Johnson Controls TCE2 Series User manual

Johnson Controls Ducted Systems

Installation Manual: R-410A Outdoor Split-

System Air Conditioner

YC2E, TCE2 and RAC143 Series

York International Corporation, 5005 York

Drive, Norman, OK 73069

2023-11-01

6158110-UIM-B-1123

Supersedes: 6158110-UIM-A-0122

2 Installation Manual: R-410A Outdoor Split-System Air Conditioner

Johnson Controls Ducted Systems

Contents

ContentsGeneral......................................................................................5

Certification.............................................................................. 5

Safety.........................................................................................5

Inspection........................................................................... 5

Limitations.......................................................................... 5

Unit installation........................................................................ 6

Location...............................................................................6

Liquid line filter-drier.........................................................7

Installing the filter-drier at outdoor unit...................7

Installing the filter-drier at indoor coil...................... 8

Piping connections.............................................................8

Precautions during line installation.................................8

Precautions during brazing of lines.................................9

Precautions during brazing of service valve...................9

Connecting the refrigerant lines................................ 9

Coil metering devices............................................................ 11

Installing a thermostatic expansion valve (TXV).......... 11

Evacuation...............................................................................12

System charge........................................................................12

Measuring indoor airflow............................................... 12

Charging the system........................................................13

Subcooling charging - TXV indoor................................. 14

R-410A saturation properties..........................................15

Optional cold weather charging.................................... 15

............................................................................................15

Electrical connections............................................................15

General information and grounding............................. 15

Field connections power wiring..................................... 16

Field connections control wiring....................................17

Field wiring..................................................................17

Instructing the user...............................................................18

Maintenance.....................................................................18

............................................................................................18

Wiring diagrams.....................................................................19

Start-up sheet.........................................................................20

Johnson Controls Ducted Systems

Installation Manual: R-410A Outdoor Split-System Air Conditioner 3

4 Installation Manual: R-410A Outdoor Split-System Air Conditioner

Johnson Controls Ducted Systems

General

Read all sections of this manual and keep the manual for

future reference.

These outdoor condensing units are designed to be

connected to a matching indoor coil. They are shipped

with a filter-drier that must be installed in the liquid line.

Units with quick-connect coupling connections are

factory-charged with refrigerant to be matched with the

appropriate pre-charged refrigeration piping and indoor

coil.

Certification

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 damage.

WARNING

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 assistance.

For additional information, consult a qualified installer

or service agency.

CAUTION

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.

CAUTION

R-410A systems operate at higher pressures than

R-22 systems. Do not use R-22 service equipment

or components on R-410A equipment. Service

equipment must be rated for R-410A.

Inspection

As soon as a unit is received, inspect it for possible

damage during transit. If damage is evident, note the

extent of the damage on the carrier’s delivery receipt.

A separate request for inspection by the carrier’s agent

must be made in writing. Contact your Local Distributor

for more information.

Requirements for installing or servicing R-410A

equipment

• Gauge sets, hoses, refrigerant containers, and the

recovery system must be designed to handle the POE

type oils and the higher pressures of R-410A.

• Manifold sets must be high side and low side with low

side retard.

• All hoses must have a 700 psig service pressure rating.

• Leak detectors must be designed to detect HFC

refrigerant.

• Recovery equipment, including refrigerant recovery

containers, must be specifically designed to handle

R-410A.

• Do not use an R-22 TXV.

Limitations

You must install the unit in accordance with all national,

state, and local safety codes, and the following limitations:

• Limitations for the indoor unit, coil, and appropriate

accessories must also be observed.

• The outdoor unit must not be installed with any

duct work in the air stream. The outdoor fan is the

propeller type and is not designed to operate against

any additional external static pressure.

• The maximum and minimum conditions for operation

must be observed to ensure a system that gives

maximum performance with minimum service.

Installation Manual: R-410A Outdoor Split-System Air Conditioner 5

Johnson Controls Ducted Systems

Table 1: Application limitations

Ambient air temperature on outdoor coil (°F) Air temperature on indoor coil (°F)

Model Minimum DB Maximum DB Minimum DB Maximum DB

YC2E/TCE2B/RAC143 55 125 57 72

• The unit must not be operated at outdoor

temperatures below 55°F without an approved low

ambient operation accessory kit installed.

• The maximum allowable line length for this product

is 80 ft. To install more than the maximum allowable

line length, consult the Piping Application Guide (P/N

247077).

Unit installation

Location

Before starting the installation, select and check the

suitability of the location for both the indoor and outdoor

unit. Observe all limitations and clearance requirements.

The outdoor unit must have sufficient clearance for air

entrance to the condenser coil, air discharge, and service

access. See Figure 1 and Figure 2.

NOTICE

For multiple unit installations, units must be spaced a

minimum of 24 in. (61 cm) apart (coil face to coil face).

If installing the unit on a hot sun-exposed roof or a paved

ground area that is seasonally hot, the unit must be raised

sufficiently above the roof or ground to avoid taking the

accumulated layer of hot air into the outdoor unit.

If installing the system during seasonally cold weather

of 55°F or below, weigh in the charge. For charging or

checking the system charge at 55°F or below, see the

Optional cold weather charging procedures near the

end of the System charge section. There is an optional

cold weather charging accessory kit to prevent the

outdoor unit from taking in cold air below 55°F. The kit

part number can be found in the list of accessory kits at

www.simplygettingthejobdone.com.

Provide adequate structural support for the unit.

Figure 1: Typical installation clearances

Installation Manual: R-410A Outdoor Split-System Air Conditioner6

Johnson Controls Ducted Systems

Figure 2: Alternative installation clearances

Liquid line filter-drier

The filter-drier is packaged and shipped along with the

outdoor unit. It is located outside the unit next to the

service valves.

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 desired.

CAUTION

Using a granular type drier may result in damage to

the equipment.

CAUTION

Filter-drier must be wrapped in wet rag while brazing.

Filter-drier Source 1 part S1-401021 applies to all AC

models.

Installing the filter-drier at outdoor unit

About this task:

Complete the following steps and see Figure 3 to install a

filter-drier at the outdoor unit:

1. Connect low pressure nitrogen to the liquid line

service port.

2. Insert a short piece of 3/8 in. tubing into the liquid

line service valve piping connection. Install filter

drier (direction arrow toward indoor coil) on the

short piece of tubing and insert the liquid line

going to the indoor coil into the opposite end of

the filter drier.

3. Wrap a wet rag around the liquid line base valve

and filter drier.

4. Braze the liquid line connections.

Installation Manual: R-410A Outdoor Split-System Air Conditioner 7

Johnson Controls Ducted Systems

Figure 3: Liquid line filter-drier installation at outdoor

unit

Installing the filter-drier at indoor coil

About this task:

Complete the following steps and see Figure 4 to install a

filter-drier at the indoor coil:

1. Connect low pressure nitrogen to the liquid line

indoor coil.

2. Insert a short piece of 3/8 in. tubing into the liquid

line indoor coil. Install filter drier (direction arrow

toward indoor coil) on the short piece of tubing

and insert the liquid line going to the indoor coil

into the opposite end of the filter drier.

3. Wrap a wet rag around the filter drier.

4. Braze the liquid line connections.

Figure 4: Liquid line filter-drier installation at indoor

coil

Piping connections

The outdoor condensing unit must be connected to the

indoor evaporator coil using field-supplied refrigerant

grade (ACR) copper tubing that is internally clean and

dry. Units must be installed only with the tubing sizes for

approved system combinations as specified in the Tabular

Data Sheet. The charge given is applicable for total tubing

lengths up to 15 ft (4.6 m). Refer to the Piping Application

Guide (P/N 24077) for installing tubing of longer lengths

and elevation differences.

NOTICE

Using a larger than specified line size could result

in oil return problems. Using too small a line results

in loss of capacity and other problems caused by

insufficient refrigerant flow. Slope horizontal vapor

lines at least 1 in. (2.5 cm) every 20 ft (6.1 m) toward

the outdoor unit to facilitate adequate oil return. If

more than the 80 ft line length is necessary, facilitate

correct refrigerant velocity with adjusted line diameter

in accordance with the Piping Application Guide (P/N

24077).

CAUTION

This system uses R-410A refrigerant, which operates

at higher pressures than R-22. No other refrigerant

may be used in this system. Gauge sets, hoses,

refrigerant containers, and the recovery system must

be designed to handle R-410A. If you are unsure,

consult the equipment manufacturer.

WARNING

Never install a suction-line filter-drier in the liquid line

of an R-410A system. Failure to follow this warning

can cause a fire, injury or death.

Precautions during line installation

• Install the lines with as few bends as possible. Be

careful not to damage the couplings or kink the

tubing. Use clean hard drawn copper tubing where no

appreciable amount of bending around obstruction is

necessary. If soft copper must be used, be careful to

avoid sharp bends, which may cause a restriction.

• Install the lines so that they do not obstruct service

access to the coil, air handling system, or filter.

Installation Manual: R-410A Outdoor Split-System Air Conditioner8

Johnson Controls Ducted Systems

• Isolate the refrigerant lines to minimize noise

transmission from the equipment to the structure.

• Insulate the vapor line with a minimum of 3/8 in.

foam rubber insulation (Armaflex or equivalent).

Also insulate liquid lines that are exposed to direct

sunlight, high temperatures, or excessive humidity.

• Tape and suspend the refrigerant lines as shown in

Figure 5. Do not allow tube metal-to-metal contact.

• Use PVC piping as a conduit for all underground

installations as shown in Figure 6. Keep buried lines

as short as possible to minimize the build up of liquid

refrigerant in the vapor line during long periods of

shutdown.

Figure 5: Installation of vapor line

Figure 6: Underground installation

• Pack fiberglass insulation and a sealing material such

as permagum around refrigerant lines where they

penetrate a wall to reduce vibration and to retain

some flexibility.

• For systems with total line length exceeding 75 ft

(22.86 m), refer to the Piping Application Guide (P/

N 24077) for vapor and liquid line sizing, calibration

of liquid line pressure loss or gain, determination

of vapor line velocity, elevation limitations, TXV

connections, system charging or traps.

Precautions during brazing of lines

All outdoor unit and indoor coil connections are copper-

to-copper and must 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 provided to evacuate and

charge per this instruction.

Serious service problems can be avoided by taking

adequate precautions to assure an internally clean and

dry system.

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 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 necessary to displace air and prevent

oxidation.

Precautions during brazing of service

valve

WARNING

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.

Precautions must be taken to prevent heat damage to

service valve by wrapping a wet rag around it as shown in

Figure 7. Protect all painted surfaces, insulation, and the

plastic base during brazing. After brazing, cool the joint

with a wet rag.

Open the valve by removing the service valve cap, fully

inserting a hex wrench into the stem, and backing out

counterclockwise until the valve stem just touches the

chamfered retaining wall.

Connecting the refrigerant lines

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.

Installation Manual: R-410A Outdoor Split-System Air Conditioner 9

Johnson Controls Ducted Systems

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.

3. Carefully remove the plugs from the indoor coil

liquid and vapor connections at the indoor coil.

Figure 7: Heat protection

CAUTION

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 pressure which must be released

to prevent excessive pressure build-up and

possible coil damage.

4. Braze the liquid line to the indoor coil liquid

connection. Nitrogen must be flowing through the

indoor coil.

5. Slide the grommet away from the vapor connection

at the indoor coil. Braze the vapor line to the

indoor coil vapor connection. After the connection

has cooled, slide the grommet back into original

position.

6. Protect the vapor valve with a wet rag and braze

the vapor line connection to the outdoor unit. The

nitrogen flow must be exiting the system from the

vapor service port connection. After this connection

cools, remove the nitrogen source from the liquid

fitting service port.

7. Replace the Schrader core in the liquid and vapor

valves.

8. Go to the section for TXV installation.

9. Leak test all refrigerant piping connections,

including the service port flare caps, to be sure they

are leak tight. Do not over-tighten (between 40 in.

lb and 60 in. lb maximum).

NOTICE

Line set and indoor coil can be pressurized

to 250 psig with dry nitrogen 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.

10. Evacuate the vapor line, indoor coil, and liquid line

to 500 microns or less.

11. Replace cap on service ports. Do not remove the

flare caps from the service ports except when

necessary for servicing the system.

CAUTION

Do not connect manifold gauges unless

trouble is suspected. Approximately 3/4 oz

of refrigerant is lost each time a standard

manifold gauge is connected.

12. Release the refrigerant charge into the system

by opening the liquid line valve first. After a few

minutes, the suction line valve may be opened.

Open both the liquid and vapor valves by removing

the plunger cap and with an hex wrench, back out

counterclockwise until the valve stem just touches

the chamfered retaining wall. If the service valve

is a ball valve, use a adjustable wrench to turn the

valve stem 1/4 turn counterclockwise to open.

Do not overturn or the valve stem may break or

become damaged. See Precautions during brazing

of service valve.

13. Replace the plunger cap finger tight, then tighten

an additional 1/12 turn (1/2 hex flat). The cap must

be replaced to prevent leaks.

WARNING

Never attempt to repair any brazed

connections while the system is under

pressure. Personal injury could result.

Installation Manual: R-410A Outdoor Split-System Air Conditioner10

Johnson Controls Ducted Systems

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