Johnson Controls PC090 THRU 240, PD 180 THRU 240 dimensions Start Installation

430645-YIM-D-0610

Always punch a small hole in sealing disks before unbrazing to prevent the pressure in the line from blowing them off. Do not use a drill as copper shavings can enter system.

NOTE: Solenoid and hot gas bypass valves (if used) should be opened manually or electrically during brazing or evacuating.

NOTE: Schrader valves located on unit service valves should have their stems removed during brazing to prevent damage to the valve and reduce system evacuation time.

Start Installation

Start the installation of main lines at the heat pump. Verify holding charge in unit by cracking open valve. If pressure is present, close valve and proceed with installation. If no pressure is present, check system for leaks.

Verify all service valves are fully seated by screwing the stems of both valves down into the valve bodies until they stop. Remove the Schrader valve stem and connect a low-pressure nitrogen source to the service port on the suction line valve body. Punch a small hole in the sealing disk; the flow of nitrogen will prevent any debris from entering the system. Wrap the valve body with a wet rag to prevent overheating during the brazing process. Overheating the valve will damage the valve seals. Unbraze the sealing disk, cool the valve body and prepare the joint for connections of the main lines. Repeat for the liquid line valve body.

Never remove a cap from an access port unless the valve is fully back-seated with its valve stem in the maximum counter-clockwise position because the refrigerant charge will be lost. Always use a refrigeration valve wrench to open and close these service valves.

Connect the main liquid line to the liquid line service valve connection, while maintaining a flow of nitrogen. Cool the valve body and replace the Schrader valve stem in the service port.

Install the liquid line from the heat pump to the evaporator liquid connection, maintaining a flow of nitrogen during all brazing operations.

The filter-drier and sight glass must be located in the liquid line, leaving the O.D. unit.

Connect a low-pressure nitrogen source to the Schrader valve located on the evaporator section coil headers. Punch a small hole in the sealing disks, the flow of nitrogen will prevent any debris from entering the system. Unbraze both liquid and

suction sealing disks and prepare the joints for connections of the main lines.

Connect the main liquid line to the liquid line connection on the evaporator section, while maintaining a flow of nitrogen.

Make the suction line connection at the evaporator and run the line to the heat pump. Connect the main suction line to the suction line service valve connection, while maintaining a flow of nitrogen. Cool the valve body and replace the Schrader valve stem in the service port.

Once the brazing process is complete, leak testing should be done on all interconnecting piping and the evaporator before proper evacuation to below 500 microns is performed.

Verify evacuation with micron guage or thermocouple. Once the line set and evaporator section is properly evacuated, the service valves can be opened and the heat pump is now ready to charge with the appropriate weight of refrigerant. Calculate the correct system charge for the outdoor unit, the indoor unit and the field line set.

Charge the system by introducing liquid refrigerant into the liquid line through the liquid port connection. Complete adding the refrigerant in vapor form into the suction port when the compressor is started.

The correct refrigerant pressures are indicated as shown in Figures 11 thru 16.

This system uses R-410A Refrigerant which operates at higher pressures than R-22. No other refrigerant may be used in this system. Gage sets, hoses, refrigerant containers and recovery systems must be designed to handle R-410A. If you are unsure, consult the equipment manufacturer. Failure to use R-410A compatible servicing equipment may result in property damage or injury.

Wear safety glasses and gloves when handling refrigerants. Failure to follow this warning can cause serious personal injury.

NOTE: This instruction covers the installation and operation of the basic heat pump. For refrigerant piping installation instructions refer to document 247077 "Application Data - General Piping Recommendations for Split System Air Conditioning and Heat Pumps".

Johnson Controls Unitary Products 11