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- Page 1 Installation Manual: R-454B Outdoor Split-System Single-Phase Heat Pump - YH4, XH4, and RH4 Series York International Corporation, 5005 6396600-UIM-B-0724 York Drive, Norman, OK 73069 Supersedes: 6396600-UIM-A-0324 2024-07-24 Johnson Controls Ducted Systems...
- Page 2 Installation Manual: R-454B Outdoor Split-System Single-Phase Heat Pump - YH4, XH4, and RH4 Series Johnson Controls Ducted Systems...
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Page 3: Table Of Contents
Contents About the unit..............................5 Certification...............................5 DS Solutions App.............................. 5 Safety................................. 6 Understanding safety symbols and instructions................6 Safety requirements..........................7 A2L refrigerant safety considerations....................8 General................................8 Room size requirements..........................9 Mechanical ventilation..........................11 Refrigerant equipment checks......................... 11 Electrical devices checks..........................12 Detection of refrigerant.......................... - Page 4 Checking the indoor cubic feet per minute (CFM) settings..............42 Determining the total system charge....................42 Charging with gauges......................... 43 Subcooling charging charts........................44 Heating charging charts..........................51 Starting up the system..........................57 Energizing the crankcase heater (if applicable)................57 Instructing the owner............................ 58 Maintenance and repair........................58 Required procedures for A2L systems....................
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Page 5: About The Unit
About the unit Read all sections of this manual. Keep this manual and the manual for the matching indoor unit for future reference. The outdoor units are designed to connect to a matching indoor coil with sweat connect lines. Sweat connect units are factory charged with refrigerant for a nominal sized matching indoor coil and 15 ft of field-supplied lines. -
Page 6: Safety
Safety It is important to understand the safety symbols used in this manual. Read safety information carefully and follow all safety requirements to ensure correct installation. Understanding safety symbols and instructions This is a safety alert symbol. When you see this symbol on labels or in manuals, be alert to the potential for personal injury. -
Page 7: Safety Requirements
Safety requirements WARNING Incorrect installation may create a condition where the operation of the product could cause personal injury or property damage. Incorrect installation, adjustment, alteration, service, or maintenance can cause injury or property damage. Refer to this manual for assistance. For additional information, consult a qualified contractor, installer, or service agency. -
Page 8: A2L Refrigerant Safety Considerations
A2L refrigerant safety considerations CAUTION You must read all of this section before installing this unit. WARNING Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacturer. The appliance shall be stored in a room without continuously operating ignition sources (for example, open flames, an operating gas appliance, or an operating electric heater). -
Page 9: Room Size Requirements
Table 1: Item Safety consideration number If conducting work in relation to the refrigerating system that involves exposing any pipework, do not use any sources of ignition in such a manner that may lead to the risk of fire or explosion. All possible ignition sources, including cigarette smoking, must be kept sufficiently far away from the site of installation, repair, removal, and disposal, during which refrigerant might possibly be released to the surrounding space. - Page 10 Table 3: Minimum room area System charge (lb-oz) Minimum room area Minimum total Minimum system airflow (CFM) conditioned area (ft 8-12 9-12 10-0 10-4 10-8 10-12 11-0 11-4 11-8 11-12 12-0 12-4 12-8 12-12 13-0 13-4 13-8 13-12 14-0 14-4 14-8 14-12 15-0...
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Page 11: Mechanical Ventilation
Table 3: Minimum room area System charge (lb-oz) Minimum room area Minimum total Minimum system airflow (CFM) conditioned area (ft 17-4 1005 17-8 1020 Note: • Minimum room area refers to the smallest air conditioned room on the lowest floor of the residence. -
Page 12: Electrical Devices Checks
Electrical devices checks Table 6: Item Safety consideration number Repair and maintenance to electrical components must include initial safety checks and component inspection procedures. If a fault exists that could compromise safety, then do not connect any electrical supply to the circuit until the fault is satisfactorily dealt with. If the fault cannot be corrected immediately but it is necessary to continue operation, use an adequate temporary solution. -
Page 13: Wiring Installation
Wiring installation NOTICE Cap unused wiring connections. NOTICE The mitigation control board has a bank of DIP switches. For use with a JHE or JME air handler indoor model, both DIP switches must be in the 0 or off position. For use with all other indoor models, both DIP switches must be in the 1 or on position. - Page 14 Figure 1: Mitigation control wiring Figure 2 shows the DIP switches on the mitigation control board in the on position. Figure 2: DIP switches in on position Field-testing the sensor After wiring and configuring the system, provide a Y call for cooling. Simulate an A2L leak by disconnecting the A2L sensor wire from the A2L control board, or else move the test jumper from NC (Normally Closed) to Test.
- Page 15 Figure 3: Test jumper After 15 s, verify that the call for the compressor is removed. Verify that the Y output pin has no voltage and that the G output pin has 24 VAC. Reinstall the sensor, then wait 5 min and verify that the system returns to cooling mode. When the system is in standby mode, repeat the above test for a W call for heating.
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Page 16: Installation Overview
Installation overview Complete all of the stages outlined in Figure 4. You may not need to perform tasks indicated with a dashed outline, depending on the specific installation. Figure 4: Installation overview Installation Manual: R-454B Outdoor Split-System Single-Phase Heat Pump - YH4, XH4, and RH4 Series Johnson Controls Ducted Systems... -
Page 17: Preparing For Installation
Preparing for installation WARNING These units are partial unit air conditioners, complying with the partial unit requirements of this standard, and must only be connected to other units that have been confirmed as complying to corresponding partial unit requirements of this standard, UL 60335-2-40/CSA C22.2 No. 60335-2-40. Complete the necessary preparation before you begin the installation: 1. - Page 18 • Select a location for the outdoor unit that meets the following general requirements for installation: Is away from bedroom windows or other room windows where the sound of the unit operation might be objectionable. Provides adequate structural support for the unit. Allows sufficient clearance for air entrance to the outdoor coil, air discharge, and service access.
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Page 19: Inspecting The Unit
Inspecting the unit Remove the shipping carton and inspect the unit immediately after receiving it for possible damage during transit. If damage is evident, do the following: a. Note the extent of any damage on the carrier's receipt. b. Make a separate written request for the carrier's agent to inspect the unit. c. - Page 20 • Recovery equipment (including refrigerant recovery containers) must be specifically designed to handle R-454B. • Only use a TXV that is specifically designed for R-454B refrigerant. • If an indirect refrigerating circuit is used, inspect the secondary circuit for refrigerant presence. •...
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Page 21: Installing The Outdoor Unit
Installing the outdoor unit There are three installation options for the outdoor unit: ground installation, roof installation, and wall-mounted installation. You must follow all requirements for the specific type of installation. See Selecting a location for installation for location requirements for ground, roof, and wall-mounted installation. - Page 22 Figure 5: Typical installation clearances Figure 6: Alternative installation clearances Installation Manual: R-454B Outdoor Split-System Single-Phase Heat Pump - YH4, XH4, and RH4 Series Johnson Controls Ducted Systems...
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Page 23: Mounting The Outdoor Unit On A Wall
Mounting the outdoor unit on a wall Before you begin: On occasion, site conditions may require direct wall mounted brackets to be used to locate and support the outdoor unit. In these applications, address unit base pan support, structural integrity, safe access, and serviceability, as well as the possible sound and vibration transmission into the structure. - Page 24 Table 10: Replacing refrigerant piping Installation condition Approach You are replacing an outdoor unit that uses Replace the refrigerant piping to reduce R-22, R-410A, or other refrigerant with an cross-contamination of oils and refrigerants. outdoor unit that uses R-454B refrigerant Installing the refrigerant piping.
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Page 25: Installing The Refrigerant Piping
Installing the refrigerant piping To install the refrigerant piping correctly, you must do the following: 1. Install the vapor line and liquid line. 2. Install a liquid-line filter drier on the liquid line. 3. Braze the refrigerant lines and service valves. 4. - Page 26 • Install the lines so that they do not obstruct service access to the coil, air handling system, or filter. • Take care to isolate the refrigerant lines to minimize noise transmission from the equipment to the structure. • Insulate the vapor line with a minimum of 1/2 in. foam rubber insulation such as Armaflex or an equivalent.
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Page 27: Installing The Liquid Line Filter-Drier
Installing the liquid line filter-drier About this task: The liquid line filter-drier is packaged and shipped along with the outdoor unit. CAUTION Filter-drier is required to be installed in liquid line. The recommended location is at the indoor coil before the refrigerant metering device. It can be installed at the outdoor unit if required. CAUTION Using a granular type drier may result in damage to the equipment. - Page 28 CAUTION Dry nitrogen must 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 must continue until the joint cools. Always use a pressure regulator and safety valve to ensure that only low pressure dry nitrogen is introduced into the tubing.
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Page 29: Installing The Thermostatic Expansion Valve (Txv)
Take the following precautions when brazing the service valve: • Wrap a wet rag around the service valve to prevent heat damage as shown in Figure • Protect items such as all painted surfaces, insulation, and the plastic base during brazing. •... - Page 30 CAUTION Do not over-torque. Do not use slip joint pliers. This distorts the aluminum distributor and the brass fitting, potentially causing leaks. Slide the nut removed in Step 3 over the supplied liquid line. Place the supplied PTFE washer from the TXV kit on the TXV, and install liquid line to the top of the TXV. Adjust assembly so liquid line aligns with hole in access panel.
- Page 31 Figure 11: TXV bulb and equalizer line installations CAUTION In all cases, mount the TXV bulb after vapor line is brazed and has had sufficient time to cool. Failure to use suction line grommet may result in premature TXV failure. If the indoor coil is an A coil, skip to Step 8.
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Page 32: Checking For Refrigerant Leaks
Figure 12: Correct bulb location What to do next: After the refrigerant piping is installed, leak test the system. Checking for refrigerant leaks About this task: NOTICE Pressurize the refrigerant piping and the indoor coil to 250 psig with dry nitrogen and leak test with a bubble type leak detector. -
Page 33: Releasing Refrigerant Into The System
Releasing refrigerant into the system Before you begin: Make sure that you have checked the refrigerant system for leaks and evacuated the refrigerant lines and indoor coil before releasing the refrigerant charge into the system. See Checking for refrigerant leaks Evacuating the refrigerant lines and indoor coil. -
Page 34: Connecting The Wiring
Connecting the wiring To connect the wiring correctly, you must do the following: 1. Observe the general information and grounding information. 2. Install the feild connections power wiring. 3. Install the field connections control wiring. 4. Control the dehumidification of the unit. 5. -
Page 35: Completing The Field Power Wiring Connections
Figure 13: Outdoor unit swing away control box Completing the field power wiring connections Install the correct size weatherproof disconnect switch outdoors and within sight of the unit. Remove the screws at the top and sides of the corner cover. Slide the control box cover down and remove from unit. - Page 36 Route the 24 V control wiring (NEC Class 2) from the outdoor unit to the indoor unit and thermostat. NOTICE To eliminate erratic operation, seal the hole in the wall at the thermostat with permagum or equivalent to prevent air drafts affecting the operation of in the thermostat. NOTICE Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges, or any other adverse environmental effects.
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Page 37: Control Wiring Diagrams
Control wiring diagrams Figure 15: Standard ECM air handler and standard single-stage heat pump - conventional wiring NOTICE The mitigation control board has a bank of dip-switches. For use with indoor model JHE air handler, both switches must be in the 0 or OFF position. JHE air handler outdoor unit harness leads have both a Y1 and Y2 IN/OUT disconnect that must be separated during wiring connections. - Page 38 Figure 16: Standard ECM modular air handler and standard single-stage heat pump conventional wiring NOTICE The mitigation control board has a bank of dip-switches. For use with indoor model JME air handler, both switches must be in the 0 or OFF position. For single-stage applications, JME Y1 and Y/Y2 must be bonded together as shown.
- Page 39 NOTICE The mitigation control board has a bank of DIP switches. For use with indoor model JHE or JME air handlers, both switches must be in the 0 or OFF position. For all other indoor models, both switches must be in the 1 or ON position. NOTICE JHE air handler outdoor unit harness leads have both a Y1 and Y2 IN/OUT disconnect that may need to be separated during wiring connections.
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Page 40: Using The Optional S1-2Hu16700124 Dehumidification Control
Table 11: Low-voltage wire connections Wire Connection 24V power 24V common Reversing valve input 1st stage compressor 2nd stage compressor (where applicable) Auxiliary heat input (not always used) WOUT Auxiliary heat output (energized during defrost) Y2OUT High speed indoor airflow output For full field low-voltage wiring, refer to the mitigation control kit and the indoor unit Installation Manual. -
Page 41: Charging The System
Charging the system CAUTION If a field-installed device is placed in the inner-connecting refrigerant lines that can store a significant refrigerant charge, for example, a refrigerant mass flow meter or a liquid receiver, the unit may not perform as designed. If such a performance-affecting device is installed and it is possible to check the unit in heating mode, the unit pressures should be confirmed in heating mode. -
Page 42: Measuring Indoor Airflow
To ensure that the unit performs at the published levels, it is important to determine the indoor airflow and add refrigerant charge accordingly. To charge the system, follow these steps: 1. Measure the indoor airflow. 2. Determine the total system charge. 3. -
Page 43: Charging With Gauges
Note that the total system charge = item 1 + item 2 + item 3. Check the unit against the pressure value listed on the cooling chart on the unit or the appropriate heat charging chart in this manual. Make any adjustment necessary. Add or subtract refrigerant to obtain the pressure listed on the charging chart. -
Page 44: Subcooling Charging Charts
CAUTION Compressor damage occurs if system is insufficiently charged. On new system installations, charge the system according to the Tabular Data Sheet for the matched coil and follow the guidelines in this manual. To charge with gauges, follow these steps: Before using the gauges, confirm that the gauges are accurate by comparing the gauges against a calibrated pressure gauge that has been calibrated against a national standard. - Page 45 Table 13: 1.5 ton cooling charging chart for JH(E,C)24*C and CT(F,M,U)30*C in upflow and horizontal left Indoor wet bulb (°F) at 80°F dry bulb Outdoor ambient DB (°F) Pressure (psig) and subcooling (°F) at liquid base valve 186 (9) 188 (9) 191 (9) 193 (9) 203 (8)
- Page 46 Table 16: 1.5 ton cooling charging chart for JH(E,C)18*B and CT(F,M,U)24*B in downflow and horizontal right Indoor wet bulb (°F) at 80°F dry bulb Outdoor ambient DB (°F) Pressure (psig) and subcooling (°F) at liquid base valve 189 (12) 191 (13) 194 (12) 196 (11) 206 (12)
- Page 47 Table 19: 3 ton cooling charging chart for JH(E,C)(30,36)*D and CT(F,M,U)(30,36)*D in upflow and horizontal left Indoor wet bulb (°F) at 80°F dry bulb Outdoor ambient DB (°F) Pressure (psig) and subcooling (°F) at liquid base valve 193 (4) 195 (5) 198 (4) 201 (3) 211 (5)
- Page 48 Table 22: 3 ton cooling charging chart for JH(E,C)42*F and CT(F,M,U)48*F in downflow and horizontal right Indoor wet bulb (°F) at 80°F dry bulb Outdoor ambient DB (°F) Pressure (psig) and subcooling (°F) at liquid base valve 193 (5) 195 (6) 198 (5) 201 (5) 211 (6)
- Page 49 Table 25: 4 ton cooling chart for JH(E,C)60*H and CT(F,M,U)60*H in upflow and horizontal left Indoor wet bulb (°F) at 80°F dry bulb Outdoor ambient DB (°F) Pressure (psig) and subcooling (°F) at liquid base valve 199 (8) 201 (8) 205 (8) 209 (6) 216 (8)
- Page 50 Table 28: 5 ton cooling charging chart for JH(E,C)60*H and CT(F,M,U)60*H in downflow and horizontal right Indoor wet bulb (°F) at 80°F dry bulb Outdoor ambient DB (°F) Pressure (psig) and subcooling (°F) at liquid base valve 192 (1) 194 (2) 196 (2) 198 (3) 208 (1)
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Page 51: Heating Charging Charts
Heating charging charts Note: An asterisk (*) on indoor match names is used in place of the cabinet width, refrigerant type, and metering device characters. Refer to the indoor unit manuals for the details on indoor unit nomenclature. Table 31: 1.5 ton heating charging chart for JH(E,C)24*C and CT(F,M,U)30*C in upflow and horizontal left Ambient temperature... - Page 52 Table 34: 1.5 ton heating charging chart for JH(E,C)18*B and CT(F,M,U)24*B in downflow and horizontal right Ambient temperature (°F) Indoor temperature (°F) Liq. Pressure (Subcool) (29) (29) (29) (32) (33) (34) (35) (36) (37) (37) (38) (39) (33) (34) (36) (35) (37) (38)
- Page 53 Table 37: 3 ton heating charging chart for JH(E,C)(30,36)*D and CT(F,M,U)(30,36)*D in upflow and horizontal left Ambient temperature (°F) Indoor temperature (°F) 1500 Liquid pressure (subcool) (10) (11) (12) (13) (14) (17) (15) (17) (19) (19) (21) (23) (20) (22) (25) (22) (25)
- Page 54 Table 41: 4 ton heating charging chart for JH(E,C)48*G and CT(F,M,U)60*G in upflow and horizontal left Ambient temperature (°F) Indoor temperature (°F) 1200 Liquid pressure (subcool) (18) (18) (18) (22) (22) (22) (40) (41) (42) (24) (25) (26) (22) (24) (27) (33) (33)
- Page 55 Table 44: 4 ton heating charging chart for JH(E,C)60*H and CT(F,M,U)60*H in downflow and horizontal right Ambient temperature (°F) Indoor temperature (°F) 2000 Liquid pressure (subcool) (33) (32) (32) (35) (35) (35) (37) (37) (37) (35) (36) (38) (34) (34) (34) (34) (34)
- Page 56 Table 48: 5 ton heating charging chart for JH(E,C)60*J and CT(F,M,U)60*J in downflow and horizontal right Ambient temperature (°F) Indoor temperature (°F) 1500 Liquid pressure (subcool) (33) (34) (35) (37) (38) (39) (38) (40) (41) (38) (40) (43) (37) (39) (42) (38) (38)
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Page 57: Starting Up The System
Starting up the system Before you begin: When the outdoor unit is in place and the refrigerant piping and wiring are complete, you must start up the system and make sure that the system is operating correctly. CAUTION Do not operate the system until all the checks outlined in this procedure have been performed. WARNING Do not touch any of the parts at the discharge gas side by hand. -
Page 58: Instructing The Owner
Instructing the owner When installation and start-up is complete, instruct the owner on the following: • Processing warranty cards or online registration • Reviewing the User’s Information Manual • Operating and maintaining the unit correctly, how to start, stop, and adjust the temperature setting •... -
Page 59: Required Procedures For A2L Systems
• Ensure that the recovery equipment is in good working order and suitable for recovering flammable refrigerants. • Always recover the refrigerant charge into the correct recovery cylinders if venting is not allowed by local and national codes. • Ensure that cylinders are labelled for the recovered refrigerant, and that they have pressure- relief valves and working shut-off valves. -
Page 60: Decommissioning
Table 49: A2L required procedures Procedure Repair the system and purge with nitrogen Required during brazing. Leak test and pressure test the unit. Required Evacuate the system. Required Charge the system. Required Decommissioning Before you begin: Before attempting the procedure, complete the following: •... -
Page 61: Test Input
Test input The control includes a TEST input connector that can be used for various testing functions during installation and service. The TEST input connector is shown in Figure Table 50 summarizes the behavior of the control when the two TEST pins are connected. More detailed descriptions of the various functions are included in other sections of this document. - Page 62 Figure 19: Heat pump flow diagram Figure 20: Demand defrost control module Installation Manual: R-454B Outdoor Split-System Single-Phase Heat Pump - YH4, XH4, and RH4 Series Johnson Controls Ducted Systems...
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Page 63: System Components And Operation
System components and operation Anti-short-cycle delay The control includes a 5 min anti-short-cycle delay (ASCD) timer to prevent the compressor from short-cycling after a power or thermostat signal interruption. The ASCD timer is applied when the control is first powered from the indoor unit thermostat and immediately following the completion of a compressor run cycle. -
Page 64: Demand Defrost
Table 53: Faults Description Status LED High-pressure switch fault (not in lockout yet) 2 flashes System in high-pressure switch lockout (last 3 flashes mode of operation was normal compressor) System in high-pressure switch lockout (last 4 flashes mode of operation was defrost) System in low-pressure switch lockout (last 5 flashes mode of operation was normal compressor) -
Page 65: Defrost Curves
Defrost curves The control uses a set of defrost curve parameters that are selected using the defrost curve selection jumper. The location of the defrost curve selection jumper is shown in the Tabular Data Sheet or Table 54 for each heat pump model. Defrost curve selection The second page of the Tabular Data Sheet or Table 54... -
Page 66: Defrost Termination
control allows another defrost cycle when needed. The timer is based on accumulated compressor runtime. Defrost termination The control terminates the defrost cycle immediately after the liquid line temperature reaches the terminate temperature or after 14 min of defrost operation. See Figure The control does the following to terminate a defrost cycle: •... -
Page 67: Pressure Switch Fault Detection And Lockout
Pressure switch fault detection and lockout The heat pump is equipped with a high pressure switch and low pressure switch that connect to the control at the pressure switch terminals. If the high pressure switch input opens for more than 40 ms, the control de-energizes the compressor. -
Page 68: Wiring Diagrams
Wiring diagrams Figure 22: Wiring diagram - single-phase - 208/230V PSC fan motor Installation Manual: R-454B Outdoor Split-System Single-Phase Heat Pump - YH4, XH4, and RH4 Series Johnson Controls Ducted Systems... -
Page 69: Start-Up Sheet
Start-up sheet Installation Manual: R-454B Outdoor Split-System Single-Phase Heat Pump - YH4, XH4, and RH4 Series Johnson Controls Ducted Systems... - Page 70 Subject to change without notice. Published in U.S.A. Copyright © 2024 by Johnson Controls. All rights reserved. Johnson Controls Ducted Systems...
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