Johnson Controls 13 SEER SERIES Installation Instructions Manual
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INSTALLATION INSTRUCTIONS
EARTH-FRIENDLY R-410A REFRIGERANT
!
RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION!
WARNING
!
THESE INSTRUCTIONS ARE INTENDED AS AN AID TO
QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPER
INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT.
READ THESE INSTRUCTIONS THOROUGHLY
ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOL-
LOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER
INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE
POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK,
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICEMAN
13 & 14.5 SEER SERIES
CONDENSING UNITS
1
1
⁄
- 5 TONS FEATURING
2
NOTE: Appearance of unit may vary.
DO NOT DESTROY THIS MANUAL
(13 & 14.5 SEER
MODELS IN CERTAIN
MATCHED SYSTEMS)
BEFORE
R-410
r e f r i g e r a n t
92-21354-78-01
SUPERSEDES 92-21354-78-00
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Summary of Contents for Johnson Controls 13 SEER SERIES
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Page 1: Installation Instructions
INSTALLATION INSTRUCTIONS 13 & 14.5 SEER SERIES CONDENSING UNITS ⁄ - 5 TONS FEATURING EARTH-FRIENDLY R-410A REFRIGERANT R-410 r e f r i g e r a n t NOTE: Appearance of unit may vary. RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION! WARNING THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPER... -
Page 2: Table Of Contents
TABLE OF CONTENTS 1.0 SAFETY INFORMATION ..........3 2.0 GENERAL . -
Page 3: Safety Information
1.0 SAFETY INFORMATION WARNING THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED LICENSED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOL- LOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. -
Page 4: General
2.0 GENERAL WARNING The information contained in this manual has been prepared to assist in the proper THE MANUFACTURER’S WAR- installation, operation and maintenance of the air conditioning system. Improper RANTY DOES NOT COVER ANY installation, or installation not made in accordance with these instructions, can result DAMAGE OR DEFECT TO THE in unsatisfactory operation and/or dangerous conditions, and can cause the related AIR CONDITIONER CAUSED BY... -
Page 5: Dimensions
2.3 (SEE FIGURE 1) AIR DISCHARGE: ALLOW FIGURE 1 DIMENSIONS 60” MINIMUM CLEARANCE. A-00008 AIR INLETS (LOUVERED PANELS) ALLOW 6” MINIMUM CLEARANCE SERVICE ACCESS ALLOW 24” CLEARANCE NOTE: GRILLE APPEARANCE MAY VARY. SEE DETAIL A DIMENSIONAL DATA 18, 24 13 Seer Model Size 36, 42 48, 60 14.5 Seer Model Size... -
Page 6: Electrical And Physical Data
2.4 ELECTRICAL & PHYSICAL DATA (SEE TABLE 1) TABLE 1 ELECTRICAL AND PHYSICAL DATA – 13 SEER Electrical Physical Compressor Fuse or HACR Outdoor Coil Weight Fan Motor Minimum Refrig. Model Circuit Breaker Phase Full Load Circuit Rated Load Locked Rotor Number Frequency (Hz) Amperes... -
Page 7: Condenser Location
WARNING DISCONNECT POWER UNIT BEFORE STARTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH. • Frequent washing of the cabinet, fan blade and coil with fresh water will remove most of the salt or other contaminants that build up on the unit. •... -
Page 8: Unit Mounting
3.7 UNIT MOUNTING If elevating the condensing unit, either on a flat roof or on a slab, observe the following guidelines. • The base pan provided elevates the condenser coil 3/4” above the base pad. • If elevating a unit on a flat roof, use 4” x 4” (or equivalent) stringers positioned to distribute unit weight evenly and prevent noise and vibration. -
Page 9: Specifications Of R-410A
CONCRETE PAD SPECIFICATIONS: FIGURE 2 GREATER THAN OR EQUAL TO 2-1/2” THICK SOLID CONCRETE TIE-DOWN KIT ASSEMBLY DENSITY GREATER THAN OR EQUAL TO 144 LBS/FT OR EQUIVALENT PAD LENGTH GREATER THAN OR EQUAL TO (UNIT LENGTH +2”) PAD WIDTH GREATER THAN OR EQUAL TO (UNIT WIDTH +2) (6) 1-1/2”... -
Page 10: Quick Reference Guide For R-410A
up to 800 psig high-side and 250 psig low-side with a 550 psig low-side retard. Hoses need to have a service pressure rating of 800 psig. Recovery cylinders need to have a 400 psig service pressure rating. DOT 4BA400 or DOT BW400. Combustibility: At pressures above 1 atmosphere, mixture of R-410A and air can become combustible. -
Page 11: Replacement Units
CAUTION When coil is installed over a finished ceiling and/or living area, it is recommended that a secondary sheet metal condensate pan be constructed and installed under entire unit. Failure to do so can result in property damage. 8.0 REPLACEMENT UNITS To prevent failure of a new condensing unit, the existing evaporator tubing system must be correctly sized and cleaned or replaced. -
Page 12: Tubing Connections
• If a portion of the liquid line passes through a hot area where liquid refrigerant can be heated to form vapor, insulating the liquid line is required. • Use clean, dehydrated, sealed refrigeration grade tubing. • Always keep tubing sealed until tubing is in place and connections are to be made. - Page 13 TABLE 3 LIQUID LINE SIZE – OUTDOOR UNIT ABOVE INDOOR COIL Liquid Line Size Outdoor Unit Above Indoor Coil Line Size (Cooling Only - Does not apply to Heat Pumps) System Line Size Connection Size Total Equivalent Length - Feet Capacity (Inch O.D.) (Inch I.D.)
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Page 14: Leak Testing
• Clean the fittings before brazing. • Remove the cap and schrader core from service port to protect seals from heat damage. • Use an appropriate heatsink material around the copper stub and the service valves before applying heat. • IMPORTANT: Do not braze any fitting with the TEV sensing bulb attached. -
Page 15: Checking Refrigerant Charge
Air conditioning systems require a specified airflow. Each ton of cooling requires between 350 and 450 cubic feet of air per minute (CFM), or 400 CFM nominally. Duct design and construction should be carefully done. System performance can be lowered dramatically through bad planning or workmanship. Air supply diffusers must be selected and located carefully. -
Page 16: Charging By Weight
If the refrigerant lines utilize extended lengths, add 4 psi to the liquid pressure val- ues shown in the chart. Remove refrigerant charge if the refrigerant liquid pressure is above the cor- rected chart value. Add refrigerant charge if the liquid pressure is below the corrected chart value. 13.2 CHARGING BY WEIGHT For a new installation, evacuation of interconnecting tubing and evaporator coil is adequate;... -
Page 17: Control Wiring
14.3 CONTROL WIRING (See Figure 3) If the low voltage control wiring is run in conduit with the power supply, Class I insu- lation is required. Class II insulation is required if run separate. Low voltage wiring may be run through the insulated bushing provided in the 7/8 hole in the base panel, up to and attached to the pigtails from the bottom of the control box. -
Page 18: Low Ambient Control (Lac)
FIGURE 3 CONTROL WIRING FOR GAS OR ELECTRIC HEAT FOR TYPICAL GAS OR OIL HEAT FOR TYPICAL ELECTRIC HEAT 15.3 LOW AMBIENT CONTROL (LAC) This component senses compressor head pressure and shuts the heat pump fan off when the head pressure drops to approximately 220 PSIG [1516.8 kPa]. This allows the unit to build a sufficient head pressure at lower ambient in order to main- tain system balance and obtain improved capacity. -
Page 19: Trouble Shooting
17.0 TROUBLE SHOOTING In diagnosing common faults in the air conditioning system, it is useful to present the logical pattern of thought that is used by experienced technicians. The charts which follow are not intended to be an answer to all problems, but only to guide your thinking as you attempt to decide on your course of action. -
Page 20: Mechanical Checks Flow Chart
17.2 MECHANICAL CHECKS FLOW CHART Unit Running? Pressure problems? Go to Electrical Checks Flow Chart High Head Pressure Low Head Pressure Low Suction Pressure Dirty Condenser Coil Low on Charge Dirty Filters Inoperative Outdoor Fan Open IPR Valve Dirty Evaporator Overcharge Low Ambient Temperature Inadequate Airflow... -
Page 21: Superheat Calculation
17.3 SUPERHEAT CALCULATION TABLE 7 TEMPERATURE PRESSURE CHART 1. Measure the suction pressure at the suction line service valve. TEMP R-410A 2. Convert the suction pressure to saturated temperature. See Table 7. (Deg. F) PSIG 3. Measure the temperature of the suction line at the suction line service valve. -150 —... -
Page 22: General
17.5 GENERAL TROUBLE SHOOTING CHART WARNING DISCONNECT ALL POWER TO UNIT BEFORE SERVICING. CONTACTOR MAY BREAK ONLY ONE SIDE. FAILURE TO SHUT OFF POWER CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH. SYMPTOM POSSIBLE CAUSE REMEDY Unit will not run •... -
Page 23: Wiring Diagrams
18.0 WIRING DIAGRAMS FIGURE 4 18.1 PSC DIAGRAM SINGLE-PHASE WIRING DIAGRAM 90-101229-01 01-19-04... -
Page 24: Ecm Diagram
FIGURE 5 18.2 ECM DIAGRAM CM 0509...
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