Johnson Controls VBR09 Series User manual

Form Number: 145.18-IOM3 (1220)
Supersedes: 145.18-IOM3 (1019)
Installation Guide
Issue Date: 2020-12-10
Johnson Controls
Single Riser Hi-Rise Water Source Heat
Pump, Cabinet Model VBR/VMR/VTR/
VUR09-36 and Chassis Model VSCS09-36
Installation, Operation, and Maintenance Manual

2 Single Riser Hi-Rise Water Source Heat Pump, Cabinet Model VBR/VMR/VTR/VUR09-36 and Chassis Model
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Contents
ContentsImportant!....................................................................................................................................................... 5
Read before proceeding!.................................................................................................................... 5
General safety guidelines......................................................................................................................... 5
Safety symbols............................................................................................................................................ 5
Changeability of this document............................................................................................................... 6
Associated literature.................................................................................................................................. 6
Riser nomenclature........................................................................................................................................ 7
Cabinet nomenclature................................................................................................................................... 8
Chassis nomenclature................................................................................................................................... 9
Installation.................................................................................................................................................... 10
Notice and disclaimer....................................................................................................................... 10
Disclaimer................................................................................................................................................. 10
Pre-installation................................................................................................................................... 10
Shipping.................................................................................................................................................... 10
Inspection and storage........................................................................................................................... 11
Preparations for installing the unit........................................................................................................ 11
Rigging................................................................................................................................................ 13
Cabinet riser installation................................................................................................................... 13
Placing the cabinet.................................................................................................................................. 14
Single riser cabinet dimensions....................................................................................................... 18
Riser loop............................................................................................................................................ 20
Hoses................................................................................................................................................... 21
Electrical wiring.................................................................................................................................. 25
Field-installed power wiring................................................................................................................... 25
Field-installed low voltage wiring.......................................................................................................... 25
Optional surface mount thermostat connection wiring..................................................................... 27
Optional remote mounted thermostat wiring..................................................................................... 27
Optional ADA door mounted thermostat............................................................................................. 27
ECM continuous fan................................................................................................................................. 28
Closet and drywall installation......................................................................................................... 28
Acoustic RA panel.............................................................................................................................. 29
Supply air ductwork.......................................................................................................................... 33
Horizontal supply air............................................................................................................................... 34
Top discharge supply air......................................................................................................................... 34
Top mounted fresh air intake.......................................................................................................... 37
Top mounted fresh air intake with motorized damper....................................................................... 38
System flushing and cleaning.......................................................................................................... 40
Flushing the system................................................................................................................................. 40
Cleaning the system................................................................................................................................ 41
Chassis installation............................................................................................................................ 45
Installing units with JIC style (37° flare) valve connection and hoses............................................... 45
Johnson Controls
Single Riser Hi-Rise Water Source Heat Pump, Cabinet Model VBR/VMR/VTR/VUR09-36 and Chassis Model
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Operation...................................................................................................................................................... 51
Pre start-up checklist........................................................................................................................ 51
Initial start-up.................................................................................................................................... 51
System loop temperatures............................................................................................................... 52
Fan speed adjustment...................................................................................................................... 54
Refrigerant charge adjustment....................................................................................................... 55
Electrical data..................................................................................................................................... 59
Unit controls....................................................................................................................................... 63
Sequence of operation............................................................................................................................ 63
Continuous blower.................................................................................................................................. 63
Safety control reset.................................................................................................................................. 64
Operation errors...................................................................................................................................... 64
Safety controls.......................................................................................................................................... 65
Random start............................................................................................................................................ 65
Compressor protection........................................................................................................................... 65
Microprocessor control unit flash codes.............................................................................................. 66
Communication........................................................................................................................................ 66
Maintenance................................................................................................................................................. 67
Appendix....................................................................................................................................................... 69
Limited warranty............................................................................................................................... 73
Compressor - five year limited warranty........................................................................................ 74
Labor and cost not covered............................................................................................................. 74
Exclusions.................................................................................................................................................. 74
R-410A quick reference guide..................................................................................................................... 75
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Important!
Read before proceeding!
General safety guidelines
This equipment is a relatively complicated apparatus. During rigging, installation, operation,
maintenance, or service, individuals may be exposed to certain components 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, installation, 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 which it is situated, as well as severe
personal injury or death to themselves and others 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 individual 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:
DANGER
Indicates a possible hazardous situation which will result in death or serious injury if proper care is not
taken.
WARNING
Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment
if proper care is not taken.
CAUTION
Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or
environmental pollution if proper care is not taken or instructions and are not followed.
Note: Highlights additional information useful to the technician in completing the work being
performed properly.
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WARNING
External wiring, unless specified 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 accordance
with the manufacturer's published specifications and must be performed only by a qualified electrician.
The manufacturer will NOT be responsible for damage/problems resulting from improper connections
to the controls or application of improper control signals. Failure to follow this warning will void the
manufacturer’s warranty and cause serious damage to property or personal injury.
WARNING
This product can expose you to chemicals including formaldehyde, which is known to the state of
California to cause cancer. For more information, go to http://www.P65Warnings.ca.gov.
Changeability of this document
In complying with the manufacturer's’ policy for continuous product improvement, the information
contained in this document is subject to change without notice. There is 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 service office.
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, rigging, 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 equipment.
Revision notes
Affected section Description Date implemented
Cabinet
nomenclature Updated cabinet nomenclature November 2020
Chassis
nomenclature Updated chassis nomenclature November 2020
Associated literature
Manual description Form number
Vertical Stacked Heat Pump Start-Up and Performance Checklist 145.18-CL1
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Riser nomenclature
Note: VTR and VUR Single Risers are not available in reduce up or reduce down riser end
options.
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Cabinet nomenclature
Single Riser Hi-Rise Water Source Heat Pump, Cabinet Model VBR/VMR/VTR/VUR09-36 and Chassis Model
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Chassis nomenclature
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Installation
Note:
After installing the unit, show the user how to turn off the electricity to the unit. Point out the
control and switch locations for turning off the electricity.
Ensure the user understands the importance of following all safety precautions.
Notice and disclaimer
This unit contains refrigerant installed by the factory that is approved for use in the unit’s intended
country of installation or market. Distributors are only authorized to provide refrigerants that have
been approved for use in the countries or markets they serve.
The refrigerant used in this unit is identified on the unit's nameplate and in this manual. Any
additions of refrigerant into this unit must comply with the country’s requirements with regard
to refrigerant use and should be obtained from manufacturer approved distributors. Use of
unapproved refrigerant substitutes will void all warranties and can cause injury or death.
Disclaimer
Customer modifications to certified products are prohibited. If performed without the express
written approval of the manufacturer, modifications will void all warranties (expressed or implied)
and may result in hazardous situations resulting in equipment damage, serious physical injury or
property damage, or death.
The manufacturer has certified the product as being compliant with applicable government and/or
industry standards. Product certification is designated either on the product itself or in the product
literature. The certification mark identifies the applicable standards as well as the Nationally
Recognized Test Lab (NRTL) or other testing facility that conducted the testing, where applicable.
If changes are made to the product, an engineering review is required to assess the impact to the
product certification. In some instances, the changes may require that the NRTL or testing facility
review and re-approve the product by means of a field or site inspection and certification.
Modifications may invalidate product certifications or violate country standards. Any person or
entity making changes to the product is responsible for obtaining the required engineering review
and approval, as well as covering certification and other related costs.
Pre-installation
After installing the unit, give this IOM to the end user. If help is needed with any of the installation
instructions or matters relating to the unit, contact the sales office where you bought the unit. You
can also refer to the unit rating plate for a contact name.
Shipping
Cabinets and risers ship in one of the following configurations:
• Cabinets are stacked on their side with risers attached. Chassis ship on separate skids.
• Risers ship loose, packaged in boxes and sorted by floor. Cabinets ship upright up to four per
skid. Chassis ship on separate skids.
• Risers ship loose, packaged in boxes, and sorted by floor. Cabinets ship upright on skids with
chassis inside the cabinet. Chassis electrical and water connections are not installed. The
chassis is secured to the service panel. Remove the screws before removing the service panel
and chassis.
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The cabinet must remain standing upright. Do not place cabinets on their side with the chassis
inside.
Inspection and storage
Store cabinets, chassis, and risers the same way they were shipped. Ensure the storage area is
dry and protected from the environment. Keep the units in their upright position. If the risers
are stored at the job site, ensure the pipe ends are capped to prevent foreign object debris and
contamination.
In areas where construction is not complete (including dry wall, plaster, paint, and where any
emission of dust particulates or fumes from outgassing are present), all precautions must be taken
to protect the cabinet, openings, and chassis from contamination or physical damage.
Upon delivery, perform the following inspections:
1. Inspect the unit for shipment damage. Notify the Transportation Company of any damage
and note the damage on the shipping receipt.
CAUTION
Rough handling may dislocate and damage internal components.
2. Inspect the riser projections at each end of the cabinet for misalignment or end damage that
would prevent making an acceptable connection.
3. Inspect the thermostats and other accessories that have been shipped separately for
quantity and transit damage.
Store the refrigeration chassis in the normal upright orientation to maintain oil in the compressor
sump.
Preparations for installing the unit
About this task:
Before installing the unit, perform the following preparations:
1. Verify the model number on the unit nameplate with the ordering and shipping information
to ensure the correct unit has been shipped.
2. Carefully inspect each unit before delivery to the installation site. All cabinets may not be
equipped with the same size riser or the same air supply grille arrangement. In most cases,
each cabinet is individually tagged for a specific location in the building.
3. Keep the cabinet sealed with the shipping materials until all plastering, painting, and
construction work is complete.
4. Remove the inner service panel and manually check the blower wheel for free rotation.
5. Match the refrigeration chassis to the proper cabinets by referring to the cabinet and chassis
nameplate and label information.
6. Remove the chassis refrigeration access panel (top cover) and inspect the unit. Ensure that
the refrigerant tubing is free from obvious physical damage and kinks, and check that piping
does not touch other unit components.
7. Ensure the compressor is mounted on neoprene isolators with metal spacing sleeves inside.
Secured it with nuts that are snug against the metal spacer sleeves.
8. Inspect all electrical connections. Connections must be clean and tight at the terminals.
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WARNING
DO NOT USE THE RISERS TO LIFT THE CABINET ASSEMBLY!
WARNING
DO NOT install this unit outdoors.
DANGER
A compressor/unit comprises a pressurized system. Never loosen threaded joints while the system is
under pressure and never open pressurized system parts.
DANGER
Before servicing, open and tag all disconnect switches.
DANGER
Do not install units in a flammable environment due to the danger of an explosion.
WARNING
Safety guards, shields, barriers, covers, and protective devices must not be removed while the
compressor/unit is operating.
WARNING
All safety features, disengagement, and interlocks must be in place and function correctly before the
equipment is put into operation. Never bypass or wire around any safety device.
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WARNING
Use gloves and protective goggles where appropriate and have a gas mask close at hand. Use electrical
protection equipment and tools suited for electrical operations.
WARNING
Personnel must be qualified according to national safety rules and regulations.
WARNING
Only manufacturer-qualified personnel should install this system. If not, it may cause water leakage,
electric shock, or fire.
Rigging
WARNING
Follow all applicable regulations and safety practices during rigging and lifting.
Prepare and follow a written rigging and lifting plan. Lifting must be directed by a trained,
professional rigger.
Spreader bars must be used and must be long enough to prevent rigging from contacting the unit.
Use only the designated lift points according to the unit’s manual and use ALL lifting points.
Locate the center of gravity through trial lifts to account for possible variations in unit
configuration. Use rigging and lifting techniques that keep the unit stable and level. Keep clear of
the unit when lifted.
Cabinet riser installation
CAUTION
Do not use the risers to lift or move the cabinets.
Risers are not designed to support or lift any part of the cabinet. Do not use them to lift a cabinet.
The risers are attached using nylon ties to allow for slight adjustments during installation, and
expansion of riser column during operation. Care must be taken during installation to avoid
damage to risers and riser stub-outs.
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CAUTION
Improper handling and installation of risers could damage riser stub-outs and valves which could result
in property damage, serious injury, or death.
CAUTION
Do not allow the risers to bottom out. Riser stub-out should be centrally located with the stub-out opening of
the cabinet riser. Do not allow riser stub-outs or risers to contact the cabinet sheet metal.
WARNING
Do not drag risers on floor while moving the cabinet.
When the risers are shipped loose, riser installation can be completed before cabinet installation.
When installing risers, ensure the riser stub-outs are centered in the cabinet openings. Ensure that
the risers cannot bottom out in swage (see Figure 1).
When the risers are shipped attached to cabinets, complete the installation of risers and cabinets at
the same time. Detaching the riser from the cabinet is unnecessary.
Placing the cabinet
About this task:
The correct location of the cabinet in relation to the floor sleeve and risers is shown in Figure 3 . To
place the cabinet correctly, perform the following steps:
1. Place the cabinet in a horizontal position on the floor adjacent to its installation location
(when risers are attached to cabinet).
The units are designed to accommodate a maximum supply and return riser stub-out
movement of 1-1/2 inches due to expansion and contraction (a total movement of 3 inches). If
the total calculated riser expansion or contraction exceeds 1-1/2 inches, the field must provide
expansion compensation.
Note: The initial positioning of the riser stub-out is correct when the top of the riser pipe
is 3 inches above the top of the cabinet (applies to standard riser models only: VTR/VUR)
2. Install field or factory-provided riser extensions, if required, to the unit-mounted risers prior
to moving the cabinet into final position.
3. Raise the cabinet upright. Lower the risers through the floor cutout, aligning the risers into
the swaged section of the unit on the floor below.
Note: Take extra care not to scrape or dent risers during positioning. The riser tailpiece
should insert approximately 2 inches into the 3-inch long swaged section of the unit
below.
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CAUTION
DO NOT allow the riser tailpiece to bottom out into the swaged section. This ensures the correct riser
positioning and compensates for variations in floor-to-floor dimensions.
4. Center the risers in the pipe chase, and level the cabinet using shims as necessary.
5. Plumb risers in two planes to ensure proper unit operation and condensate drainage.
6. Anchor the cabinets into place using rubber isolated sheet metal angles. Approved and
tested sheet metal angles are available from factory.
It is strongly recommended to install vibration isolation pads to reduce noise transmission into
the floor. Failure to use isolation kits could result in loud unit operation.
WARNING
Do not drill or drive screws into the cabinet in the area of the internal drain pan.
7. Center the risers’ horizontal stub-outs (complete with factory-installed shut-off valves) in the
cabinet slot openings. Ensure that the stub-outs are perpendicular to the side/back panel.
8. Verify all risers are vertical and that they penetrate the swaged joint at least 1 inch.
Factory provided risers come with a 3-inch deep swage. Do not allow risers to completely
bottom out at 3 inches in the swage. The 3-inch swage depth is oversized to allow for
adjustments, if necessary, to keep riser stub-outs and valves centered in the cabinet opening.
Figure 1: Ideal riser insertion depth
9. Center the riser stub-outs in the cabinet opening to allow for expansion and contraction.
Riser stub-outs must not contact any sheet metal opening. Otherwise, damage can occur to
the stub-outs, resulting in water leaks and property damage.
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Figure 2: Correct/incorrect stub-out positions in cabinet riser opening
10. Braze or solder riser joints with industry accepted solder or brazing rod material.
Note: The riser system must be secured to the building structure. Cabinets are not
designed to support the riser system.
11. Secure the riser system at a minimum of one point to the building structure. Cabinets are not
intended to support the riser system. If the temperature range of the system exceeds the
allowed expansion and contraction limits (1-1/2 inches maximum), the installing contractor
must make riser compensation provisions.
12. Ensure the individual unit shut-off valves are closed until the circulating loop system is
cleaned and flushed.
Table 1: Single riser VSHP unit physical data
Model series 09 12 15 18 24 30 36
Nominal cooling (ton) 0.75 1 1.25 1.5 2 2.5 3
Compressor type Rotary Scroll
Refrigerant charge (oz) 23 31 35 40 46 50 52
Air coil type Enhanced copper tubes, enhanced aluminum fins
Face area (sq.ft) 1.46 1.56 2.35 2.35 2.63 3.33 3.33
Rows/FPI 2/16 3/14 3/14 3/14 3/14 3/14 3/14
Water coil type Enhanced surface co-axial
Standard blower/motor DWDI forward-curved centrifugal / PSC direct-drive
Diameter x width (in) 9x4T 9x4T 9x7T 9x7T 9x7 9x8 9x8
Motor HP 0.10 0.10 0.17 0.17 0.25 0.33 0.50
Hi-static blower/motor DWDI forward-curved centrifugal / PSC direct-drive
Diameter x width (in) 9x4T 9x4T 9x7T 9x7T 10x7T 10x8T 10x8T
Motor HP 0.10 0.17 0.17 0.25 0.33 0.33 0.50
ECM blower/motor DWDI forward-curved centrifugal / ECM direct-drive
Diameter x width (in) 9x4T 9x4T 9x7T 9x7T 10x7T 9x8 9x8
Motor HP 0.33 0.33 0.33 0.33 0.33 0.50 0.50
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Table 1: Single riser VSHP unit physical data
Model series 09 12 15 18 24 30 36
Hi-static ECM blower/
motor DWDI forward-curved centrifugal / ECM direct-drive
Diameter x width (in) 9x4T 9x4T 9x7T 9x7T 10x7T 10x8T 10x8T
Motor HP 0.33 0.33 0.33 0.33 0.33 0.50 0.50
Chassis water pump Cast iron water pump cw integral check valve (cartridge style)
Pump HP 1/40 1/25 1/25 1/25 1/25 1/8 1/8
Water connection (JIC) (in) 0.5 0.5 0.5 0.5 0.75 0.75 0.75
Filter quantity-size (in) 1-14x25
x1
1-14x25
x1
1-16x30
x1
1-16x30
x1
1-16x30
x1
1-20x30
x1
1-20x30
x1
Cabinet weight (lb)** 130 130 145 145 150 175 175
Cabinet wright (lb) 77 79 104 109 149 170 173
Note:
* Nominal Capacity calculated in accordance with ARI/ISO Standard 13256-1 for Water
Loop Application.
** Cabinet weight is approximate and does not include weight of risers.
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Single riser cabinet dimensions
Figure 3: Single riser cabinet and floor sleeve dimensions
Table 2: Cabinet dimensions
Model A B RA flange width (in.)
09–12 17 17 16
15–24 20 20 19
30–36 24 24 23
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Note:
1. The single riser and condensate riser openings are pre-punched on all sides and field
convertible. Cut the tabs to remove the knock-out.
2. The single riser openings are 9.5 inches x 2.5 inches. During riser installation, ensure the
stub-out is centered in the supply and return openings.
3. The condensate P-trap is accessible either from the front by removing the bottom cover
plate or from the top by removing the drain pan.
4. The floor cutouts are given for reference only. The actual opening might be affected by
site conditions.
5. For the master/satellite configuration (see Figure 4), the satellite cabinet water and drain
connections must be field extended to match the satellite cabinet location. The use of
elbows and extendion beyond 24 inches is not permitted on the water side because of
the potential for a higher water pressure drop.
6. A shut-off valve is not provided with the satellite side of the riser stub. Field-install shut-
off valve with field hose kit (ordered separately).
7. See Figure 8 for more details about installation.
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Figure 4: Master/satellite configuration for single riser cabinets
Riser loop
1. Install the following parts at the base of each supply and return riser to enable system
flushing, balancing, and servicing:
- A drain valve
- Shut-off/balancing valves
- Flow indicators
- Drain tees
2. Install strainers at the inlet of each circulating pump.
3. Insulate loop water piping that runs through unconditioned areas of the building or outside
the building.
When the loop water temperature is maintained between nominal operating limits of
60.0–90.0°F, the piping does not sweat or suffer undue heat loss at conditioned space
temperatures.
4. Install vents in the piping loop as required to bleed residual air from the piping system during
filling and servicing.
5. Determine the riser shut-off valves and hose kits required for job-specific site conditions:
a. Factory supplied risers come with the appropriate hose kits with Joint Industrial
Committee (JIC) type fittings (see Figure 5).
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