to be sure all
crates and cartons have been received. Examine units for shipping damage, removing the units from the packaging if necessary. Units in
question should also be internally inspected. If any damage is noted, the carrier should make the proper notation on the delivery receipt,
acknowledging the damage.
Unit Location
Locate the unit in an indoor area that allows for easy removal of the filter and access panels. Location should have enough space for
service personnel to perform maintenance or repair. Provide sufficient room to make water, electrical and duct connection(s). If the unit
is located in a confined space, such as a closet, provisions must be made for return air to freely enter the space by means of a louvered
door, etc. Any access panel screws that would be difficult to remove after the unit is installed should be removed prior to setting the unit.
On horizontal units, allow adequate room below the unit for a condensate drain trap and do not locate the unit above supply piping. Care
should be taken when units are located in unconditioned spaces to prevent damage from frozen water lines and excessive heat that could
damage electrical components.
Installing Vertical Units
Prior to setting the unit in place, remove and discard the compressor hold down shipping bolt
located at the front of the compressor mounting bracket.
Vertical units are available in left or right air return configurations. Top flow vertical units should
be mounted level on a vibration absorbing pad slightly larger than the base to provide isolation
between the unit and the floor. It is not necessary to anchor the unit to the floor (see right).
Safety Considerations
General Installation Information
Figure 1: Vertical Unit Mounting
(RLXV080-300)
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RL SERIES INSTALLATION MANUAL
CONTROL BOX
RIGHT RETURN
CONTROL BOX AND WATER
LEFT RETURN
2’PRIMARY
SERVICEACCESS
FOR LEFT RETURN
2’PRIMARY
CONTROL BOX
RIGHT RETURN
SERVICEACCESS
FOR RIGHT RETURN
2’SECONDARY
SERVICEACCESS
CONTROL BOX
AND WATER
LEFT RETURN
TOP DISCHARGE
2’PRIMARY
SERVICEACCESS
FOR LEFT RETURN
2’PRIMARY
SERVICEACCESS
FOR RIGHT RETURN
2’SECONDARY
SERVICEACCESS
SIDE DISCHARGE
56 in
[142.2 cm]
2 in [5.1 cm]
1 in [2.5 cm]
2 in [5.1 cm]
18.1 in [46 cm]
1.8 in [4.6 cm]
56 in
[142.2 cm]
22.6 in
[57.4 cm]
TOP PANEL
COVER
58.1 in [147.6 cm]
61.3 in [155.7 cm]
34.1 in
[86.6 cm]
2.9 in
[7.4 cm]
16.1 in
[40.9 cm]
TOP VIEW
Left or Right Return
SIDE VIEW
Left or Right Return
34.1 in
[86.6 cm]
58.1 in [147.6 cm]
61.3 in [155.8 cm]
21.6 in
[54.9 cm] 18.1 in [46.0 cm] 1.42 in [3.6 cm]
16.1 in
[40.9 cm]
2.9 in
[7.4 cm]
15.6 in
[39.6 cm]
12.5 in [31.8 cm]
36.3 in
[92.2 cm]
2.6 in [6.6 cm]
DRAIN CONNECTION
WATER OUT
WATER IN
ELECTRICAL
CONNECTIONS ELECTRICAL CONNECTIONS
AIR COILS
34.4 in
[87.4 cm]
4.0 in [10.2 cm]
2.2 in [5.6 cm]
10.1 in [25.7 cm]
2.0 in
[5.1 cm]
2.2 in
[5.6 cm]
7.2 in
[18.3 cm]
LEFT RETURN RIGHT RETURN
15.6 in
[39.6 cm]
4.0 in [10.2 cm]
2.2 in [5.6 cm]
10.1 in [25.7 cm]
2.2 in
[5.6 cm]
12.5 in [31.8 cm]
36.3 in
[92.2 cm]
2.6 in [6.6 cm]
DRAIN CONNECTIO
N
WATER OUT
WATER IN
AIR COILS
34.4 in
[87.4 cm]
7.2 in
[18.3 cm]
2.0 in
[5.1 cm]
TOP OR SIDE DISCHARGE
Legend
AP = Alternate Service Panel
BP = Blower Service Panel
CP = Control Access Panel
CMP = Compressor Service Panel
AP
CMP AP
CMP CPCP
CP CP
REV 2/11/0
8
Vertical Dimensions
7-10 Tons
JOHNSON CONTROLS
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RL SERIES INSTALLATION MANUAL
LEFT RETURN
6.0 in
15.2 cm
13.0 in
33.0 cm
15.2 in
38.7 cm
19.0 in
48.2 cm
24.5 in
62.2 cm
18.0 in
45.7 cm
18.0 in
45.7 cm
16.0 in
40.6 cm 16.0 in 40.6 cm
16.0 in
40.6 cm 16.0 in 40.6 cm
1.5 in
3.7 cm
1.5 in
3.7 cm
2.0 in
5.1 cm 2.0 in 5.1 cm
34.0 in
86.4 cm
14.2 in
36.1 cm
14.2 in
36.1 cm
2.6 in
6.5 cm
6.5 in
16.5 cm
88.1 in
223.8 cm
RIGHT RETURN
TOP DISCHARGE SIDE DISCHARGE
88.1 in
223.8 cm
86.3 in
219.1 cm
1.0 in
2.5 cm
66.0 in
167.5 cm
2.0 in
5.1 cm
1.0 in
2.5 cm
34.0 in
86.4 cm
2.9 in
7.3 cm
86.3 in
219.1 cm
88.1 in
223.8 cm
18.0 in
45.8 cm
13.8 in
35.1 cm
18.0 in
45.8 cm 13.8 in 35.1 cm
TOP PANEL
COVER
2.9 in
7.3 cm
66.0 in
167.5 cm
2.0 in
5.1 cm
DRAIN CONNECTION
ELECTRICAL
CONNECTIONS
40.4 in
102.6 cm 41.8 in 106.2 cm
AIR COILS
AIR COILS
41.8 in
106.2 cm 40.4 in 102.6 cm
15.2 in
38.7 cm
19.0 in
48.2 cm
24.5 in
62.2 cm
2.6 in
6.5 cm
6.5 in
16.5 cm
6.0 in
15.2 cm
13.0 in
33.0 cm
1.7 in
4.4 cm
1.7 in
4.4 cm
DRAIN CONNECTION WATER OUT
WATER IN
WATER OUT
WATER IN
ELECTRICAL
CONNECTIONS
2’ PRIMARY
SERVICE ACCESS
2’ SECONDARY
SERVICE ACCESS
2’ PRIMARY
SERVICE ACCESS 2’ PRIMARY SERVICE ACCESS
Legend
AP = Alternate Service Panel
BP = Blower Service Panel
CP = Control Access Panel
CMP = Compressor Service Panel
CONTROL BOX
AND WATER
RIGHT RETURN
CONTROL BOX
AND WATER
LEFT RETURN
CONTROL BOX
LEFT RETURN
AP
CMP
AP
CMP
CP CP
CPCP
CONTROL BOX
RIGHT RETURN
TOP VIEW
L or R Return
SIDE VIEW
L or R Return
TOP OR SIDE DISCHARGE
REV 8/16/07
Vertical Dimensions cont.
13-25 Tons
JOHNSON CONTROLS
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RL SERIES INSTALLATION MANUAL
RIGHT RETURN LEFT RETURN
26.2
4.1
15.6
89.0
34.5
90.0
37.3
92.5
7.6
7.615.6
85.91.6
TOP VIEW
26.2
4.1
15.6
89.0
34.5
90.0
37.3
92.5
7.6 7.6 15.6
85.9 1.6
DRAIN CONNECTION
END DISCHARGE
OPTION
15.62
13.5
2.9
6.1
20.1
21.0
END VIEW
DRAIN CONNECTION
END DISCHARGE
OPTION
15.62
2.9
6.1
20.1 21.0
SIDE DISCHARGE WATER IN
WATER OUT
OPTION
SIDE VIEW
18.6
3.4
29.929.9
24.5
23.5
SIDE DISCHARGE
WATER IN
WATER OUT
OPTION
18.6
3.4
29.929.9
24.5 23.5
13.5
Legend
AP = Alternate Service Panel
BP = Blower Service Panel
CP = Control Access Panel
CMP = Compressor Service Panel
CMP
CMP
CMP
CMP CPCP
BP BP
2’PRIMARY
SERVICEACCESS
2’SECONDARY
SERVICEACCESS 2’SECONDARY SERVICEACCESS
REV 4/28/08
Horizontal Dimensions
7-10 Tons
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RL SERIES INSTALLATION MANUAL
Installing Horizontal Units
Mounting Horizontal Units
Units are available with side or end discharge in left-hand or right-hand return air configurations. Horizontal units are normally suspended
from a ceiling by four 1/2 in. diameter threaded rods. The rods are usually attached to the unit corners by the bottom panel mounting
channel and the mounting grommets furnished with each unit.
CAUTION: Do not use rods smaller than 1/2 in. diameter since they may not be strong enough to support the unit. The
rods must be securely anchored to the ceiling (the units are approximately 800 lbs.).
To p Vi e w
90.5
26.244.13
Figure 3: Mounting HardwareFigure 2: Mounting Rod Layout
Ball Valves
Water Loop
Flexible Duct
Collar
1/2”
Threaded Rods
(4)
P/T Plugs
Hose Kits
Insulate supply
plenum anduse at
least a 90° elbow
to reduce noise
Condensate
Drain
Connection
Power
Disconnect Low
Voltage
Isolation
Grommets
(Included)
Figure 1: Typical Horizontal Application
Layout the threaded rods per the dimensions in Figure 2. Assemble the hangers to the unit as shown in Figure 3. Securely tighten the
brackets to the unit. When attaching the hanger rods to the bracket, a double nut is recommended since vibration could loosen a single
nut. The unit should be pitched approximately 1/2 in. towards the drain in both directions, to facilitate condensate removal.
1/2 in. Threaded Rod
(not included)
Vibration
Isolator
Washer
(not included)
Hex Nuts
(not included)
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