Johnson Controls UC User manual

Johnson Controls Unitary Products 900589-UIM-A-1012
UN-CASED “A” COILS
UPFLOW FOR COOLING/HEAT PUMPS
FLEX COILS FOR FIELD INSTALLED TXV
MODELS: UC
INSTALLATION MANUAL
ISO 9001
Certified Quality
Management System
LIST OF SECTIONS
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
COIL METERING DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DUCT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
CONDENSATE DRAIN CONNECTIONS . . . . . . . . . . . . . . . . . . . . . .4
REFRIGERANT LINE CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . .4
COIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
AIR SYSTEM ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
INSTALLATION VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
LIST OF FIGURES
Component Location - Coil UC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Coil - UC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
TXV Bulb Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Proper Bulb Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Upflow Coil Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Pressure Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
TXV Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Drain Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Location of Trapped and Plugged Drain Connections . . . . . . . . . . . . .5
LIST OF TABLES
Dimensions - UC Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Coil Air Flow Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Coil Projection Dimensions - UC Coils . . . . . . . . . . . . . . . . . . . . . . . . .4 Air Flow Data - Static Pressure Drop . . . . . . . . . . . . . . . . . . . . . . . . . .5
SECTION I: 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 indicated 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.
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 additional information, consult a qualified installer or service
agency.
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.
The furnace area must not be used as a broom closet or for any other
storage purposes, as a fire hazard may be created. Never store items
such as the following on, near or in contact with the furnace.
1. Spray or aerosol cans, rags, brooms, dust mops, vacuum clean-
ers or other cleaning tools.
2. Soap powders, bleaches, waxes or other Cleaning compounds;
plastic items or containers; gasoline, kerosene, cigarette lighter
fluid, dry cleaning fluids or other volatile fluid.
3. Paint thinners and other painting compounds.
4. Paper bags, boxes or other paper products
Never operate the furnace with the blower door removed. To do so
could result in serious personal injury and/or equipment damage.

900589-UIM-A-1012
2Johnson Controls Unitary Products
SECTION II: GENERAL INFORMATION
This instruction covers the installation of the following coils with 80+ or
90+ AFUE furnaces.
The coils have sweat connect fittings. All coils are shipped with a low
pressure inert gas holding charge.
INSPECTION
As soon as a coil is received, it should be inspected for possible dam-
age during transit. If damage is evident, the extent of the damage
should be noted on the carrier’s delivery receipt. A separate request for
inspection by the carrier’s agent should be made in writing. See Local
Distributor for more information. Check drain pan for cracks or break-
age.
CLEARANCES
DURING INSTALLATION
Clearance must be provided for:
1. Refrigerant piping and connections
2. Maintenance and servicing access - including cleaning the coil
3. Condensate drain line
4. Filter removal / change
5. Removal of coil assembly
FIGURE 1: Component Location - Coil UC
PRIMARY
DRAIN SECONDARY
DRAIN
ALTERNATE
DRAIN
LOCATIONS
SUCTION LINE
CONNECTION
LIQUID LINE
CONNECTION
Models Dimensions 1
1. All dimensions are in inches.
Refrigerant
Connections 2
2. Refrigerant line sizes may require larger lines for extended line lengths. See Application Data part number 247077.
Height Width Line Size
A B Liquid Vapor
UC18A 17 13
3/8
3/4
UC18B 16 1/2 16
UC24A 21 13
UC24B 20 1/2 16
UC30A 21 13
UC30B 20 1/2 16
UC36A 23 1/2 13
7/8
UC36B 22 1/2 16
UC36C 22 19 1/2
UC42B 26 1/2 16
UC42C 25 1/2 19 1/2
UC48C 23 1/2 19 1/2
UC48D 23 23
UC60C 25 1/2 19 1/2
UC60D 25 23
FIGURE 2: Coil - UC TABLE 1: Dimensions - UC Coils
21.0
A
B

900589-UIM-A-1012
Johnson Controls Unitary Products 3
LIMITATIONS
These coils should be installed in accordance with all national and local
safety codes.
SECTION III: COIL METERING DEVICES
The coil will require a TXV or orifice to be installed in the field. Refer to
installation manual with TXV kit. It is recommended to install the TXV kit
prior to installation of coil in cabinet and brazing line sets.
TXV METERING DEVICE
COIL INSTALLATION - UC
These upflow coils are designed for installation on top of upflow fur-
naces only.
If the coil is used with a furnace of a different size, use a 45° transition
to allow proper air distribution through the coil.
1. Create opening in furnace duct large enough to allow coil installa-
tion (See Figure 5). See Figure 2 for coil dimensions.
2. Install field fabricated support brackets using screws or rivets (See
Figure 5). Brackets should be installed level or pitched slightly
toward the drain end (high in the back, low in the front). Pitch
should not exceed 1/4" per length of coil.
3. Position the coil over the furnace opening as shown in Figure 5.
4. Check for air leakage between the coil drain pan and supply duct
and seal appropriately.
TABLE 2: Coil Air Flow Limits
Coil
Size Outdoor Unit Tons CFM Limits
Minimum Maximum
18 1-1/2 525 675
24 1-1/2 525 675
2 700 900
30 2 700 900
2-1/2 875 1125
36 2-1/2 875 1125
3 1050 1350
42 3 1050 1350
3-1/2 1225 1575
48 3 1050 1350 3-1/2 1225 1575
4 1400 1800
60 4 1600 1800
5 1750 2250
FIGURE 3: TXV Bulb Installation
VAPOR
LINE
THERMAL
EXPANSION
VALVE BULB
THERMAL
EXPANSION
VALVE
DISTRIBUTOR
BODY
LIQUID
LINE
TXV
EQUALIZER
LINE
(Wrapped with
insulation)
FIGURE 4: Proper Bulb Location
COIL UNDER PRESSURE.
Relieve pressure by depressing schrader core. Coil requires TXV or
orifice to be added. See outdoor unit documentation for correct TXV
to be used. Refer to coil nameplate for TXV identification for this unit.
The coil should be open to the air for no more than 2 minutes to keep
moisture and contaminates from entering the system. If the coil can-
not be brazed into the refrigeration system in that time, the ends
should be temporarily closed or plugged. For a short term delay, use
masking tape over the ends of the copper tubing to close the tube to
the air. For a longer term delay, use plugs or caps. There is no need
to purge the coil if this procedure is followed.
Do not drill any holes or drive any screws into the front duct flange on
the coil in order to prevent damaging coil tubing (see Figure 5).
Refer to the heat pump add-on control instruction before installing an
add-on heat pump coil.
TXV BULB
(Cover completely
with insulation)
SCREW
CLAMP
NUT
SUCTION LINE
NOTICE
NOTICE

900589-UIM-A-1012
4Johnson Controls Unitary Products
CRITICAL COIL PROJECTION
The coil assembly must be located in the duct such that a minimum dis-
tance is maintained between the top of the coil and the top of the duct.
Refer to Table 4.
SECTION IV: DUCT CONNECTIONS
The vast majority of problems encountered with combination heating
and cooling systems can be linked to improperly designed or installed
duct systems. It is therefore highly important to the success of an instal-
lation that the duct system be properly designed and installed.
Use flexible duct collars to minimize the transmission of vibration/noise
into the conditioned space.
Where return air duct is short, or where sound may to be a problem,
sound absorbing glass fiber should be used inside the duct. Insulation
of duct work is a must where it runs through an unheated space during
the heating season or through an uncooled space during the cooling
season. The use of a vapor barrier is recommended to prevent absorp-
tion of moisture from the surrounding air into the insulation. The supply
air duct should be properly sized by use of a transition to match unit
opening. All ducts should be suspended using flexible hangers and
never fastened directly to the structure. Duct work should be fabricated
and installed in accordance with local and/or national codes. This
includes the standards of the National Fire Protection Association for
Installation of Air-Conditioning and Ventilating Systems, NFPA No. 90B.
SECTION V: CONDENSATE DRAIN
CONNECTIONS
All drain lines should be pitched away from unit drain pan and should be
no smaller than the coil drain connection.
Route the drain line so that it doesn’t interfere with accessibility to the
coil, furnace, air handling system or filter and will not be exposed to
freezing temperatures.
Instruct the owner that the evaporator coil drain pan should be
inspected and cleaned regularly to prevent odors and assure proper
drainage.
Coils should be installed level or pitched slightly toward the drain end.
Suggested pitch should not exceed 1/4-inch per foot of coil.
If the coil is provided with a secondary drain it should be piped to a loca-
tion that will give the occupant a visual warning that the primary drain is
clogged. If the secondary drain is not used it must be capped.
DO NOT use TeflonTM tape, “pipe dope”, or other sealants. The use of a
sealant may cause damage and premature failure of the drain pan.
SECTION VI: REFRIGERANT LINE
CONNECTION
Connect lines as follows:
1. Suction and liquid line connections are made outside the duct.
2. Wrap a water soaked rag around the coil connection tubes inside
the duct to avoid damaging the TXV bulb.
3. Purge refrigerant lines with dry nitrogen.
4. Braze the suction and liquid lines.
5. Attach the duct access panel to the duct.
Refer to Outdoor unit Installation Manual for evacuation, leak check and
charging instructions.
Lines should be sound isolated by using appropriate hangers or strap-
ping.
All evaporator coil connections are copper-to-copper and should be
brazed with a phosphorous-copper alloy material such as Silfos-5 or
equivalent. DO NOT use soft solder.
FIGURE 5: Upflow Coil Installation
TABLE 3:
Coil Projection Dimensions - UC Coils
COIL SIZE DIMENSION “C” INCH
UC18 3-1/2
UC24 4-1/2
UC30 4-1/2
UC36 5-1/2
UC48 6-1/2
UC60 9
Dimension “C” should be at least 2/3 of dimension “D”. See Figure 5.
Equipment should never be operated without filters.
FIELD
FABRICATED
COIL ACCESS
FIELD
FABRICATED
SUPPORT
BRACKETS (x2)
“C” (MIN.)
“D”
FIELD
FABRICATED
DUCTWORK
3” (MIN.)
UPFLOW
FURNACE
AIR
FLOW
NOTICE
Avoid Double Trapping.
Threaded drain connections should be hand tightened, plus no more
than 1 turn.
Coil is under inert gas pressure. Relieve pressure from coil by
depressing schrader core.
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.
Route the refrigerant lines to the coil in a manner that will not
obstruct service access to the coil, air handling system, furnace flue
or filter.
NOTICE

900589-UIM-A-1012
Johnson Controls Unitary Products 5
SECTION VII: COIL CLEANING
If the coil needs to be cleaned, it should be washed with Calgon Coil-
clean (mix one part Coilclean to seven parts water). Allow solution to
remain on coil for 30 minutes before rinsing with clean water. Solution
should not be permitted to come in contact with painted surfaces.
SECTION VIII: AIR SYSTEM ADJUSTMENT
To check the CFM, measure the static pressure drop across the coil
using a portable manometer and static pressure tips. To prepare coil for
static pressure drop measurements - the system should have been
recently operational in cooling mode.
Drill 2 holes, one 3" after the coil (before any elbows in the ductwork)
and one 3” before the coil. Insert the pressure tips and read the pres-
sure drop from the manometer. See Table 5 to determine the air flow,
and make the necessary adjustments to keep the CFM within the air
flow limitations of the coil.
SECTION IX: INSTALLATION
VERIFICATION
Table 5 below has WET coil data. Run system for approximately 15
minutes in cooling mode prior to taking measurements.
TABLE 4:
Air Flow Data - Static Pressure Drop
Coil Size CFM @ Static Pressure Drop - IWG
(Based on wet coil)
0.10 0.15 0.20 0.25 0.30
18A 400 550 710 880 1000
18B 425 620 830 970 1125
24A 400 600 800 950 1075
24B 425 725 900 1075 1215
30A 425 600 800 950 1075
30B 450 725 900 1075 1215
36A 625 775 925 1025 1125
36B 825 976 1174 1300 1450
36C 975 1225 1375 1575 1775
42B 825 1000 1175 1325 1450
42C 1025 1275 1475 1650 1850
48C 900 1075 1300 1475 1600
48D 1008 1224 1451 1620 1788
60D 1160 1432 1598 1750 1870
FIGURE 6: Pressure Check
NOTICE
Was the coil still under pressure when received?
Depress schrader
core to check for
pressure one time.
FIGURE 7: TXV Check List
FIGURE 8: Drain Traps
FIGURE 9: Location of Trapped and Plugged Drain Connections
Is coil metering device installed correctly?
Was the correct TXV installed per the outdoor unit instructions?
Is the TXV Bulb positioned correctly?
Is Bulb Insulated?
Is Equalizer Line connected?
SECONDARY
PRIMARY
3” MIN
Were the primary and secondary
drains trapped correctly?
PRIMARY
DRAIN
ALTERNATE
DRAIN
Were all drains trapped or plugged?
TRAP APPROPRIATE SIDE
(All other drain connections should be plugged)
FURNACE
AIR
FLOW
SECONDARY
DRAIN

Subject to change without notice. Published in U.S.A. 900589-UIM-A-1012
Copyright © 2012 by Johnson Controls, Inc. All rights reserved. Supersedes: 841941-UIM-B-0612
York International Corp.
5005 York Drive
Norman, OK 73069
NOTES
*900589*