835961-UIM-D-0213
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Johnson Controls Unitary Products
PRECAUTIONS DURING BRAZING OF LINES
All outdoor unit and evaporator coil connections are copper-to-copper
and should be brazed with a phosphorous-copper alloy material such
as Silfos-5 or equivalent. DO NOT use soft solder. The outdoor units
have reusable service valves on both the liquid and vapor connections.
The total system refrigerant charge is retained within the outdoor unit
during shipping and installation. The reusable service valves are pro-
vided to evacuate and charge per this instruction.
Serious service problems can be avoided by taking adequate precau-
tions to assure an internally clean and dry system.
PRECAUTIONS DURING BRAZING SERVICE VALVE
Precautions should be taken to prevent heat damage to service valve
by wrapping a wet rag around it as shown in Figure 4. Also, protect all
painted surfaces, insulation, and plastic base during brazing. After braz-
ing cool joint with wet rag.
Valve can be opened by removing the plunger cap and fully inserting a
hex wrench into the stem and backing out counter-clockwise until valve
stem just touches the chamfered retaining wall.
Connect the refrigerant lines using the following procedure:
1. Remove the cap and Schrader core from both the liquid and vapor
service valve service ports at the outdoor unit. Connect low pressure
nitrogen to the liquid line service port.
2. Braze the liquid line to the liquid valve at the outdoor unit. Be sure to
wrap the valve body with a wet rag. Allow the nitrogen to continue
flowing. Refer to the Tabular Data Sheet for proper liquid line sizing.
3. Go to “SECTION IV” or “SECTION V” for orifice or TXV Installation
depending on application.
4. Braze the liquid line to the evaporator liquid connection. Nitrogen
should be flowing through the evaporator coil.
5. Slide the grommet away from the vapor connection at the indoor coil.
Braze the vapor line to the evaporator vapor connection. After the
connection has cooled, slide the grommet back into original position.
Refer to the Tabular Data Sheet for proper vapor line sizing.
6. Protect the vapor valve with a wet rag and braze the vapor line con-
nection to the outdoor unit. The nitrogen flow should be exiting the
system from the vapor service port connection. After this connection
has cooled, remove the nitrogen source from the liquid fitting service
port.
7. Replace the Schrader core in the liquid and vapor valves.
8. Leak test all refrigerant 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 the system. Open both the liquid
and vapor valves by removing the plunger cap and with an allen
wrench back out counter-clockwise until valve stem just touches the
chamfered retaining wall. If the service valve is a ball valve, use a
cresent wrench to turn valve stem one-quarter turn counterclockwise
to open. Do not overturn or the valve stem may break or become
damaged. See “PRECAUTIONS DURING BRAZING SERVICE
VALVE”.
12.Replace plunger cap finger tight, then tighten an additional 1/12 turn
(1/2 hex flat). Cap must be replaced to prevent leaks.
See "System Charge” section for checking and recording system
charge.
Dry nitrogen should always be supplied through the tubing while it is
being brazed, because the temperature is high enough to cause oxi-
dation of the copper unless an inert atmosphere is provided. The flow
of dry nitrogen should continue 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 flow is neces-
sary to displace air and prevent oxidation.
This is not a backseating valve. The service access port has a valve
core. Opening or closing valve does not close service access port.
If the valve stem is backed out past the chamfered retaining wall, the
O-ring can be damaged causing leakage or system pressure could
force the valve stem out of the valve body possibly causing personal
injury.
FIGURE 4:
Heat Protection
Do not install any coil in a furnace which is to be operated during the
heating season without attaching the refrigerant lines to the coil. The
coil is under 30 to 35 psig inert gas pressure which must be released
to prevent excessive pressure build-up and possible coil damage.
Line set and indoor coil can be pressurized to 250 psig with dry nitro-
gen and leak tested with a bubble type leak detector. Then release
the nitrogen charge.
Do not use the system refrigerant in the outdoor unit to purge or leak
test.
Do not connect manifold gauges unless trouble is suspected. Approx-
imately 3/4 ounce of refrigerant will be lost each time a standard man-
ifold gauge is connected.
Never attempt to repair any brazed connections while the system is
under pressure. Personal injury could result.
NOTICE
