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Summary of Contents for Johnson Controls RL Series
- Page 1 WATER SOURCE HEAT PUMPS Supersedes: 146.03-NOM1 (818) 146.03-NOM1 (1219) INSTALLATION, OPERATION, MAINTENANCE Form RL SERIES 7–25 TONS LD20072 R-410A Issue Date: December 3, 2019...
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Page 3: Table Of Contents
RL SERIES INSTALLATION MANUAL Table of Contents Model Nomenclature ............. 4 General Installation Information . -
Page 4: Model Nomenclature
RL SERIES INSTALLATION MANUAL Model Nomenclature 19-20 Model Type Vintage RLL – RL Standard Range RL Sta dard Ra * - Factory Use Only RLX – RL Extended Range RL Exte nded Ra Non-Standard Options Cabinet Configuration Config ration SS – Standard V –... -
Page 5: General Installation Information
RL SERIES INSTALLATION MANUAL General Installation Information Safety Considerations 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. -
Page 6: Vertical Dimensions
RL SERIES INSTALLATION MANUAL Vertical Dimensions 7-10 Tons TOP DISCHARGE SIDE DISCHARGE Legend AP = Alternate Service Panel BP = Blower Service Panel CP = Control Access Panel CMP = Compressor Service Panel CONTROL BOX AND WATER LEFT RETURN CONTROL BOX AND WATER... - Page 7 RL SERIES INSTALLATION MANUAL Vertical Dimensions cont. 13-25 Tons TOP DISCHARGE SIDE DISCHARGE CONTROL BOX AND WATER RIGHT RETURN CONTROL BOX AND WATER LEFT RETURN 2’ PRIMARY SERVICE ACCESS CONTROL BOX CONTROL BOX RIGHT RETURN LEFT RETURN 2’ SECONDARY SERVICE ACCESS...
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Page 8: Horizontal Dimensions
RL SERIES INSTALLATION MANUAL Horizontal Dimensions 7-10 Tons RIGHT RETURN LEFT RETURN Legend AP = Alternate Service Panel BP = Blower Service Panel CP = Control Access Panel CMP = Compressor Service Panel 2’ PRIMARY 2’ SECONDARY 2’ SECONDARY SERVICE ACCESS... -
Page 9: Installing Horizontal Units
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. - Page 10 RL SERIES INSTALLATION MANUAL Installing Horizontal Units cont. Horizontal Unit Corner Weight Distribution Front Front Back Back Model Return / Discharge Left Right Right Left Left / Side or End 080 - 120 Right / Side or End Approximate Controls Duct System An air outlet collar is provided on vertical top flow units and all horizontal units to facilitate a duct connection.
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Page 11: Installation Vertical Units
RL SERIES INSTALLATION MANUAL Installing Vertical Units Mounting Vertical Units Units are available with top/side discharge, left-hand or right-hand return air configurations. Vertical units are assembled on rails which facilitate moving and placement of the units. It is not necessary to anchor the unit to the floor. -
Page 12: Water Quality
RL SERIES INSTALLATION MANUAL Water Quality Water Quality Guidelines In ground water situations where scaling could be heavy or where biological growth such as iron bacteria will be present, a closed loop system is recommended. The heat exchanger coils in ground water systems may, over a period of time, lose heat exchange capabilities due to a buildup of mineral deposits inside. -
Page 13: System Cleaning And Flushing
RL SERIES INSTALLATION MANUAL System Cleaning and Flushing Figure 7: Flushing with Water Cleaning and Flushing Shutoff Valve Equipped Systems Prior to start up of any heat pump, the water circulating system must be cleaned and flushed of all dirt and debris. -
Page 14: Electrical Connections
RL SERIES INSTALLATION MANUAL Electrical Connections General Be sure the available power is the same voltage and phase as that shown on the unit serial plate. Line and low voltage wiring must be done in accordance with local codes or the National Electric Code. -
Page 15: Electrical Data
RL SERIES INSTALLATION MANUAL Electrical Data Blower Blower Total Rated Voltage Compressor* Model Motor Unit Circ Fuse/ Voltage Min/Max FLA*** HACR Horizontal 208-230/60/3 187/253 16.3 10.4 88.0 25.7 28.3 35.0 460/60/3 414/506 38.0 13.9 15.4 20.0 575/60/3 518/632 36.5 10.4 10.0... -
Page 16: Blower Performance Data
RL SERIES INSTALLATION MANUAL RLLH080 - Blower Performance Data Belt Drive Airflow in CFM with dry coil and clean air filter. External Static Pressure (in. w.g.) Rated CFM MTR/SHEAVE 0.59 0.65 0.71 0.75 0.78 0.81 0.86 0.90 0.37 0.40 0.43 0.47... - Page 17 RL SERIES INSTALLATION MANUAL RLLH095 - Blower Performance Data Belt Drive Airflow in CFM with dry coil and clean air filter. External Static Pressure (in. w.g.) Rated CFM MTR/SHEAVE 0.97 1.08 1.18 1.37 1.56 0.44 0.47 0.52 0.57 0.66 0.78 0.79...
- Page 18 RL SERIES INSTALLATION MANUAL RLLH120 - Blower Performance Data Belt Drive Airflow in CFM with dry coil and clean air filter. External Static Pressure (in. w.g.) Rated CFM MTR/SHEAVE 0.80 0.88 0.96 1.07 1.09 1.11 1.13 1.28 1.36 1.48 1.67 1.86...
- Page 19 RL SERIES INSTALLATION MANUAL RLLV080 - Blower Performance Data Belt Drive Airflow in CFM with dry coil and clean air filter. External Static Pressure (in. w.g.) Rated CFM MTR/SHEAVE 0.71 0.73 0.84 0.95 1.05 0.29 0.33 0.38 0.37 0.45 0.47 0.50...
- Page 20 RL SERIES INSTALLATION MANUAL RLLV095 - Blower Performance Data Belt Drive Airflow in CFM with dry coil and clean air filter. External Static Pressure (in. w.g.) Rated CFM MTR/SHEAVE 0.61 0.64 0.66 0.68 0.76 0.81 0.87 0.89 0.94 1.05 2600...
- Page 21 RL SERIES INSTALLATION MANUAL RLLV120 - Blower Performance Data Belt Drive Airflow in CFM with dry coil and clean air filter. External Static Pressure (in. w.g.) Rated CFM MTR/SHEAVE 0.50 0.51 0.59 0.68 0.68 0.79 0.92 0.92 0.92 1.08 1.16 1.30...
- Page 22 RL SERIES INSTALLATION MANUAL RLLV160 - Blower Performance Data Belt Drive Airflow in CFM with dry coil and clean air filter. External Static Pressure (in. w.g.) Rated CFM MTR/SHEAVE 0.29 0.33 0.38 0.37 0.45 0.47 0.50 0.54 0.58 0.64 0.69 0.71...
- Page 23 RL SERIES INSTALLATION MANUAL RLLV180 - Blower Performance Data Belt Drive Airflow in CFM with dry coil and clean air filter. External Static Pressure (in. w.g.) Rated CFM MTR/SHEAVE 0.94 1.05 0.61 0.64 0.66 0.68 0.76 0.81 0.87 0.89 5200...
- Page 24 RL SERIES INSTALLATION MANUAL RLLV240 - Blower Performance Data Belt Drive Airflow in CFM with dry coil and clean air filter. External Static Pressure (in. w.g.) Rated CFM MTR/SHEAVE 0.50 0.51 0.59 0.68 0.68 0.79 0.92 0.92 0.92 1.08 1.16 1.30...
- Page 25 RL SERIES INSTALLATION MANUAL RLLV300 - Blower Performance Data Belt Drive Airflow in CFM with dry coil and clean air filter. External Static Pressure (in. w.g.) Rated CFM MTR/SHEAVE 1.46 1.49 1.77 1.94 2.11 2.29 2.32 2.39 2.65 2.72 2.80 2.36...
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Page 26: Wiring Schematics
RL SERIES INSTALLATION MANUAL Wiring Schematic - Dual Compressor with Aurora 460/-575/60/3 Thermistor Array F FG CC CCG REVREV FP1 FP1 FP2 FP2 LPS LPS HPSHPS Emerg Shutdown F1-3A Load Shed K5-Alarm Relay Lockout Circuit A ACC COM ACC NO... - Page 27 RL SERIES INSTALLATION MANUAL Wiring Schematic - Dual Compressor with Aurora 460/-575/60/3 97P876-02 1/23/15 Belt Drive Belt Drive Compressor A Compressor B Blower Blower Green Motor Green Motor Gray (80) Yellow (78) Yellow (81) Gray (83) Bro wn (79) Bro wn (82)
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Page 28: Controls
RL SERIES INSTALLATION MANUAL Controls - Aurora Base Control Aurora ‘Base’ Control Field Selectable Options via Hardware DIP Switch (SW1) – Test/Configuration Button (See SW1 Operation Table) Test Mode The control is placed in the test mode by holding the push button switch SW1 for 2 - 5 seconds. - Page 29 RL SERIES INSTALLATION MANUAL Controls - Aurora Base Control cont. Cycle with Blower - The accessory relay will cycle with the Lockout – when locked out, the blower will operate continuously in blower output. “G” speed, and PSC blower motor output will remain on. The Alarm output (ALM) and Lockout output (L) will be turned on.
- Page 30 RL SERIES INSTALLATION MANUAL Controls - Aurora Base Control cont. Over/Under Voltage Shutdown - An over/under voltage condition Cooling Operation exists when the control voltage is outside the range of 18 VAC to In all cooling operations, the reversing valve directly tracks the O 30 VAC.
- Page 31 RL SERIES INSTALLATION MANUAL Controls - Aurora Base Control cont. Aurora ‘Base’ Control LED Displays Aurora Interface and Diagnostics (AID) Tool These three LEDs display the status, configuration, and The Aurora Interface and fault codes for the control. These can also be read in plain Diagnostics (AID) Tool is English via the Aurora AID Tool.
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Page 32: Blower Drive Sheaves
RL SERIES INSTALLATION MANUAL Blower Drive Sheaves Blower Sheave Adjustment Follow the procedures listed below if airflow of heat pump is to be changed from factory setting. (Refer to Figure 10.) 1. Loosen the blower motor fastening nuts from the motor mount. -
Page 33: Unit Startup
RL SERIES INSTALLATION MANUAL Unit Startup Before powering the unit, check the following: • High voltage is correct and matches nameplate • Fuses, breakers and wire size are correct • Low voltage wiring is complete • Piping has been completed and water system cleaned and flushed •... -
Page 34: Operating Parameters
RL SERIES INSTALLATION MANUAL Operating Parameters Cooling Entering Water Flow Suction Discharge Water Temp 080-300 080-300 Water Temp Air Temp GPM/Ton Pressure Pressure °F Superheat Subcooling Rise °F Drop °F DB PSIG PSIG 110-130 160-190 10-17 13-17 17-22 20-30 110-130... -
Page 35: Startup/Troubleshooting Form
RL SERIES INSTALLATION MANUAL DEALER: PHONE #: DATE: PROBLEM: MODEL #: Startup/Troubleshooting Form SERIAL #: COOLING CYCLE ANALYSIS SAT °F °F Unit Amp Draw: Loop: Open Closed Line Voltage: °F °F COIL SUCTION COMPRESSOR REVERSING COAX COAX EXPANSION VALVE LOAD... -
Page 36: Preventive Maintenance
RL SERIES INSTALLATION MANUAL Preventive Maintenance Water Coil Maintenance 1. Keep all air out of the water. An open loop system should be checked to ensure that the well head is not allowing air to infiltrate the water line. Lines should always be airtight. - Page 38 100 JCI Way, York, Pennsylvania USA 17406-8469 Subject to change without notice. Printed in USA www.johnsoncontrols.com Copyright © by Johnson Controls 2019 ALL RIGHTS RESERVED Form 146.03-NOM1 (1219) Issue Date: December 3, 2019 Supersedes: 146.00-NOM3 (818)
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