Johnson Controls HVAHR072B32S Installation And Maintenance Manual
Johnson Controls HVAHR072B32S Installation And Maintenance Manual

Johnson Controls HVAHR072B32S Installation And Maintenance Manual

Inverter-driven multi-split system heat recovery air conditioner

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Installation
and
Maintenance
Manual
INVERTER-DRIVEN
MULTI-SPLIT SYSTEM
HEAT RECOVERY
AIR CONDITIONERS
Models:
Outdoor Units;
208/230V
(H,Y)VAHR072B32S,
(H,Y)VAHR120B32S,
(H,Y)VAHR168B32S,
(H,Y)VAHR216B32S,
(H,Y)VAHR264B32S,
(H,Y)VAHR312B32S,
(H,Y)VAHR360B32S,
(H,Y)VAHR408B32S,
460V
(H,Y)VAHR072B42S,
(H,Y)VAHR120B42S,
(H,Y)VAHR168B42S,
(H,Y)VAHR216B42S,
(H,Y)VAHR264B42S,
(H,Y)VAHR312B42S,
(H,Y)VAHR360B42S,
(H,Y)VAHR408B42S,
IMPORTANT:
READ AND UNDERSTAND
THIS MANUAL BEFORE
INSTALLING THIS HEAT
RECOVERY AIR CONDITIONER.
KEEP THIS MANUAL FOR
FUTURE REFERENCE.
(H,Y)VAHR096B32S,
(H,Y)VAHR144B32S,
(H,Y)VAHR192B32S,
(H,Y)VAHR240B32S,
(H,Y)VAHR288B32S,
(H,Y)VAHR336B32S,
(H,Y)VAHR384B32S,
(H,Y)VAHR432B32S
(H,Y)VAHR096B42S,
(H,Y)VAHR144B42S,
(H,Y)VAHR192B42S,
(H,Y)VAHR240B42S,
(H,Y)VAHR288B42S,
(H,Y)VAHR336B42S,
(H,Y)VAHR384B42S,
(H,Y)VAHR432B42S
P5417009

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Summary of Contents for Johnson Controls HVAHR072B32S

  • Page 1 Installation Maintenance Manual INVERTER-DRIVEN MULTI-SPLIT SYSTEM HEAT RECOVERY AIR CONDITIONERS Models: Outdoor Units; 208/230V (H,Y)VAHR072B32S, (H,Y)VAHR096B32S, (H,Y)VAHR120B32S, (H,Y)VAHR144B32S, (H,Y)VAHR168B32S, (H,Y)VAHR192B32S, (H,Y)VAHR216B32S, (H,Y)VAHR240B32S, (H,Y)VAHR264B32S, (H,Y)VAHR288B32S, (H,Y)VAHR312B32S, (H,Y)VAHR336B32S, (H,Y)VAHR360B32S, (H,Y)VAHR384B32S, (H,Y)VAHR408B32S, (H,Y)VAHR432B32S 460V (H,Y)VAHR072B42S, (H,Y)VAHR096B42S, (H,Y)VAHR120B42S, (H,Y)VAHR144B42S, (H,Y)VAHR168B42S, (H,Y)VAHR192B42S, (H,Y)VAHR216B42S, (H,Y)VAHR240B42S, (H,Y)VAHR264B42S, (H,Y)VAHR288B42S, (H,Y)VAHR312B42S, (H,Y)VAHR336B42S,...
  • Page 3 Important Notice ● Johnson Controls Inc. pursues a policy of continuing improvement in design and performance in its products. As such, Johnson Controls Inc. reserves the right to make changes at any time without prior notice. ● Johnson Controls Inc. cannot anticipate every possible circumstance that might involve a potential hazard.
  • Page 4 Liability does not cover defects originating from unauthorized modifications performed by a customer without the written consent of Johnson Controls, Inc. Performing any mechanical alterations on this product without the consent of the manufacturer will render your warranty null and void.
  • Page 5 Interchangeability between Generation 1 and 2 Change-Over Boxes ● Generation 2 change-over box is compatible with the generation 2 outdoor unit. ● Generation 1 change-over box is compatible with the generation 1 outdoor unit when there is no generation 2 change-over box in the same system. ●...
  • Page 6: Table Of Contents

    TABLE OF CONTENTS 1. Introduction ................................1 2. Important Safety Instructions ..........................1 3. Before Installation ..............................6 3.1 Factory-Supplied Accessories ........................6 3.2 Necessary Tools and Instrument List for Installation ..................7 3.3 Flaring and Joint ............................9 3.4 Line-Up of Outdoor Units ..........................11 3.5 Combinations of Indoor Units and Outdoor Units ..................
  • Page 7: Introduction

    Never bypass or jump-out any safety device or switch. ● Johnson Controls will not assume any liability for injuries or damage caused by not following steps outlined or described in this manual. Unauthorized modifications to Johnson Controls products are prohibited as they…...
  • Page 8 Take the following precautions to reduce the risk of property damage. ● Be careful that moisture, dust, or variant refrigerant compounds not enter the refrigerant cycle during installation work. Foreign matter could damage internal components or cause blockages. ● If air filters are required on this unit, do not operate the unit without the air filter set in place. If the air filter is not installed, dust may accumulate and breakdown may result.
  • Page 9 Controls uses only refrigerants that have been approved for use in the unit’s intended home country or market. Johnson Controls distributors similarly 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 faceplate and/or in the associated manuals.
  • Page 10 ● Before installation is complete, make sure that the refrigerant leak test has been performed. If refrigerant gases escape into the air, turn OFF the main switch, extinguish any open flames and contact your service contractor. Refrigerant (Fluorocarbon) for this unit is odorless. If the refrigerant should leak and come into contact with open flames, toxic gas could be generated.
  • Page 11 ● Be sure to install circuit breakers (ground fault interrupter, isolating switch, molded case circuit breaker and so on), with the specified capacity. Ensure that the wiring terminals are tightened securely to recommended torque specifications. ● Clamp electrical wires securely with a cable clamp after all wiring is connected to the terminal block. In addition, run wires securely through the wiring access channel.
  • Page 12: Before Installation

    3. Before Installation Factory-Supplied Accessories Check to ensure that the following accessories are packed with the outdoor unit. inch (mm) Accessory 72 Model 96 Model 120 Model 144 Model 168 Model 192 Model Remarks Connection for Refrigerant Gas ID 7/8 (22.2) → ID 7/8 (22.2) →...
  • Page 13: Necessary Tools And Instrument List For Installation

    Necessary Tools and Instrument List for Installation Tool Tool Tool Handsaw Pliers Wire Cutters Copper Tube Cutter Gas Leak Detector Phillips Screwdriver, Slotted Screwdriver Brazing Kit Level Vacuum Pump Hexagon Wrench Crimper for Solderless Terminals Refrigerant Gas Hose Wrench Hoist (for Indoor Unit) Megohmmeter Scale Ammeter...
  • Page 14 G: Interchangeability is available with current R22 l: Only for Refrigerant R410A (No Interchangeability with R22) 5: Prohibited F: Only for Refrigerant R407C (No Interchangeability with R22) Interchangeability Reason of Non-Interchangeability and Attention with R22 Measuring Instrument and Tool (H: Strictly Required) R410A R407C Copper Tube Cutter,...
  • Page 15: Flaring And Joint

    Flaring and Joint • Flaring Dimension Perform the flaring work as shown below. inch (mm) Diameter -0.02 (-0.4) R410A 1/4 (6.35) 0.36 (9.1) 3/8 (9.52) 0.52 (13.2) 1/64 ~ 1/32R 1/2 (12.7) 0.65 (16.6) (T) It is impossible to perform flaring work 5/8 (15.88) 0.78 (19.7) with hard temper pipe.
  • Page 16 • Processing at Brazing Connection To prevent gas leakage at the brazing connection, refer to the following table for the insertion depth and the gap for the joint pipe. inch (mm) Diameter Min. Insertion Depth (A - D) 3/16 < D < 5/16 1/4 (6) (5 <...
  • Page 17: Line-Up Of Outdoor Units

    Line-Up of Outdoor Units (1) This outdoor unit series can build the capacity of 72 to 432 MBH by combining the outdoor units of 72 to 192 MBH. (2) The outdoor units of 216 to 432 MBH consist of the combination of two to three base units. Use the combination of units in the following table.
  • Page 18: Combinations Of Indoor Units And Outdoor Units

    Combinations of Indoor Units and Outdoor Units Table 3.1 Indoor Unit Model List Capacity (MBH) Indoor Unit Model 8 12 15 18 24 27 30 36 48 54 60 72 96 (H,Y)IDH_B21S Ducted (High Static) (H,Y)IDH_B22S (H,Y)IDM_B21S Ducted (Medium Static) Ducted (H,Y)IDM_B22S Ducted (Slim)
  • Page 19 The number of indoor units that can be connected to an outdoor unit is defined in Table 3.2. Comply with the following conditions when installing the unit. A maximum and minimum total capacity as opposed to the nominal outdoor unit capacity can be obtained through combination of indoor units.
  • Page 20: Caution About Outdoor Unit Installation

    Caution about Outdoor Unit Installation When the installation and piping work for the multiple outdoor units is performed, it is required that you determine the arrangement of the outdoor units and the piping length. Perform the installation work in strict accordance with the following requirements.
  • Page 21: Outdoor Unit Installation

    4. Outdoor Unit Installation Installation Location and Precautions To reduce the risk of serious injury or death, the following installation precautions must be followed. ● When installing the unit into… ▫ A wall: Make sure the wall is strong enough to hold the unit’s weight. It may be necessary to construct a strong wood or metal frame to provide added support.
  • Page 22: Service Space

    Service Space NOTICE: Refer to the Engineering Manual for the outdoor unit when installing the low ambient kit. When an outdoor unit is installed, allow sufficient clearance as follows: • If there is insufficient clearance for air inlets and outlets, performance drop-off and mechanical issues due to insufficient air intake may result.
  • Page 23 1) Walls on Two Sides If units are installed adjacent to tall buildings where there are two open sides, the minimum rear side clearance must be at least 11-13/16 inches (300mm). Single Installation Multiple / Serial Installation Unit: inch (mm) No limit for No limit for No limit for...
  • Page 24 3) Walls on Four Sides Single Installation Unit: inch (mm) No limit for side wall height. Min. 11-13/16 (300) + h1/2 Min. 7-7/8 Min. 7-7/8 (200) (200) ▼ No limit for Min. 31-1/2 Front Side side wall height. (800) Open Min.
  • Page 25: Transportation And Installation Work

    5. Transportation and Installation Work Transportation Transport the product as close to the installation location as practical before unpacking. When using a crane, hang the unit according to the description on the outdoor unit packing slip. ● Do not hang the unit with the sling belts at the wooden skid base. Sling Belt Position CORRECT INCORRECT...
  • Page 26 Take special care when hanging or moving the outdoor unit because its center of mass is off-center and unbalanced. See the diagram below. inch (mm) Center of Gravity Voltage Model 38-3/8 (975) 21-1/4 (540) 24-5/8 (625) 12 (330) Center of Gravity 48-5/8 (1,235) 25-13/16 (655) 26-9/16 (675) 13-3/8 (340)
  • Page 27 When using a forklift, do not insert forks into Do not apply excessive force to the squared the slots at the unit side panels. The unit can slots with forks or other materials. The bottom sustain damage. of the unit can become deformed. * Do not push the bottom base with forks.
  • Page 28: Handling Of Outdoor Unit

    Handling of Outdoor Unit Do not place or leave any foreign objects: (cables, tools), inside the outdoor unit or control module and verify that nothing remains there prior to installation and test run. Damage and fire can result due to carelessness. Installation Work 5.3.1 Concrete Foundations (1) The height of the foundation should be more than 5-7/8 inches (150mm) above the ground. (2) Provide adequate drainage around the foundation. Unit: inch (mm) Details of Installing Anchor Bolt Min.
  • Page 29 (3) Install the outdoor unit in the front-rear and right-left direction horizontally. (Use a level.) Verify that the gradient slope in all four directions (front, rear, right, and left) falls within 3/8 inch (10mm). Front Side Right Side and Rear Side and Left Side (4) Provide a strong, level, and stable foundation so that: a.
  • Page 30: Condensate Treatment

    5.3.2 Condensate Treatment Condensation is discharged during heating and defrosting operations. (Rain water is also discharged.) Comply with the following conditions. (1) Choose a place where good drainage is available, or provide a drainage ditch. (2) Do not install the unit over walkways. Condensation can spill onto people. If installing the unit in such a place, utilize the additional condensation drainage pan.
  • Page 31 • Drain Adaptor (Optional Parts) Use a drain adaptor as a condensation pipe connection. Then use an outdoor unit bottom base as a condensation drainage pan. Name Model Drain Adaptor DBS-TP10A Component Formation of Drain Adaptor Model Parts Name Material / Color Qty.
  • Page 32: Refrigerant Piping Work

    6. Refrigerant Piping Work • The pressure for this product is 601 psi (4.15MPa). The pressure required for refrigerant R410A is 1.4 times higher than for the refrigerant R22. Therefore, the refrigerant pipes for R410A must be thicker than for R22. Make sure to use specified refrigerant pipes. Otherwise, the refrigerant pipes may rupture due to excessive refrigerant pressure. Pay close attention to the pipe thickness when using copper refrigerant pipes.
  • Page 33: Piping Materials

    Piping Materials (1) Obtain locally-supplied copper pipes. (2) Use copper pipe for refrigerant piping. (3) Pay close attention to pipe thickness. (4) Use clean copper pipes. Make sure there is no dust or moisture inside the pipes. Do not use any tools which produce a lot of metal shavings such as a saw or a grinder. (5) Take special care to prevent contamination or moisture settling on interior pipe surfaces during piping work.
  • Page 34 Cautions for Piping Connection Work (1) Verify that there are no scratches, metal shavings, gaps, or deformations at the flared end before connecting pipe to the system. (2) Before tightening the flare nut, apply a small amount of oil (field-supplied) to the outside of the flare. (Do not apply any oil to the flare face or the threads.) Tighten the liquid pipe flare nut to the specified torque while using a back-up wrench to prevent damage to the unit.
  • Page 35 Precaution for Installing and Securing Piping When assembling pipes onsite with hidden elbow or socket joints, provide a service access door to facilitate close-up examination of interconnecting components. Example for Pipe Support CORRECT Outdoor Unit within + 15 Treatment for Section Installing Pipes: Install at Appropriate Intervals of Fire Prevention Multi-Kit...
  • Page 36: Piping Connection Work

    Piping Connection Work Comply with the restrictions for refrigerant piping (permissible length, height difference) in Sections 6.5 “Piping Work Conditions” and “Piping Branch Restriction.” If not, the outdoor unit can become damaged or fail. The stop valves are closed completely (factory-setting) when refrigerant piping connections are performed. Do not open these stop valves until all the refrigerant pipes are connected, pressure tested, and vacuumed.
  • Page 37 Liquid Valve Tighten the flare nut for the liquid stop valve according to the following torque. If excessive force is applied to the flare nut, refrigerant leakage may occur from the stop valve. (To prevent leakage when removing and connecting pipe, place two wrenches at the positions indicated in the following diagram. Do not put wrenches here.
  • Page 38: Piping Connection Method

    6.2.2 Piping Connection Method Perform the piping connection work for each outdoor unit. NOTICE: Ensure that the refrigerant pipe is connected to the same refrigerant system. ● Firmly secure the pipe in order to avoid vibration, excessive force on the valve, and noise. (1) Piping can be installed from the bottom base and the front piping cover.
  • Page 39 ● Prepare refrigerant piping for assembly. The following examples illustrate a small cabinet. Refer to Figure 6.2 for the position for piping connections. Unit: inch (mm) Refrigerant Low Pressure Gas Piping Connection A Refrigerant High/Low Pressure Gas Piping Connection B Refrigerant Liquid Piping Connection C Piping Cover...
  • Page 40 ● Details of Stop Valve Piping Connections Be sure to remove first the closing pipe of the gas stop valve. Refer to Figure 6.1 for the flaring work. Refer to Section 3.1 “Factory-Supplied Accessories” for the details of the accessory pipes. 72 Model 96 Model Stop Valve...
  • Page 41: Piping Work Between Outdoor Units

    Piping Work between Outdoor Units Select the pipe size according to Section 6.4 “Piping Size between Outdoor Units”. For refrigerant piping between multiple outdoor units, use the optional piping connection kit. The arrangement for outdoor units should be determined depending on the piping direction when the refrigerant piping work and installation work are planned.
  • Page 42 (3) When pipe length between outdoor units is 6.6 ft (2m) or more, an oil trap for the gas pipe should be installed so that no accumulation of refrigerant oil can occur. ● Less than 6.6 ft (2m) ● 6.6 ft (2m) or More Oil Trap Oil Trap Min.
  • Page 43 ● Construction Example The following figures show examples of a heat recovery system (three units in combination). Regarding the piping work for combining the units, refer to the “Installation and Maintenance Manual” enclosed in the piping connection kit package. Refer to the following figure to perform the piping connections between the outdoor units.
  • Page 44: Piping Sizes Between Outdoor Units

    Piping Sizes between Outdoor Units Install the outdoor unit and piping connections in accordance to whatever is applicable to your situation. Refer to the table for the outdoor unit model, the piping connection kit model, and the pipe diameter. Outdoor Unit Base Unit Refrigerant Piping To Indoor Units...
  • Page 45 Install the outdoor unit and piping connections in accordance to whatever is applicable to your situation. Refer to the table for the outdoor unit model, the piping connection kit model, and the pipe diameter. Three Unit Combination The following drawing is for a 432 model combination. (Indoor Unit on Left Side) (Indoor Unit on Right Side) Outdoor Unit A...
  • Page 46: Piping Size And Multi-Kit Selection

    Piping Size and Multi-Kit Selection For selecting the pipe sizes between the outdoor unit and the piping connection kit, and the pipe size between the piping connection kits , refer to Section 6.4 “Piping Size between Outdoor Units.” Maintain a straight-line distance of 19-11/16 inches (500mm) or more for piping after the piping connection kit.
  • Page 47 Multi-Kit (Optional Parts) Line Branch Branch using Multi-Kit (MW Model) “Multi-Kit after First Branch” is larger than “Multi-Kit for First Branch”, use the same model as “Multi-Kit for First Branch”. Multi-Kit for First Branch Outdoor Unit Capacity Model (MBH) 72 - 120 MW-NP452X3 144 - 192 MW-NP562X3...
  • Page 48 Change-Over Box ● Single Unit for 1 Branch Indoor Unit Indoor Unit Indoor Unit Side Maximum Model Maximum Branch Number Connection Capacity Connection Capacity for 1 Branch COBS048B21S ≤ 54 ≤ 54 COBS048B22S ≤ 54 ≤ 54 COBS096B21S ≤ 96 ≤...
  • Page 49 Refer to the figure at the beginning of section 6.5. Piping Size Unit: inch (mm) Main Pipe Diameter (Base Unit or Piping Connection Kit 1 to First Branch) Model: (H,Y)VAHR_B(3,4)2S inch (mm) Liquid Outdoor Unit High/Low Pressure Maximum Equivalent Piping Length Capacity Low Pressure Gas (MBH)
  • Page 50 Diameter of Pipe between Change-Over Box and Multi-Kit For Change-Over Box (Generation 1) inch (mm) Change-Over Box Total Indoor Unit Low Pressure High/Low Pressure Model Capacity (MBH) (15.88) (12.7) ≤ 29 [5/8 (15.88)] [1/2 (12.7)] COB048/096B21S (19.05) (15.88) 30 - 59 (Generation 1) [7/8 (22.2)]...
  • Page 51 ● Piping Work Conditions Comply with the following when installing the unit. Indicate what installer must comply with. This is not an example of compliance. Describe the limitation shown in the drawing. Upstream Side < For two and three units combination > Maintain a straight-line distance of 19-11/16 inches (500mm) or more for Outdoor...
  • Page 52 Item Mark Details a+b+c Total The total amount of all piping actual length. Piping Length d+e+f+g+h Maximum The actual pipe length between the stop valve of the outdoor unit or Piping Length the piping connection kit 1 and the terminal indoor unit. The actual length of pipe that takes no account for equivalent lengths Piping Length for pressure drops of elbows.
  • Page 53 NOTICE Comply with the following conditions when installing the unit. 1. For a combination of two or three outdoor units, the outdoor unit “A” should be connected to the piping connection of Kit 1. (Refer to Section 6.4 for outdoor unit models.) Refer to the Piping Kit Installation Manual for piping details. 2.
  • Page 54 ● Piping Branch Restriction * Main Piping Branch: Both branches of piping from a multi-kit are connected to the next multi-kits. (including change-over box (multiple branch type).) Indoor Unit Indoor Unit Main Piping Main Piping Branch Branch Change-Over Box (Multiple Branch Type) In the following instances, there is no limit to the number of main piping branches.
  • Page 55 Header branch can be used with a line branch at the three pipes segment and two pipes segment. Header branch can also be used after the second branch. Do not connect a line branch to a header branch. When using a header branch, make sure that the piping length L2 from the multi-kit at the first branch to the farthest indoor unit is within 131.2 ft (40m).
  • Page 56 • The number of indoor units connectable to outdoor unit is as follows: Comply with the following conditions when installing the unit. • A maximum total capacity and a minimum total capacity against the nominal outdoor unit capacity can be obtained by combination of the indoor units.
  • Page 57: Multi-Kit Connection

    Multi-Kit Connection Use the branch piping kit to ensure proper piping. Do not use a T-Joint. Secure the branch pipes horizontally to a pillar, a wall, or ceiling. When installing the piping by securing plates, wrap the branch pipe with an insulation or slip a cushioning between the pipe and the plate.
  • Page 58: Electrical Wiring

    EMI and other sources of potentially excessive electrical noise to reduce the potential for communication errors. When shielded cable is applied, secure properly and terminate cable shield as required per Johnson Controls guidelines. Plenum and riser ratings for communication cables must be considered per application and local code requirements.
  • Page 59: General Check

    When shielded cable is applied, secure properly and terminate cable shield as required per Johnson Controls guidelines. Plenum and riser ratings for communication cables must be considered per application and local codes where: •...
  • Page 60: Electrical Wiring Connection

    Electrical Wiring Connection ● This equipment can be installed with a GFCI, which is a recognized measure for added protection to a properly grounded unit. Install appropriate sized breakers / fuses / overcurrent protection switches and wiring in accordance to local codes and requirements. The equipment installer is responsible for understanding and abiding by applicable codes and requirements. ● Perform the electrical work according to the regulations of each region and this manual. A separate, dedicated electrical circuit must be used. If the electrical wiring work is performed incorrectly or there is a capacity shortage of the power circuit, it will cause an electric shock or a fire.
  • Page 61 When shielded cable is applied, secure properly and terminate cable shield as required per Johnson Controls guidelines. Plenum and riser ratings for communication cables must be considered per application and local code requirements.
  • Page 62 Install a multi-pole main switch with a space of 1/8 inch (3.5mm) or more between each phase. ATTENTION: 1. When the power supply wiring is longer, select the minimum wiring size that has a voltage drop within 2%. 2. Power supply voltage should be satisfied with the followings. Supply Voltage: Rated Voltage within +10% Starting Voltage:...
  • Page 63: Electrical Wiring For Outdoor Unit

    TB2 terminals 3 and 4 on the PCB1. When shielded cable is applied (M4), secure properly and terminate cable shield as required per Johnson Controls guidelines. Plenum and riser ratings for communication cables must be considered per application and local code. Communication cable must be a minimum of AWG18 (0.82mm...
  • Page 64 (1) Detail of Electrical Box Terminal 208/230V 60Hz 460V 60Hz Terminal Block for Power Supply Wiring (TB1) Terminal Block for Power Supply Wiring (TB1) Ground Wiring Terminal (Connect cable securely) Attach Attach insulation sleeve. insulation sleeve. Ground Wiring Ground Wiring Terminal Rubber Bushing (Connect cable securely) Cable Band...
  • Page 65: Electrical Wiring Connections Of Indoor Unit, Outdoor Unit, And Change-Over Box

    Be sure to note the following points when running cables under the unit using conduit tubing. (The pipe cover needs to be removed before performing piping and wiring.) NOTICE: ● When installing the power supply wiring, use the field-supplied conduit tube as shown below. Remove the rubber bushing from the unit for the conduit tubing installation.
  • Page 66 (6) Use the same kind of cables in the same H-LINK system. (7) Maintain at least 5 inches (127mm) between the communication cables and the power supply wiring, and also min. 5 ft (1.5m) between the communication cables and power supply wiring for other electrical device.
  • Page 67 Outdoor Unit A (Main) Outdoor Unit B (Sub) L1 L2 L3 1 2 3 4 L1 L2 L3 1 2 3 4 TB : Terminal Block Ground Ground PCB : Printed Circuit Board : Field Wiring Main Switch : Communication Line DC5V (Non-Pole Communication H-LINK System) : Field-Supplied : Optional Accessory...
  • Page 68: Dip Switch Setting Of Outdoor Unit

    DIP Switch Setting of Outdoor Unit Before performing settings: ● Turn OFF all power supplies before performing settings. DIP switch settings cannot be set without first disconnecting them from the power supply. (However, DSW4 pin Nos.1, 2, 4, and 6 DSW7 pin No.4, and push switches can be operated when power supply is ON.) The darkened square “n”...
  • Page 69 ● Setting for Transmitting Use the following settings for the outdoor unit numbers, refrigerant system numbers and end terminal resistance for this H-LINK system. ● Setting of Outdoor Unit Number (No.) If there are combined outdoor units, set DSW6 as shown below. Combination of Base Unit Base Unit Unit A...
  • Page 70 ● DSW7 Setting for Rated Voltage Voltage DSW7 Setting DSW7 is used for setting the rated voltage for the outdoor unit as shown at right. 208V 1 2 3 4 When the site power supply voltage is different from factory setting, a DSW7 setting is required. 230V CAUTION: 1 2 3 4...
  • Page 71 • Function Setting External Input/Output and Function Setting Make sure to perform external input/output and function setting while the outdoor unit is stopped. It cannot be set while the outdoor unit is operating or check mode. External Input/Output Setting Function Setting Start of Setting Start of Setting Turn ON DSW4-No.4.
  • Page 72: Additional Refrigerant Charge

    8. Additional Refrigerant Charge Airtight Test (1) Check to ensure that the stop valves for high/low pressure gas, low pressure gas and liquid pipes are closed completely before airtight test. (2) The refrigerant used for this outdoor unit is R410A. Use the manifold gauge and the charging hose for exclusive use of R410A.
  • Page 73 Airtight Test Method (1) Connect the manifold gauge to the access port of the liquid line and the gas line stop valves using charging hoses with a vacuum pump or a nitrogen cylinder. Perform the airtight test. Do not open the stop valves. Apply nitrogen gas pressure of 601 psi (4.15MPa). For checking gas leakage, use the leak detector or foaming agent.
  • Page 74: Vacuuming

    Vacuuming Connecting Connect a manifold gauge, vacuum gauge and vacuum pump to the access port (High/Low Pressure Gas Stop Valve, Low Pressure Gas Stop Valve and Liquid Stop Valve). Triple Evacuation Method According to the following < Step 1 > < Step 2 > < Step 3 > in order, conduct vacuum drying work. <...
  • Page 75: Charging Work

    Charging Work (1) An additional refrigerant charge is required according to total piping length. Refer to Table 8.1. (2) After vacuum pumping work, check that the high/low pressure gas valve, and liquid stop valve are fully closed. Charge the additional refrigerant from the access port of liquid stop valve (acceptable error must be within 1.1 lbs (0.5 kg)).
  • Page 76 (b) Operate the compressor in the cooling mode and charge the additional refrigerant from the access port of the liquid stop valve. An acceptable error must fall within 1.1 lbs (0.5 kg). At this time, keep the liquid stop valve slightly open. (c) After the refrigerant is charged, fully open the liquid stop valve and the gas stop valve.
  • Page 77: Additional Refrigerant Charge Calculation

    Additional Refrigerant Charge Calculation Table 8.1 Additional Refrigerant Charge Calculation Although this unit has been charged with refrigerant, an additional refrigerant charge is required according to piping length. Determine what additional charge of refrigerant according to the following procedures, and charge it into the system.
  • Page 78 Max. Additional Refrigerant Charge Quantity Allowed Outdoor Unit Capacity (MBH) 096 - 144 216 - 432 Max. Additional Ref. Charge [lbs (kg)] 79.4 (36.0) 88.2 (40.0) 112.5 (51.0) 114.7 (52.0) 138.9 (63.0) Initial Ref. Charge Amount of O.U. (Before Shipment) [W0 lbs (kg)] Outdoor Unit Capacity (MBH) W0 Outdoor Unit Ref.
  • Page 79: Test Run

    9. Test Run Test Run should be performed in accordance with Section 9.2. Use Table 9.1 for recording the Test Run. An electrical shock will occur if there is residual voltage. Turn OFF power at the power supply completely before attempting any electrical maintenance work. Verify that no residual voltage exists after turning OFF the power at the power supply.
  • Page 80: Test Run

    Caution for Insulation Resistance If the total unit insulation resistance is lower than one megaohm, the compressor insulation resistance may be lower, due to refrigerant being retained in the compressor. This can occur if the unit has not been used over prolonged periods of time. 1. Disconnect the cables to the compressor and measure the insulation resistance of the compressor itself.
  • Page 81 (c) Start the Test Run. ● Press “ On/Off”. The Test Run operation will start. The operation mode, the airflow volume, the airflow direction and the Test Run time can be set on the Test Run screen. Select the item by pressing “...
  • Page 82 Test Run from Outdoor Unit Side The procedures for the test run from the outdoor unit side are shown below. Setting this DIP switch is possible with the power supply ON. Setting of DIP Switch (Factory Setting) DSW4 Switch for Setting of Service Operation and Function 1.
  • Page 83 DIP Switch Setting Operation Remarks 1. Setting of Operation Mode 1. The indoor unit automatically * Note that indoor units operate in starts operating when the test run conjunction with the test run operation Cooling: Set No.2 pin of DSW4 OFF. of the outdoor unit is set.
  • Page 84 Table 9.1 Test Run and Maintenance Record MODEL: SERIAL. No. COMPRESSOR MFG. No. CUSTOMER'S NAME AND ADDRESS: DATE: 1. Is the rotation direction of the indoor fan correct? 2. Is the rotation direction of the outdoor fan correct? (Correct direction is counter clockwise.) 3.
  • Page 85 Table 9.2 Alarm Code Code Category Content of Abnormality Leading Cause Activation of Protection Device Activation of Float Switch (High Water Level in Drain Pan, Indoor Unit (Float Switch) Abnormality of Drain Pipe, Float Switch, or Drain Pan) Activation of Protection Device Activation of PSH (Pipe Clogging, Excessive Refrigerant, Inert Gas Outdoor Unit (High Pressure Cut)
  • Page 86 Code Category Content of Abnormality Leading Cause Connection of Change-Over Box to Heat Pump System, Incorrect Connection of Disconnection of Change-Over Box to Heat Recovery System, Change-Over Box Generation1 and 2 Change-Over Boxes are used in the same system Incorrect Capacity Setting of Incorrect Capacity Setting of Outdoor Unit and Indoor Unit, System Outdoor Unit and Indoor Unit...
  • Page 87: Safety And Control Device Setting

    10. Safety and Control Device Setting Compressor Protection The compressor is protected by the following devices and their combinations. (1) High Pressure Switch: This switch cuts out the operation of the compressor when the discharge pressure exceeds the setting. (2) Oil Heater: This band type heater protects against oil foaming during cold starting, as it is energized while the compressor is stopped.
  • Page 88 © 2017 Johnson Controls, Inc. P5417009-rev.6 Code No. LIT-12012492 Revised February 2019...

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