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835961-UIM-D-0213

R-410A OUTDOOR SPLIT-SYSTEM 
HEAT PUMP

MODELS: 13 SEER & 14.5 SEER - 
THG(D,F)/GHGD/THJ(D,F)/YHJ(D,F)/YHJR/THJR SERIES

1.5 TO 5 TONS – 1 & 3 PHASE

INSTALLATION MANUAL

®

LIST OF SECTIONS

GENERAL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAFETY  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
UNIT INSTALLATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ORIFICE INSTALLATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TXV INSTALLATIONS   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EVACUATION  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM CHARGE   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

ELECTRICAL CONNECTIONS  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  7
SYSTEM START-UP  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10
INSTRUCTING THE OWNER   . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  12
WIRING DIAGRAM   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  13
START UP SHEET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18

LIST OF FIGURES

Typical Installation with Required Clearances  . . . . . . . . . . . . . . . . . . . 2
Tubing Hanger  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Underground Installation   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Heat Protection   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Orifice Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Outdoor Unit Control Box - Single Phase . . . . . . . . . . . . . . . . . . . . . . . 7
Outdoor Unit Control Box - Three Phase  . . . . . . . . . . . . . . . . . . . . . . . 7
Typical Field Wiring (Air Handler / Electrical Heat) - (Three Phase)   . . 8
Typical Field Wiring (Air Handler / Electrical Heat) (Single-Phase)  . . . 8

Heat Pump Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  9
Time/Temp Control Module   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10
Demand Defrost Control Module   . . . . . . . . . . . . . . . . . . . . . . . . . . .  10
Defrost Operation Curves  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  12
Wiring Diagram - Single Phase (Demand Defrost)  . . . . . . . . . . . . . .  13
Wiring Diagram - Single Phase (Time-Temp) . . . . . . . . . . . . . . . . . .  14
Wiring Diagram - Three Phase (Demand Defrost)  . . . . . . . . . . . . . .  15
Wiring Diagram - Three Phase (Time-Temp)  . . . . . . . . . . . . . . . . . .  16

LIST OF TABLES

R-410A Saturation Properties   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TEST Input Functionality  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

X/L Output Categories   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10
Defrost Initiate Curves   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  11

SECTION I: GENERAL

The outdoor units are designed to be connected to a matching indoor
coil with sweat connect lines. Sweat connect units are factory charged
with refrigerant for a matching indoor coil plus 15 feet of field supplied
lines.

Matching indoor coils are available with a thermal expansion valve or
an orifice liquid feed sized for the most common usage. The orifice size
and/or refrigerant charge may need to be changed for some indoor-out-
door unit combinations, elevation differences, or total line lengths. Refer
to Application Data covering “General Piping Recommendations and
Refrigerant Line Length” (Part Number 247077).

SECTION II: SAFETY

This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.

Understand and pay particular attention to the signal words 

DANGER

,

WARNING

, or 

CAUTION

.

DANGER 

indicates an 

imminently

 hazardous situation, which, if not

avoided, 

will result in death or serious injury

.

WARNING 

indicates a 

potentially

 hazardous situation, which, if not

avoided, 

could result in death or serious injury

.

CAUTION 

indicates a potentially hazardous situation, which, if not

avoided 

may result in minor or moderate injury

. It is also used to

alert against unsafe practices and hazards involving only property dam-
age.

INSPECTION

As soon as a unit is received, it should be inspected for possible dam-
age during transit. If damage is evident, the extent of the damage
should be noted on the carrier’s delivery receipt. A separate request for
inspection by the carrier’s agent should be made in writing. See Local
Distributor for more information.

Improper installation may create a condition where the operation of
the product could cause personal injury or property damage.
Improper installation, adjustment, alteration, service, or maintenance
can cause injury or property damage. Refer to this manual for assis-
tance or for additional information, consult a qualified contractor,
installer, or service agency.

This product must be installed in strict compliance with the enclosed
installation instructions and any applicable local, state, and national
codes including, but not limited to building, electrical, and mechanical
codes.

Summary of Contents for THGD Series

Page 1: ...nt charge may need to be changed for some indoor out door unit combinations elevation differences or total line lengths Refer to Application Data covering General Piping Recommendations and Refrigerant Line Length Part Number 247077 SECTION II SAFETY This is a safety alert symbol When you see this symbol on labels or in manuals be alert to the potential for personal injury Understand and pay parti...

Page 2: ... to insure proper system operation and performance Line set change out is also recommended 1 Change out of the indoor coil to an approved R 410A coil condens ing unit combination with the appropriate metering device 2 Change out of the line set when replacing an R 22 unit with an R410 A unit is highly recommended to reduce cross contamination of oils and refrigerants 3 If change out of the line se...

Page 3: ...s necessary If soft copper must be used care must be taken to avoid sharp bends which may cause a restriction 2 The lines should be installed so that they will not obstruct service access to the coil air handling system or filter 3 Care must also be taken to isolate the refrigerant lines to minimize noise transmission from the equipment to the structure 4 The vapor line must be insulated with a mi...

Page 4: ...erant piping connections including the service port flare caps to be sure they are leak tight DO NOT OVERTIGHTEN between 40 and 60 inch lbs maximum 9 Evacuate the vapor line evaporator and the liquid line to 500 microns or less 10 Replace cap on service ports Do not remove the flare caps from the service ports except when necessary for servicing the system 11 Release the refrigerant charge into th...

Page 5: ...r line as follows a Hand tighten the 1 4 SAE nut to the Schrader fitting and an additional 1 3 turn to seal 7 Install the TXV bulb to the vapor line near the equalizer line using the bulb clamp s furnished with the TXV assembly Ensure the bulb is making maximum contact a Bulb should be installed on a horizontal run of the vapor line if possible On lines under 7 8 O D the bulb may be installed on t...

Page 6: ...Determine indoor coil adjustment if any from Tabular Data Sheet 3 Calculate the additional charge for lineset using the Tabular Data Sheet if line length is greater than 15 feet 4 6 m 4 Total system charge item 1 item 2 item 3 5 Permanently mark the unit data plate with the total amount of refrig erant in the system Using the charging charts The unit includes heating charging charts and cooling ch...

Page 7: ...out 5 ft above the floor where it will be exposed to normal room air circulation Do not place it on an outside wall or where it is exposed to the radiant effect from exposed glass or appliances drafts from outside doors or supply air grilles 6 Route the 24 volt control wiring NEC Class 2 from the outdoor unit to the indoor unit and thermostat Refrigerant charging should only be carried out by a qu...

Page 8: ...e airflow using the LED display on the CFM selection board FIGURE 8 Typical Field Wiring Air Handler Electrical Heat Three Phase FIGURE 9 Typical Field Wiring Air Handler Electrical Heat Single Phase THERMOSTAT INDOOR UNIT OUTDOOR UNIT LOW VOLTAGE TERMINAL BLOCK IN AIR HANDLER WITH ELECTRIC HEAT 3 4 DEFROST CONTROL 1 FIELD INSTALLED JUMPER GND SCREW CONTACTOR T2 T1 L2 L1 M R Y O W G T2 E 2 R R Y Y...

Page 9: ...hermostat demand to provide cooling as needed An attempt to start the compressor without at least 8 hours of crank case heat will damage the compressor TABLE 1 R 410A Saturation Properties Temp F Pressure PSIG Temp F Pressure PSIG Temp F Pressure PSIG Temp F Pressure PSIG Temp F Pressure PSIG 45 130 60 170 75 217 90 274 105 341 46 132 61 173 76 221 91 278 106 345 47 135 62 176 77 224 92 282 107 35...

Page 10: ...cause of a pressure switch lockout it will energize the X L output as shown in Table 3 The control has a three second delay between fault code flashes If the conditions above exist during cooling mode the system could be in the loss of charge condition DEFROST OPERATION Time Temperature Defrost 13 Seer 2 5 Ton The defrost control is a time temp control which includes a field select able tap locate...

Page 11: ...le Initiation The control will allow the heat pump to operate in the heating mode until the combination of outdoor ambient and outdoor coil temperatures indi cate that a defrost cycle is necessary The control will initiate a defrost cycle when the liquid line temperature is below the initiate point for the measured ambient temperature See Figure 13 continuously for 4 1 2 minutes This delay elimina...

Page 12: ...ollowing removal of the fault condition 1 Power is cycled to the R or Y inputs of the control This will cause the soft lockout condition to be reset when the thermostat is satisfied or when the thermostat is set to SYSTEM OFF and back to HEAT or COOL mode 2 The TEST terminals are shorted for more than two seconds When the soft lockout condition is reset the control will stop displaying the fault c...

Page 13: ...835961 UIM D 0213 Johnson Controls Unitary Products 13 SECTION VII WIRING DIAGRAM FIGURE 14 Wiring Diagram Single Phase Demand Defrost ...

Page 14: ...ANGE PNK PINK PUR PURPLE RED RED WHT WHITE YEL YELLOW BLK BLK BRN PNK YEL PNK HPS HTS LPS BRN PNK YEL PNK YEL PNK SEE UNIT INSTALLATION INSTRUCTIONS FOR LOW VOLTAGE TERMINATIONS COND FAN X L PUR RED DEFROST CONTROL BLK WHT BRN BLK REV VALVE YEL ORG RV R C Y O W W1 66 PRES SWITCH DFST T STAT M BRN PNK YEL PNK BLK GRY LS BLU DANGER SHOCK HAZARD TURN OFF ELECTRICAL POWER BEFORE SERVICING TO PREVENT P...

Page 15: ...OMPONENTS SHOWN IN DASH LINES ARE OPTIONAL WIRING MUST CONFORM TO NATIONAL AND LOCAL CODES IF ANY OF THE ORIGINAL WIRE SUPPLIED WITH THIS UNIT MUST BE REPLACED IT MUST BE REPLACED WITH 105 C THERMOPLASTIC OR ITS EQUIVALENT WHERE POWER SUPPLY HAS ONE 1 240 VOLT CONDUCTOR AND ONE 1 NEUTRAL CONDUCTOR CONNECT L2 OF CONTACTOR TO NEUTRAL FAN RELAY AND WIRES LABELED 460V ONLY USED ON 380 415V OR 460V 1 2...

Page 16: ... BLK 208 230 BRN PNK YEL PNK HPS HTS LPS BRN PNK YEL PNK YEL PNK SEE UNIT INSTALLATION INSTRUCTIONS FOR LOW VOLTAGE TERMINATIONS COND FAN X L PUR RED DEFROST CONTROL BLK WHT BRN BLK REV VALVE YEL ORG RV R C Y O W W1 66 PRESS SWITCH DFST T STAT M BRN PNK GRY BLK YEL 460V BLK 460V LS BLU DANGER SHOCK HAZARD TURN OFF ELECTRICAL POWER BEFORE SERVICING TO PREVENT POSSIBLE DAMAGE TO THE EQUIPMENT AND PO...

Page 17: ...835961 UIM D 0213 Johnson Controls Unitary Products 17 NOTES ...

Page 18: ...pplicable Electrical Line Voltage Outdoor Unit Model Outdoor Unit Serial Filter Thermostat Accessories Filter Location s Connections Per Installation Instructions and Local Codes Gas piping is connected if applicable Supply plenum and return ducts are connected and sealed Filter Size Vent system is connected if applicable Thermostat wiring complete Heat anticipator is set to the recommended value ...

Page 19: ...mp Cut Out Balance Point Defrost Curve Y2 Lock FFUEL Switch Point Hot Heat Pump Fill in the information ie ON OFF or the appropriate Value for the fields that apply to the defrost control board installed Run Time Time and Temperature board only 30 60 or 90 minutes Bonnet Sensor Present HEAT Refrigerant Charge and Metering Device TXV Fixed Orifice R 22 R 410A Oz 45s Elbows TXV Orifice Size Liquid L...

Page 20: ...edes 835961 UIM C 0712 York International Corp 5005 York Drive Norman OK 73069 Explain operation of system to equipment owner Explain the importance of regular filter replacement and equipment maintenance Owner Education Provide owner with the owner s manual Explain thermostat use and programming if applicable to owner Comments Section ...

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