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Johnson Controls AP18BX21, Installation And Maintenance Manual

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Johnson Controls AP18BX21 Installation And Maintenance Manual Download Page 35

PMGB0406B rev.1 

35

 

To reduce the risk of serious injury or death, the following refrigerant 
precautions must be followed.

 

Ɣ

As originally manufactured, this unit contains refrigerant installed by Johnson Controls. Johnson 
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 
identi

¿

 ed on the unit’s faceplate and/or in the associated manuals. Any additions of refrigerant into this 

unit must comply with the country’s requirements with regard to refrigerant use and should be obtained 
from Johnson Controls distributors. Use of any non-approved refrigerant substitutes will void the 
warranty and will increase the potential risk of injury or death.

 

Ɣ

If installed in a small room, take measures to prevent the refrigerant from exceeding the maximum 
allowable concentration in the event that refrigerant gases should escape.  Refrigerant gases can cause 
asphyxiation (0.026 lbs/ft

3

 (0.42 kg/m

3

) based on ISO 5149 for R410A). Consult with your distributor for 

countermeasures (ventilation system and so on). If refrigerant gas has leaked during the installation 
work, ventilate the room immediately. 

 

Ɣ

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 

À

 ames and contact 

your service contractor. Refrigerant (Fluorocarbon) for this unit is odorless. If the refrigerant should leak 
and come into contact with open 

À

 ames, toxic gas could be generated. Also, because the 

À

 uorocarbons 

are heavier than air, they settle to the 

À

 oor, which could cause asphyxiation.

 

Ɣ

When installing the unit, and connecting refrigerant piping, keep all piping runs as short as possible, 
and make sure to securely connect the refrigerant piping before the compressor starts operating. If 
the refrigerant piping is not connected and the compressor activates with the stop valve opened, the 
refrigerant cycle will become subjected to extremely high pressure, which can cause an explosion or 

¿

 re. 

 

Ɣ

Tighten the 

À

 are nut with a torque wrench in the speci

¿

 ed manner. Do not apply excessive force to the 

À

 are nut when tightening. If you do, the 

À

 are nut can crack and refrigerant leakage may occur. 

 

Ɣ

A compressor/unit comprises a pressurized system. Never loosen threaded joints while the system is 
under pressure and never open pressurized system parts. 

 

Ɣ

When maintaining, relocating, and disposing of the unit, dismantle the refrigerant piping after the 
compressor stops.

Refrigerant Precautions

(Ins)DX-Kit̲4e-rev1.indd   35

(Ins)DX-Kit̲4e-rev1.indd   35

2016/11/25   15:32:48

2016/11/25   15:32:48

Summary of Contents for AP18BX21

Page 1: ...er Combined Model DX Kit Air Handler Model H Y MAHP18B21S H Y MAHP24B21S H Y MAHP30B21S H Y MAHP36B21S H Y MAHP36C21S H Y MAHP48C21S H Y MAHP48D21S H Y MAHP60C21S H Y MAHP60D21S EXV 018E EXV 024E EXV 030E EXV 036E EXV 036E EXV 048E EXV 048E EXV 060E EXV 060E AP18BX21 AP24BX21 AP30BX21 AP36BX21 AP36CX21 AP48CX21 AP48DX21 AP60CX21 AP60DX21 Compatibility Ins DX Kit 4e rev1 indd C 1 Ins DX Kit 4e rev1...

Page 2: ...PMGB0406B rev 1 2 Ins DX Kit 4e rev1 indd C 2 Ins DX Kit 4e rev1 indd C 2 2016 11 25 15 32 11 2016 11 25 15 32 11 ...

Page 3: ...ring 49 22 Test Run 71 23 Cautions 74 24 Startup Sheet 75 List of Tables Table 1 Dimensions 9 Table 2 Physical and Electrical Data Cooling Only 20 Table 3 Electrical Data Cooling Only 21 Table 4 Electrical Heat Minimum Fan Speed 21 Table 5 KW MBH Conversions For Total Power Input Requirement 21 Table 6 Electric Heat Performance Data 208 230 1 60 208 230 3 60 22 Table 7 Electrical Data For Single S...

Page 4: ...ing Connections Heat Pump and Heat Recovery Systems 51 Figure 26 Positions of Electrical Wiring Connection 52 Figure 27 Reconnect Wiring 53 Figure 28 Wired Controller Connections 54 Figure 29 Wired Connections from the Control Box 55 Figure 30 Attaching Cable Holders to Air Handler 56 Figure 31 Wiring Holes of Air Handler 57 Figure 32 Thermistor Positions 58 Figure 33 Thermistor Connectors 59 Figu...

Page 5: ...hese versatile models for cooling or heat pump opera tion with or without electric heat Top or side power and control wiring color coded leads for control wiring easy to install drain connec tions and electric heaters all combine to make installation easy and minimize installation cost Electric heat kits are available as eld installed accessories Single phase kits are available from 2 5 kW to 25 k...

Page 6: ...her cleaning tools Soap powders bleaches waxes or other Cleaning compounds plastic items or containers gasoline kerosene cigarette lighter Àuid dry cleaning Àuids or other volatile Àuid Paint thinners and other painting compounds Paper bags boxes or other paper products Never operate the air handler with the blower door removed To do so could result in serious personal injury and or equipment dama...

Page 7: ...st be observed as applicable These air handlers should be transported and handled in an upright upÀow position Failure to do so may result in unit damage and personal injury Con guration conversions should be done at site of installation 12 These instructions cover minimum requirements and conform to existing national standards and safety codes In some instances these instructions exceed certain l...

Page 8: ...e unit in place or connecting any wiring duct work or piping When installing the air handler it is important to note that the Schrader core on the suction line stub out must be relocated to the equalizer connection port located on the coil See the circled ports in the gure below Figure 2 Pressure Check G A 1 1 2 7 11 32 C FILTER ACCESS DRAIN CONNECTIONS FOR UPFLOW APPLICATIONS REFRIGERANT CONNECTI...

Page 9: ...al J or other approved methods Reference Figure 3 and Table 1 1 Only connect the air handler to a duct system that has an external static pressure within the allowable range 2 AirÀow must be within the minimum and maximum limits approved for electric heat indoor coils and out door units Refer to the Dx Kit section for details 3 Install the air handler so that supply ducts carry air circulated by t...

Page 10: ...n and supply duct connections 2 Using hanging brackets to wall mount this single piece air handler unit is not recommended 3 Normal operating sound levels may be objectionable if the air handler is placed directly over some rooms such as bedrooms study etc 4 Select a location that will permit installation of condensate line to an open drain or outdoors allowing con densate to drain away from struc...

Page 11: ...ngers of the support bar There are four position identi ers A B C or D The lettered hole location can differ from unit to unit due to the cabinet width of the air handler After removal and re installation install the center support bar in the same lettered position that it was originally 3 Note the lettered position of the center support bar for the coil drain pan Remove the center support bar by ...

Page 12: ...ed position that it was originally NOTICE When installing a coil blow off wing make sure that each notch in the coil blow off wing see Figure 5 slides around the anchor screw with the bottom of the notch fully set against the screw Ensure that coil blow off wing is installed with the Àange bending away from the coil data plate 7 Install center support bar for the coil drain pan onto the lettered p...

Page 13: ...nding air into the insulation Properly size the supply air duct by use of a transition to match unit opening Suspend all ducts using Àexible hangers and never fastened directly to the structure Fabricate and install duct work in accordance with local and or national codes This includes the standards of the National Fire Protection Association for Installation of Air Conditioning and Ventilating Sy...

Page 14: ...nit parts bag With the screws from the parts bag install one of the duct Àanges Duct Àanges have holes on both legs with one leg longer than the other You can use the longer leg to mate against the air handler so that different thicknesses of duct board are made Àush with the outer surface of the air handler Repeat the procedure for the other two Àanges Refer to Figure 7 If you do not use the Àang...

Page 15: ...e to the supply opening ap proximately 8 high and running the full width of the plenum Refer to Figure 8 The use of this block off plate enables better air circulation across the limit switches Air Filters Return air lters are required and must be eld supplied Filtration can be accomplished external to the unit or the integral lter rack may be used A 1 lter access rack is built into the unit Remov...

Page 16: ...tinue the Àow of dry nitrogen until the joint has cooled Always use a pressure regulator and safety valve to insure that only low pressure dry nitrogen is introduced into the tubing Only a small Àow is necessary to displace air and prevent oxidation Instructions for Liquid Refrigerant Line of the Air Handler Step 1 Remove bottom front cover The heat ex changer is exposed Step 2 See accessory pipin...

Page 17: ...s together Do not re install the piston Step 7 Attach the accessory piping to the distributor body Tighten the nut with a torque of 16 20 ft lbs Then manually raise the distributor body to align with the liquid line connection hole Ins DX Kit 4e rev1 indd C 17 Ins DX Kit 4e rev1 indd C 17 2016 11 25 15 32 26 2016 11 25 15 32 26 ...

Page 18: ...y toward the drain end Suggested pitch should not exceed 1 4 inch per foot of coil The drain pan connections are designed to ASTM Standard D 2466 Schedule 40 Use 3 4 PVC or steel threaded pipe Since the drains are not subject to any pressure it is not necessary to use Schedule 40 pipe for drain lines 8 Electric Heater Installation If the air handler requires electric heat install the electric heat...

Page 19: ...ect wire size Use Caution when sizing aluminum rather than copper conductors as aluminum conductors are rated for less current than copper conductors of the same size Figure 9 Line Power Connections Power may be brought into the unit through the supply air end of the unit top left when unit is in the upÀow vertical position or the left side panel Use the hole appropriate to the unit s orientation ...

Page 20: ...0 x 20 x 1 Permanent Type Kit 1PF0601 1PF0601 1PF0601 1PF0601 1PF0602 Shipping Operating Weight lbs 91 85 93 87 119 113 119 113 120 114 Models 48C 48D 60C 60D Blower Diameter x Width 10 x 10 10 x 10 10 x 10 10 x 10 Motor HP 1 2 HP 1 2 HP 1 HP 1 HP Nominal RPM 1040 1040 1007 1007 Voltage 208 230 208 230 208 230 208 230 Full Load Amps 230V 2 9 2 9 4 1 4 1 Filter Type DISPOSABLE OR PERMANENT Size 20 ...

Page 21: ...w Low 6HK 1 2 6501306 12 5kW Med Low Med Low Low Low Low 6HK 1 2 6501506 6HK36501525 14 4kW Med Low Med Low Low Low Low 6HK 1 2 6501806 6HK36501825 17 3kW Low Med Low Low Low Low 6HK 1 2 6502006 6HK46502025 19 2kW Low Med Med Med 6HK 1 2 6502506 6HK46502525 24kW Med Med 1 0 1 0 no service disconnect OR 1 with service disconnect 2 1 2 1 with service disconnect no breaker jumper bar OR 2 with servic...

Page 22: ... 13 15 9 6HK 1 2 6502006 19 2 14 4 17 6 49 2 60 2 7 2 8 8 14 4 17 6 6HK 1 2 6502506 24 18 22 61 5 75 2 7 2 8 8 18 22 3PH 6HK36501025 9 6 7 2 8 8 24 6 30 1 7 2 8 8 7 2 8 8 6HK36501525 14 4 10 8 13 2 36 9 45 1 10 8 13 2 10 8 13 2 6HK36501825 17 3 13 15 9 44 3 54 2 13 15 9 13 15 9 6HK46502025 19 2 14 4 17 6 49 2 60 2 7 2 8 8 14 4 17 6 6HK46502525 24 18 22 61 5 75 2 9 11 18 22 1 0 1 0 no service disco...

Page 23: ...6B 6HK 0 1 6500206 10 14 1 15 2 15 20 6HK 0 1 6500506 20 24 9 27 2 25 30 6HK 0 1 6500806 32 38 1 41 8 40 45 6HK 0 1 6501006 40 46 5 51 1 50 60 6HK 1 2 6501306 52 59 7 65 8 60 70 6HK 1 2 6501506 60 68 2 75 0 70 80 6HK 1 2 6501806 72 81 4 89 7 90 90 6HK 1 2 6502006 80 89 8 98 9 90 100 36C 6HK 0 1 6500206 10 13 6 14 7 15 15 6HK 0 1 6500506 20 24 4 26 7 25 30 6HK 0 1 6500806 32 37 6 41 3 40 45 6HK 0 1...

Page 24: ... 20 20 6HK 0 1 6500506 20 26 8 29 0 30 30 6HK 0 1 6500806 32 40 0 43 7 40 45 6HK 0 1 6501006 40 48 4 53 0 50 60 6HK 1 2 6501306 52 61 6 67 6 70 70 6HK 1 2 6501506 60 70 0 76 9 70 80 6HK 1 2 6501806 72 83 3 91 5 90 100 60D 6HK 0 1 6500206 10 15 9 17 1 20 20 6HK 0 1 6500506 20 26 8 29 0 30 30 6HK 0 1 6500806 32 40 0 43 7 40 45 6HK 0 1 6501006 40 48 4 53 0 50 60 6HK 1 2 6501306 52 61 6 67 6 70 70 6HK...

Page 25: ...3 1 45 40 50 45 6HK16502006 80 47 0 43 3 51 5 47 9 50 45 60 50 48D 6HK16501306 52 22 4 37 6 24 4 41 5 25 40 25 45 6HK16501506 60 25 3 43 3 27 6 47 9 30 45 30 50 6HK16501806 72 42 6 39 0 46 8 43 1 45 40 50 45 6HK16502006 80 47 0 43 3 51 5 47 9 50 45 60 50 6HK16502506 100 47 0 43 3 21 7 51 5 59 9 24 0 50 45 25 60 60 25 60C 6HK16501306 52 23 9 37 6 25 9 41 5 25 40 30 45 6HK16501506 60 26 8 43 3 29 1 ...

Page 26: ... 7 66 2 72 7 70 80 60C 6HK36501025 23 1 30 1 32 8 35 35 6HK36501525 34 6 42 6 46 6 45 50 6HK36501825 41 6 50 3 55 1 55 60 60D 6HK36501025 23 1 30 1 32 8 35 35 6HK36501525 34 6 42 6 46 6 45 50 6HK36501825 41 6 50 3 55 1 55 60 6HK46502025 46 2 55 1 60 4 60 70 6HK46502525 57 7 67 7 74 2 70 80 1 Asterisk denotes the 20kW and 25kW heater models 6HK46502025 and 6HK46502525 come with service disconnects ...

Page 27: ... 40 35 60D 6HK46502025 46 2 30 1 25 0 32 8 27 6 35 25 35 30 6HK46502525 57 7 36 4 31 3 39 7 34 6 40 35 40 35 1 The 20kW and 25kW heater models 6HK46502025 and 6HK46502525 come with service disconnects standard 2 MOP Maximum Overcurrent Protection device must be HACR type circuit breaker or time delay fuse The 1st circuit includes blower motor amps Refer to your local codes to determine the correct...

Page 28: ...N A N A 24B High High 1142 1114 1078 1051 988 931 778 Low Medium 854 840 826 800 738 688 605 30B High High 1316 1270 1213 1151 1081 1008 917 Low Medium 1139 1104 1059 1005 952 880 769 36B High High 1601 1552 1485 1414 1337 1258 1178 Low Medium 1385 1352 1302 1252 1193 1106 1057 36C High High 1671 1636 1581 1513 1439 1330 1210 Low Medium 1326 1310 1280 1238 1162 1081 994 48C High High 1775 1727 166...

Page 29: ...prepare coil for static pressure measurements run the fan only to assure a dry coil NOTICE Refer to Table 11 for coil Air Flow Data CFM Drill 2 holes one 12 away from the air handler in the supply air duct and on 12 away from the air handler in the return air duct before any elbows in the duct work Insert the pressure tips and energize the blower motor See Table 11 to determine the air Àow and mak...

Page 30: ...ated in these instructions WERE THE PRIMARY AND SECONDARY DRAINS TRAPPED CORRECTLY PLUG UNUSED SECONDARY DRAIN SECONDARY 3 MINIMUM PRIMARY PREMADE TRAPS HANDMADE TRAP A0272 001 Figure 12 Drain Traps Figure 13 Location of Coil Trapped and Plugged Drain Connections Ins DX Kit 4e rev1 indd C 30 Ins DX Kit 4e rev1 indd C 30 2016 11 25 15 32 47 2016 11 25 15 32 47 ...

Page 31: ... within the range limits according to the table below Temperature Maximum Minimum Cooling Operation Indoor 89o F DB 73o F WB 32o C DB 23o C WB 69o F DB 59o F WB 21o C DB 15o C WB Outdoor 118o F DB 48o C DB 14o F DB 10o C DB Heating Operation Indoor 80o F DB 27o C DB 59o F DB 15o C DB Outdoor 59o F WB 15o C WB 4o F WB 20o C WB DB Dry Bulb WB Wet Bulb The temperature may change depending on the outd...

Page 32: ...ncorrect installation could cause leaks electric shock re or explosion In areas where Seismic Performance requirements are speci ed the appropriate measures should be taken during installation to guard against possible damage or injury that might occur in an earthquake if the unit is not installed correctly injuries may occur due to a falling unit Ɣ Use appropriate Personal Protective Equipment PP...

Page 33: ...an and could run inside of the control box possibly causing electrical failures Ɣ When installing the unit in a hospital or other facility where electromagnetic waves are generated from nearby medical and or electronic devices be prepared for noise and electronic interference Electromagnetic Interference EMI Do not install where the waves can directly radiate into the control box controller cable ...

Page 34: ...ere harmful gases can be generated from decomposition Ɣ Do not position the drain pipe for the indoor unit near any sanitary sewers where corrosive gases may be present If you do toxic gases can seep into breathable air spaces and can cause respiratory injuries If the drain pipe is installed incorrectly water leakage and damage to the ceiling Àoor furniture or other possessions may result If the d...

Page 35: ... ventilate the room immediately Ɣ 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 Àames and contact your service contractor Refrigerant Fluorocarbon for this unit is odorless If the refrigerant should leak and come into contact with open Àames toxic gas could be generat...

Page 36: ...ely through the wiring access channel Ɣ When installing the power lines do not apply tension to the cables Secure the suspended cables at regular intervals but not too tightly Ɣ Make sure that the terminals do not come into contact with the surface of the control box If the terminals are too close to the surface it may lead to failures at the terminal connection Ɣ Turn OFF and disconnect the unit ...

Page 37: ... power device arc furnace electric furnace large sized induction motor and large sized switch It consumes large quantities of electrical power Regarding that mentioned above surge voltage may be inducted into the power supply wiring for the crated air conditioner due to a spike in power consumption for this device and an activation of the switch Check the eld regulations and standards before perfo...

Page 38: ...n motor control board The control box should be mounted on the air handler 17 Before Installation Item No Description Item No Description 1 VRF Outdoor Unit 10 Air Handler DX Kit 11 Fan Motor for Air Handler 2 Control Box 12 Liquid Pipe Line 3 Expansion Valve Box 13 Gas Pipe Line 4 Air Inlet Thermistor Probe 14 H LINK Communication Cable 5 Air Outlet Thermistor Probe 15 Power Supply Wiring 6 Liqui...

Page 39: ...irings Avoid unpackaging the DX Kit until it arrives at the installation site Install the DX Kit as soon as possible after unpacking Unpack and place the DX Kit on the Àoor Position the DX Kit with the bottom surface facing downward on the soft packing insulation material Any super cial damage to this item can compromise its moisture sealing qualities Do not lay any objects on this product This DX...

Page 40: ...uid Piping Thermistor 1 For Refrigerant Gas Piping Thermistor Cable Clamp 8 For Securing Pipe Insulation and Thermistor Thermistor Holder for Piping 1 For Attaching Liquid Piping Thermistor to Piping 1 For Attaching Gas Piping Thermistor to Piping Butyl Sheet 1 For Refrigerant Liquid Piping Thermistor 1 For Refrigerant Gas Piping Thermistor Reducer 1 For Changing Pipe Diameter of Gas Pipe Connecti...

Page 41: ...duct If necessary please contact your contractor 17 5 Field Supplied Items 17 6 Necessary Tools and Instrument List for Installation NOTE Use tools and measuring instruments vacuum pump gas hose charging cylinder manifold gauge exclusively for refrigerant R410A No Tool No Tool 1 Cordless Drill 12 Flare Kit 2 Handsaw 13 Torque Wrench 3 Phillips Screwdriver 14 Charging Cylinder 4 Vacuum Pump 15 Mani...

Page 42: ...from medical equipment a Do not install this product where the electromagnetic wave radiates directly to the control box communication cable or wired controller b Install this product and components as far away as practicable or at least 9 8ft 3m from any electromagnetic wave radiator c Prepare a steel box and install the wired controller in it Prepare a steel conduit tube and wire the controller ...

Page 43: ...178 178 3 8 10 10 1 26 26 15 15 381 381 17 17 1 16 16 433 433 19 1 8 485 485 4 5 16 16 109 109 3 3 16 81 81 A B C D 4 4 3 4 120 120 7 7 3 8 187 187 1 1 1 4 32 32 Ø7 8 22 2 22 2 Mounting Hole Mounting Hole Ø1 26 Ø1 26 Expansion Valve Box Expansion Valve Box Electrical Control Box Electrical Control Box Model Model Dimension Dimension EXV 018E EXV 018E EXV 024E EXV 024E EXV 030E EXV 030E EXV 036E EX...

Page 44: ...nger Control Box Control Box 12 12 1 4 311 4 0 3 311 4 0 3 A A 4 4 3 4 120 0 3 120 0 3 1 1 3 8 35 35 Top Panel Top Panel 4 x 4 x 1 8 3 3 Air Outlet Air Outlet Air Inlet Air Inlet A A AP24BX21 AP24BX21 AP18BX21 AP18BX21 inch mm inch mm AirHandlerModel AirHandlerModel AP30BX21 AP30BX21 AP36BX21 AP36BX21 AP36CX21 AP36CX21 AP48CX21 AP48CX21 AP60CX21 AP60CX21 AP48DX21 AP48DX21 AP60DX21 AP60DX21 79 6 79...

Page 45: ... insulate the copper pipes inlet on the expansion valve box cover to avoid any liquid ltration and accumulation Installation position b is prohibited 1 4 7 7 R 1 8 2 5 2 5 R 3 16 16 5 5 5 5 Details of Mounting Holes 19 3 Mounting Expansion Valve Box Figure 19 Details of Mounting Hole Ins DX Kit 4e rev1 indd 45 Ins DX Kit 4e rev1 indd 45 2016 11 25 15 32 54 2016 11 25 15 32 54 ...

Page 46: ...saw or a grinder 1 The tolerance of refrigerant piping length differs depending on the combination with the outdoor unit Refer to Installation and Maintenance Manual of the outdoor unit for details 2 Select the piping size from the following table For details on refrigerant piping work vacuum pump and refrigerant charge refer to the Installation and Maintenance Manual for the outdoor unit Use the ...

Page 47: ...r Gas Pipe Line Make sure to attach the reducer accessory on the gas pipe connection Control Box of DX Kit Direction of Refrigerant Flow in Cooling Mode Indoor Unit Liquid Pipe Line Expansion Valve Box of DX Kit Outdoor Unit Air Handler Gas Pipe Line Make sure to attach the reducer accessory on the gas pipe connection Control Box of DX Kit Direction of Refrigerant Flow in Cooling Mode Indoor Unit ...

Page 48: ...with insulation eld supplied Fasten with cable clamps at three locations along the pipe Field Supplied Affix vinyl tape position at the vertical part Insulation for Refrigerant Pipe Field Supplied Securely fasten cable clamps and vinyl tape in order to prevent the accumulation of moisture Expansion Valve Box Side Check for any gap between the indoor unit and the insulation Insulation Material Fiel...

Page 49: ...ll result in an electric shock or a re Ɣ Check to ensure that the indoor fan and the outdoor fan have stopped before attempting any electrical wiring work or for any scheduled electrical work that is being performed Ɣ Tighten screws according to the following torque M3 5 0 9 ft lbs 1 2 N m for 208V for 208V Connector Connector for 230V for 230V PCB1 PCN1 CN1 2 2 1 2 2 1 1 1 208V 208V 230V 230V TF ...

Page 50: ...al current drain is found and repaired B Check to ensure that the stop valves for the outdoor unit are fully opened and then start the system C Check to see that the main power has been switched ON for longer than 12 hours prior activating the system Power to the crankcase heater needs this time interval to warm the compressor oil up to operating temperature x Do not touch any of the parts by hand...

Page 51: ... Kit Indoor Unit with DX Kit Indoor Unit with DX Kit Switchbox GFCI Main Switch GFCI Main Switch Refer to the Installation and Maintenance Manual for the connected outdoor unit for details of wire GFCI and main switch for outdoor unit Figure 25 Electrical Wiring Connections Heat Pump and Heat Recovery Systems NOTES 1 Follow local codes and regulations when selecting eld wires 2 Select a GFCI with ...

Page 52: ... Voltage Side Control Cable TB2 3 4 1 2 8 7 9 11 10 12 2 1 3 5 4 6 Expansion Valve Box Terminal Block for Expansion Valve Cable TB3 3 4 1 2 6 5 Figure 26 Positions of Electrical Wiring Connection 21 3 Position of Electrical Wiring Connection Ɣ Check for the recommended size GFCI in table 7 1 of the Installation and Maintenance Manual for the outdoor unit Ɣ Between indoor and outdoor units use dual...

Page 53: ...ng to the torque speci cation as shown in the table on previous page Stranded Wire Single Wire Connect it with Crimping Terminal Connect it Direct As Shown Below 8 All electrical work should be performed in strict accordance with electrical schematics in the Installation and Maintenance Manual 9 If Power Supply Voltage 208V 230V is introduced into the Communication Line If 208V 230V are applied to...

Page 54: ...Controller Connections between different Refrigerant Cycles b Single Wired Controller for Individual Operation Setting Outdoor Unit A B Outdoor Unit Indoor Unit Indoor Unit Indoor Unit Indoor Unit A B A B A B Individual Simultaneous Thermo ON OFF individually Individual Wired Controller Wired Controller Wired Controller with DX Kit with DX Kit with DX Kit with DX Kit Outdoor Unit Indoor Unit A B T...

Page 55: ...3 CN404 CN401 X4 X5 R 12 11 7 5 8 10 9 2 1 3 6 4 3 2 1 4 3 2 1 3 2 6 5 4 1 3 2 6 5 4 1 4 3 2 1 2 1 PCN6 PCN7 PCN3 PCN2 YH2 C4 R3 PC4 Z2 DSA SSR1 R8 R6 R2 R4 PC2 PC3 C35 ZD2 HA CN8 CN7 C3 C8 C2 REG3 LED4 LED3 L2 DM2 N THM5 THM4 THM3 THM2 CN2 CN4 CN3 TP L4 L3 EF4 Z3 Z4 FUNC ZD1 C11 HIC1 DM1 CN11 CN17 LED1 C12 CN1 D12 D11 D10 DSW7 DSW3 DSW4 DSW5 DSW6 RSW1 RSW2 DSW8 R1 THM1 L1 PCN1 EFR1 EFS1 C1 Z1 CN1...

Page 56: ...holders for the securing wires using the screw already attached to the unit Secure the wiring neatly with the cable holders and cable clamps and make sure that the wiring will not be held down by the covers Otherwise the wiring may be damaged and serious accident and malfunction of the air handler may result 21 4 2 Wiring Holes of Air Handler Make sure there are no shavings left inside the control...

Page 57: ...CN7 C3 C8 C2 REG3 LED4 LED3 L2 DM2 N THM5 THM4 THM3 THM2 CN2 CN4 CN3 TP L4 L3 EF4 Z3 Z4 FUNC ZD1 C11 HIC1 DM1 CN11 CN17 LED1 C12 CN1 D12 D11 D10 DSW7 DSW3 DSW4 DSW5 DSW6 RSW1 RSW2 DSW8 R1 THM1 L1 PCN1 EFR1 EFS1 C1 Z1 CN1925 CN14 PC1 C15 EF1 R12 R13 REG1 REG2 01 9 8 7 65 4 3 2 5 4 3 2 1 0 9 8 7 6 1 Float Sw 2 3 4 5 6 7 8 9 11 10 12 EXP VALVE 1 2 3 4 6 CONTROL 1 2 A B 1 2 L1 L2 1 2 3 4 PS DrainPump ...

Page 58: ...ith cable clamps for securing the thermistor cable Protect the wiring from sharp edges Ø1inch 26mm Connecting Hole for Communication Cable Wired Controller Cable Thermistor Cable and Expansion Valve Cable Air Outlet Thermistor HI MED LO 21 4 3 1 Liquid and Gas Pipes Thermistors In all cases mount the pipe thermistors after piping are brazed and suf ciently cooled In case that the thermistors suppl...

Page 59: ...InletThermistor THM1 Blue THM1 Blue ConnectorforAirOutletThermistor ConnectorforAirOutletThermistor THM2 Red THM2 Red Connector for Liquid PipeThermistor Connector for Liquid PipeThermistor THM3 Black THM3 Black Connector for Gas PipeThermistor Connector for Gas PipeThermistor THM5 Yellow THM5 Yellow X2 X2 YX2 YX2 X3 X3 YX5 YX5 YX4 YX4 YX3 YX3 P P CN402 CN402 CN403 CN403 CN404 CN404 CN401 CN401 X4...

Page 60: ...Outlet Thermistor Red THM2 47 1 4 1200 Air inlet and outlet thermistors are supplied with the control box The purpose and identi cation of each one is as follows Figure 34 Thermistor Installation with Details 21 4 3 2 Air Inlet and Outlet Thermistor Liquid Pipe Thermistor Liquid Pipe Thermistor Thermistor Holder Piping Thermistor Butyl Sheet Pipe Insulation Pipe Insulation Gas Pipe Line Liquid Pip...

Page 61: ...Remove both upper and lower front panels of the air handler to access the blower and coil compartment 2 Remove the control box cover with the four screws 3 Pass the two connector side of thermistor cable through the connecting hole and connect the thermistor connectors to the corresponding connectors on the PCB 4 Route the thermistor probe end inside the air handler by passing through the connecti...

Page 62: ... A B Extension Length inch mm PCB Connector Number Thermistor Extension Connector Color Thermistor Extension Connector Color Thermistor Connector Color THM1 Blue Blue Blue 39 3 8 1000 THM2 Red Red Red 19 11 16 500 THM3 Black Black Black 59 1 16 1500 THM5 Yellow Yellow Yellow 59 1 16 1500 Air Outlet Thermistor THM2 r o t s i m r e h T t e l n I r i A THM1 Ins DX Kit 4e rev1 indd 62 Ins DX Kit 4e re...

Page 63: ... PCN7 PCN3 PCN2 YH2 C4 R 3 PC4 Z2 DSA SSR1 R8 R6 R2 R4 PC2 PC3 C35 ZD2 HA CN8 CN7 C3 C8 C2 REG3 LED4 LED3 L2 DM2 N THM5 THM4 THM3 THM2 CN2 CN4 CN3 TP L4 L3 EF4 Z3 Z4 FUNC ZD1 C11 HIC1 DM1 CN11 CN17 LED1 C12 CN1 D12 D11 D10 DSW7 DSW3 DSW4 DSW5 DSW6 RSW1 RSW2 DSW8 R1 THM1 L1 PCN1 EFR1 EFS1 C1 Z1 CN1925 CN14 PC1 C15 EF1 R12 R13 REG1 REG2 01 9 8 7 654 3 2 54 3 2 1 0 9 8 7 6 PCB1 PCB1 X2 YX2 X3 YX5 YX4...

Page 64: ...g Figure 39 Connection to Fan Motor Inside Air Handler FanCasing Fan Motor Run Capacitor FanMotorTerminals ControlBoxCover Ø7 8inch 22 2mm Conduit Hole for Fan Motor Wiring ControlBox PCB2 PCB1 Useeitherwiringholes of air handler for routing the fan motor wiring inside the air handler R X2 X4 To MEDTerminal of Fan Motor From X4 on PCB2 Conduit for Fan MotorWiring To HITerminal of Fan Motor FromX2o...

Page 65: ...Figure 40 Connection to Expansion Valve Box 4 5 2 3 1 6 4 3 6 EXP VALVE 1 2 X2 YX2 X3 YX5 YX4 YX3 P CN402 CN403 CN404 CN401 X4 X5 R 12 11 7 5 8 10 9 2 1 3 6 4 3 2 1 4 3 2 1 3 2 6 5 4 1 3 2 6 5 4 1 4 3 2 1 2 1 PCN6 PCN7 PCN3 PCN2 YH2 C4 R3 PC4 Z2 DSA SSR1 R8 R6 R2 R4 PC2 PC3 C35 ZD2 HA CN8 CN7 C3 C8 C2 REG3 LED4 LED3 L2 DM2 N THM5 THM4 THM3 THM2 CN2 CN4 CN3 TP L4 L3 EF4 Z3 Z4 FUNC ZD1 C11 HIC1 DM1 ...

Page 66: ...ure 41 Connection for Power Supply Ø1inch 26mm Connecting Hole for Communication Cable WiredController Cable Thermistor Cable and ExpansionValve Cable Ø7 8 inch 22 2mm Conduit Hole for Power SupplyWiring Control Box Cover Power SupplyWiring and GroundWiring WiredControllerCable CommunicationCable TerminalBlockTB1 GroundTerminal ControlBox TerminalBlockTB2 Conduit for Power SupplyWiring ToTB3onExpa...

Page 67: ...03 CN404 CN404 CN401 CN401 X4 X4 X5 X5 R 12 11 11 7 5 8 10 9 2 1 3 6 4 3 2 1 4 3 2 1 3 2 6 5 4 1 3 2 6 5 4 1 4 3 2 1 2 1 PCN6 PCN6 PCN7 PCN7 PCN3 PCN3 PCN2 PCN2 YH2 YH2 C4 C4 R3 R3 PC4 PC4 Z2 DSA DSA SSR1 SSR1 R8 R8 R6 R6 R2 R2 R4 R4 PC2 PC2 PC3 PC3 C35 C35 ZD2 ZD2 HA HA CN8 CN8 CN7 CN7 C3 C3 C8 C8 C2 C2 REG3 REG3 LED4 LED4 LED3 LED3 L2 DM2 DM2 N THM5 THM5 THM4 THM4 THM3 THM3 THM2 THM2 CN2 CN2 CN4...

Page 68: ...box terminal block TB2 and expansion valve box terminal block TB3 2 2 3 3 4 4 5 6 6 Figure 43 Expansion Valve Box Terminal Block TB3 Expansion Valve Box Expansion Valve Box 1 2 3 4 5 6 4 3 6 EXP VALVE 1 2 TB3 Expansion Valve Box 1 2 3 4 5 6 4 3 6 EXP VALVE 1 2 3 4 1 2 6 5 1 2 3 4 5 6 EXP VALVE EXP VALVE 1 2 3 4 Terminal Block 3 TB3 6 Ins DX Kit 4e rev1 indd 68 Ins DX Kit 4e rev1 indd 68 2016 11 25...

Page 69: ...centralized control this setting is required 1 2 3 4 5 6 ON OFF 1 2 3 4 5 6 ON OFF DSW6 Tens Digit Unit No Setting RSW1 Units Digit Setting Position Set by inserting slotted screwdriver into the groove Ex Set at No 16 Unit DSW6 RSW1 Set No 1 Pin at ON side Set at 6 3 4 1 0 89 2 5 6 7 3 4 1 0 8 9 2 5 6 7 Before shipment DSW6 and RSW1 are set at 0 For the units supporting H LINK II the unit No can b...

Page 70: ...ings Otherwise the setting will be invalidated and not take effect NOTES Ɣ The Ŷ mark indicates setting for DIP switches Figures show setting before shipment Ɣ When the unit number and the refrigerant cycle are set record the unit number and refrigerant cycle to facilitate service and maintenance thereafter NOTICE Each function can be selected with the wired controller Refer to the Installation an...

Page 71: ... Check to ensure that the main power supply has been turned ON for more than 12 hours to warm up the compressor oil by the crankcase heater 5 Verify that all DIP Switch settings are correct Refer to Section 21 5 DIP Switches Setting After all installation work is completed Test Run should be performed 1 Check to ensure that stop valves gas and liquid for the outdoor unit are fully opened 2 Wheneve...

Page 72: ...d indoor unit numbers by 7 Segment displays e To complete Test Run press On Off again or wait for the set Test Run time to pass When changing the Test Run time press or to select TEST TIME Then set the test run time 30 to 600 minutes by pressing or Adj Sel OFF Test Run 2 units MODE SPEED AUTO COOL Test Time 120min Inverter 60Hz Ɣ The RUN indicator on the wired controller for the indoor unit will À...

Page 73: ...connection 12 Outlet Air Thermistor failure 13 Freeze Protection Thermistor failure 14 Gas Piping Thermistor failure 20 29 Problem with the outdoor unit Refer to the Installation and Maintenance Manual for outdoor units 31 System Incorrect capacity setting for indoor and outdoor units Incorrect capacity code setting for combination excessive or insuf cient total indoor unit capacity code 32 Incorr...

Page 74: ...ized and trained personnel All the installation work of the air conditioning is completed Hand over this information to the building owner and request they maintain all the equipment manuals and warranty Do NOT operate the air conditioning just to run checks on electrical wiring until preparations for the Test Run phase is completed NOTICE 23 1 Limitation of Air Handler When the outdoor temperatur...

Page 75: ...PMGB0406B rev 1 75 24 Startup Sheet Ins DX Kit 4e rev1 indd 75 Ins DX Kit 4e rev1 indd 75 2016 11 25 15 33 07 2016 11 25 15 33 07 ...

Page 76: ...PMGB0406B rev 1 76 Ins DX Kit 4e rev1 indd 76 Ins DX Kit 4e rev1 indd 76 2016 11 25 15 33 07 2016 11 25 15 33 07 ...

Page 77: ...PMGB0406B rev 1 11 2016 Code No LIT 12012314 Revised September 2016 2016 Johnson Controls Inc Ins DX Kit 4e rev1 indd B C 1 Ins DX Kit 4e rev1 indd B C 1 2016 11 25 15 33 07 2016 11 25 15 33 07 ...

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