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18510 Newport Dr_BLD6085_2025
Permit Packet Coversheet Community and Economic Development City of Arlington • 18204 59th Avenue NE • Arlington, WA 98223 • Phone (360) 403-3551 Permit Number: BLD6085 Permit Type: Residential Mechanical Address: 18510 Newport Dr Completed (Month/Year): November 2024 Land Use Bonding or Assignment of Funds Issued Permit o Confidential Documents. Contact the Application City to obtain. Narrative As-Builts Legal Description Letters and Project Documents Vicinity Map Other: Site Plan Landscape Plan Civil Complete Streets Checklist Issued Permit Traffic Impact Analysis Application Snohomish County Traffic Mitigation Offer Other Applications WSDOT Traffic Offer Form Construction Calculation Worksheet Tree Survey Approved Plans Stormwater Drainage Report Review Comment Form Geotech Report Letters and Project Documents Critical Area Evaluation Form Other Agency Permits SEPA Checklist Reports: Public Notice Material o Drainage Report Pg: Water / Sewer Availability Certificate o Stormwater Pg: Unanticipated Discovery Plan Form o Geotech Pg: Aerial Photo of Site o All Other Reports Proposed Building Materials SEPA and Noticing Materials Lighting Plans and Lighting Cut Sheets As-Builts Color Elevations Other: Plat Map Title Report Building Lot Closures ✔ Issued Permit Preliminary Civil Plans ✔ Application Archaeological Survey Additional Applications o Confidential Documents. Contact the ✔ Approved Plans City to obtain. ✔ Letters and Project Documents Topography (Existing Conditions) Calculations CC&R’s ✔ Project Specification Manuals Deeds / Easements / Conveyances Reports /Dedications Certificate of Occupancy Letters and Project Documents Other: Page 1 of 1 RESIDENTIAL MECHANICAL APPLICATION Community and Economic Development City of Arlington • 18204 59th Ave NE • Arlington, WA 98223 • Phone (360) 403-3551 This application is for new, addition, altered or replaced mechanical installation and new or altered gas piping. Please fill out all pages of this application and include all information. Type of Permit: ï² New Installation ï² Addition/Alteration/Repair ï² Gas Piping Property Address: Project Valuation: Lot #: Parcel ID No.: Preferred Contact: ï² Owner ï² Contractor Project Description: Owner Name: Home No.: Email Address: Cell No.: Mailing Address: City: State: Zip: Contractor Name: Office No.: Email Address: Cell No.: Mailing Address: City: State: Zip: L&I Contractor License Number: Expiration Date: • New gas piping requires a pressure test hooking to any appliance • Sediment traps (drips) are required on all gas lines • Gas lines are required to be supported/secured every 6 to 8 feet • Proper Combustion air and venting required for all appliances • A shut-off valve is required within 6 feet of all appliances Gas Piping Information ï² Not Applicable ï² CSST ï²Brass ï²Other Proposed Piping Material: ï²Black Steel ï²Galvanized Steel _______________________________________ Proposed Piping Size: ï²Â½â€ ï² â…â€ ï² Â¾â€ ï² 1â€ ï² 1Â½â€ ï² 2†Distance from Meter to furthest Appliance: Total BTU’s of all Appliances: Residential mechanical permits will be assessed a base fee, fee per unit, and inspection fee (plan review per Table 4-8 may be required for certain permits) Type of Fixture No. of Cost per Unit Subtotal Model No. Units Additional Plan Review fees x $ 75.00 = Air Conditioning Unit ≤ 100 Btu/h x $ 15.00 = Air Conditioning Unit > 100 Btu/h x $ 25.00 = Air Conditioning Unit > 500 Btu/hp x $ 50.00 = Air Handling Units x $ 15.00 = Base Mechanical Fee 1 x $ 25.00 = $ 25.00 Boiler <100Btu/h >3hp x $ 15.00 = REV03.2022 Page 1 of 3 Residential mechanical permits will be assessed a base fee, fee per unit, and inspection fee (plan review per Table 4-8 may be required for certain permits) Boiler >1 million Btu/h<50hp x $ 25.00 = Boiler >1.5 million Btu/h<50hp x $ 50.00 = Boiler >100Btu/h 3-15hp x $ 15.00 = Boiler >500Btu/h 15-30hp x $ 25.00 = Commercial Hoods -Type I x $ 25.00 = Commercial Hoods -Type II x $50.00 = Diffusers x $ 15.00 = Dryer Ducting x $ 15.00 = Ductwork (drawings required) x $ 25.00 = Evaporative Coolers x $ 15.00 = Exhaust/Ventilation Fans x $ 15.00 = Fireplace/Insert/Stove x $ 15.00 = Forced Air Heat ≤100 Btu/h x $ 15.00 = Forced Air Heat >100 Btu/h x $ 25.00 = Gas Clothes Dryer x $ 15.00 = Gas Fired Air Conditioning Unit ≤ 100 Btu/h x $ 15.00 = Gas Fired Air Conditioning Unit > 100 Btu/h x $ 25.00 = Gas Fired Air Conditioning Unit > 500 Btu/hp x $ 50.00 = Gas Piping ≤ 5 units x $ 15.00 = Gas Piping for each additional unit > 5 x $ 2.00 = Heat Exchangers x $ 15.00 = Heat Pump-Condensing Unit x $ 25.00 = Hot Water Heat Coils x $ 15.00 = Miscellaneous Appliance - regulated by $ 15.00 x = mechanical code, not otherwise specified Package Units ≤ 100 Btu / > 100 Btu x $ 25.00/$50.00 = Range/Cook top-Gas Fired x $ 15.00 = Refrigeration Unit ≤100Btu/h x $ 15.00 = Refrigeration Unit >100Btu/h x $ 25.00 = Refrigeration. Unit >500Btu/h x $ 50.00 = Re-inspection fee x $ 75.00 = Residential Range Hood x $ 15.00 = Unit Heaters ≤ 100 Btu/h x $ 15.00 = Unit Heaters >100 Btu/h x $ 25.00 = Variable Air Volume Boxes (part of Air $ 10.00 x = Conditioning System) Wall Heaters - Gas Fired x $ 25.00 = Water Heater - Gas Fired x $ 25.00 = Permit Fee Inspection Fee $75.00 Processing/Technology Fee $25.00 Total I hereby certify that the above information is correct and that the construction on, and the occupancy and the use of the above described property will be in accordance with the laws, rules and regulation of the State of Washington. Signature Print Name Date REV2.2024 Page 2 of 3 PRESSURE PIPING SCHEMATIC COMPLETE FOR GAS PIPING ONLY ï² SCHEMATIC IS TO SCALE ï² SCHEMATIC NOT TO SCALE Show Pipe Size(s) and Length(s) from meter to all appliances NOTE: Any interior pressure regulators must be indicated REV2.2024 Page 3 of 3 Installation Manual: R-410A Outdoor Split- System Air Conditioner YC2D, TCD2, RAC134, YC2F, TCF2, and RAC150 Series York International Corporation, 5005 York 6136936-UIM-C-1123 Drive, Norman, OK 73069 Supersedes: 6136936-UIM-B-0523 C 2023-11-01 Johnson Controls Ducted Systems 2 Installation Manual: R-410A Outdoor Split-System Air Conditioner Johnson Controls Ducted Systems Contents General......................................................................................5 Certification..............................................................................5 Safety.........................................................................................5 Inspection...........................................................................5 Limitations..........................................................................5 ........................................................................................6 Unit installation........................................................................6 Location...............................................................................6 Liquid line filter-drier.........................................................8 Installing the filter-drier at outdoor unit...................8 Installing the filter-drier at indoor coil......................8 Piping connections.............................................................9 Precautions during line installation.................................9 Precautions during brazing of lines.................................9 Precautions during brazing of service valve.................10 Connecting the refrigerant lines..............................10 Coil metering devices............................................................11 Installing a thermostatic expansion valve (TXV)..........11 Evacuation...............................................................................13 System charge........................................................................13 Measuring indoor airflow...............................................13 Charging the system........................................................13 Subcooling charging - TXV indoor................................. 15 R-410A saturation properties..........................................15 Optional cold weather charging....................................16 ............................................................................................16 Electrical connections............................................................16 General information and grounding.............................16 Field connections power wiring.....................................17 Field connections control wiring....................................18 Field wiring..................................................................18 Instructing the user...............................................................19 Maintenance.....................................................................19 ............................................................................................19 Wiring diagrams.....................................................................20 Start-up sheet.........................................................................24 Installation Manual: R-410A Outdoor Split-System Air Conditioner 3 Johnson Controls Ducted Systems 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 CAUTION future reference. These outdoor condensing units are designed to be This product must be installed in strict compliance connected to a matching indoor coil. They are shipped with a filter-drier that must be installed in the liquid line. with the enclosed installation instructions and any applicable local, state, and national codes including Units with quick-connect coupling connections are but not limited to building, electrical, and mechanical factory-charged with refrigerant to be matched with the appropriate pre-charged refrigeration piping and indoor codes. coil. Certification 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 Safety for more information. Requirements for installing or servicing R-410A This is a safety alert symbol. When you see this equipment symbol on labels or in manuals, be alert to the potential for personal injury. • Gauge sets, hoses, refrigerant containers, and the Understand and pay particular attention to the signal recovery system must be designed to handle the POE words DANGER, WARNING, or CAUTION. type oils and the higher pressures of R-410A. DANGER indicates an imminently hazardous situation, • Manifold sets must be high side and low side with low which, if not avoided, will result in death or serious side retard. injury. • All hoses must have a 700 psig service pressure rating. WARNING indicates a potentially hazardous situation, which, if not avoided, could result in death or serious • Leak detectors must be designed to detect HFC injury. refrigerant. CAUTION indicates a potentially hazardous situation, • Recovery equipment, including refrigerant recovery which, if not avoided may result in minor or moderate containers, must be specifically designed to handle injury. It is also used to alert against unsafe practices and R-410A. hazards involving only property damage. • Do not use an R-22 TXV. Limitations WARNING You must install the unit in accordance with all national, state, and local safety codes, and the following limitations: Improper installation may create a condition where the • Limitations for the indoor unit, coil, and appropriate operation of the product could cause personal injury accessories must also be observed. or property damage. Improper installation, adjustment, • The outdoor unit must not be installed with any alteration, service, or maintenance can cause injury or duct work in the air stream. The outdoor fan is the property damage. Refer to this manual for assistance. propeller type and is not designed to operate against For additional information, consult a qualified installer any additional external static pressure. or service agency. • 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 • 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). Table 1: Application limitations Model Ambient air temperature on outdoor coil (°F) Air temperature on indoor coil (°F) Minimum DB Maximum DB Minimum DB Maximum DB YC2D/TCD2B/RAC134 55 115 57 72 YC2E/YC2F/TCE2B/ TCF2B/RAC143/ 55 125 57 72 RAC150/ TCD2B 3 phase Unit installation If installing the unit on a hot sun-exposed roof or a paved ground area that is seasonally hot, the unit must be raised Location sufficiently above the roof or ground to avoid taking the accumulated layer of hot air into the outdoor unit. Before starting the installation, select and check the If installing the system during seasonally cold weather suitability of the location for both the indoor and outdoor of 55°F or below, weigh in the charge. For charging or unit. Observe all limitations and clearance requirements. checking the system charge at 55°F or below, see the The outdoor unit must have sufficient clearance for air Optional cold weather charging procedures near the entrance to the condenser coil, air discharge, and service end of the System charge section. There is an optional access. See Figure 1 and Figure 2. 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 NOTICE www.simplygettingthejobdone.com. Provide adequate structural support for the unit. For multiple unit installations, units must be spaced a minimum of 24 in. (61 cm) apart (coil face to coil face). 6 Installation Manual: R-410A Outdoor Split-System Air Conditioner Johnson Controls Ducted Systems Figure 1: Typical installation clearances Figure 2: Alternative installation clearances Installation Manual: R-410A Outdoor Split-System Air Conditioner 7 Johnson Controls Ducted Systems Liquid line filter-drier Figure 3: Liquid line filter-drier installation at outdoor unit 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. 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: CAUTION 1. Connect low pressure nitrogen to the liquid line indoor coil. Filter-drier must be wrapped in wet rag while brazing. 2. Insert a short piece of 3/8 in. tubing into the liquid line indoor coil. Install filter drier (direction arrow Filter-drier Source 1 part S1-401021 applies to all AC toward indoor coil) on the short piece of tubing models. and insert the liquid line going to the indoor coil Installing the filter-drier at outdoor unit into the opposite end of the filter drier. 3. Wrap a wet rag around the filter drier. About this task: Complete the following steps and see Figure 3 to install a 4. Braze the liquid line connections. filter-drier at the outdoor unit: Figure 4: Liquid line filter-drier installation at indoor 1. Connect low pressure nitrogen to the liquid line coil 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. 8 Installation Manual: R-410A Outdoor Split-System Air Conditioner Johnson Controls Ducted Systems Piping connections • Isolate the refrigerant lines to minimize noise transmission from the equipment to the structure. The outdoor condensing unit must be connected to the indoor evaporator coil using field-supplied refrigerant • Insulate the vapor line with a minimum of 3/8 in. grade (ACR) copper tubing that is internally clean and foam rubber insulation (Armaflex or equivalent). dry. Units must be installed only with the tubing sizes for Also insulate liquid lines that are exposed to direct approved system combinations as specified in the Tabular sunlight, high temperatures, or excessive humidity. Data Sheet. The charge given is applicable for total tubing lengths up to 15 ft (4.6 m). Refer to the Piping Application • Tape and suspend the refrigerant lines as shown in Guide (P/N 24077) for installing tubing of longer lengths Figure 5. Do not allow tube metal-to-metal contact. and elevation differences. • Use PVC piping as a conduit for all underground installations as shown in Figure 6. Keep buried lines NOTICE as short as possible to minimize the build up of liquid refrigerant in the vapor line during long periods of shutdown. Using a larger than specified line size could result in oil return problems. Using too small a line results Figure 5: Installation of vapor line 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 Figure 6: Underground installation 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 • Pack fiberglass insulation and a sealing material such as permagum around refrigerant lines where they Never install a suction-line filter-drier in the liquid line penetrate a wall to reduce vibration and to retain of an R-410A system. Failure to follow this warning some flexibility. can cause a fire, injury or death. • For systems with total line length exceeding 75 ft (22.86 m), refer to the Piping Application Guide (P/ Precautions during line installation N 24077) for vapor and liquid line sizing, calibration • Install the lines with as few bends as possible. Be of liquid line pressure loss or gain, determination careful not to damage the couplings or kink the of vapor line velocity, elevation limitations, TXV tubing. Use clean hard drawn copper tubing where no connections, system charging or traps. appreciable amount of bending around obstruction is Precautions during brazing of lines necessary. If soft copper must be used, be careful to All outdoor unit and indoor coil connections are copper- avoid sharp bends, which may cause a restriction. to-copper and must be brazed with a phosphorous- • Install the lines so that they do not obstruct service copper alloy material such as Silfos-5 or equivalent. Do access to the coil, air handling system, or filter. 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 Installation Manual: R-410A Outdoor Split-System Air Conditioner 9 Johnson Controls Ducted Systems the outdoor unit during shipping and installation. The 2. Braze the liquid line to the liquid valve at the reusable service valves are provided to evacuate and outdoor unit. Be sure to wrap the valve body with a charge per this instruction. wet rag. Allow the nitrogen to continue flowing. Serious service problems can be avoided by taking 3. Carefully remove the plugs from the indoor coil adequate precautions to assure an internally clean and dry system. liquid and vapor connections at the indoor coil. Figure 7: Heat protection 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 CAUTION WARNING Do not install any coil in a furnace which is to This is not a backseating valve. The service access be operated during the heating season without port has a valve core. Opening or closing valve does attaching the refrigerant lines to the coil. The not close service access port. If the valve stem is coil is under pressure which must be released backed out past the chamfered retaining wall, the to prevent excessive pressure build-up and O-ring can be damaged causing leakage or system possible coil damage. pressure could force the valve stem out of the valve body possibly causing personal injury. 4. Braze the liquid line to the indoor coil liquid connection. Nitrogen must be flowing through the Precautions must be taken to prevent heat damage to service valve by wrapping a wet rag around it as shown in indoor coil. Figure 7. Protect all painted surfaces, insulation, and the 5. Slide the grommet away from the vapor connection plastic base during brazing. After brazing, cool the joint at the indoor coil. Braze the vapor line to the with a wet rag. indoor coil vapor connection. After the connection Open the valve by removing the service valve cap, fully has cooled, slide the grommet back into original inserting a hex wrench into the stem, and backing out counterclockwise until the valve stem just touches the position. chamfered retaining wall. 6. Protect the vapor valve with a wet rag and braze Connecting the refrigerant lines the vapor line connection to the outdoor unit. The nitrogen flow must be exiting the system from the Connect the refrigerant lines using the following vapor service port connection. After this connection procedure: cools, remove the nitrogen source from the liquid fitting service port. 1. Remove the cap and Schrader core from both the 7. Replace the Schrader core in the liquid and vapor liquid and vapor service valve service ports at the valves. outdoor unit. Connect low pressure nitrogen to the liquid line service port. 8. Go to the section for TXV installation. 10 Installation Manual: R-410A Outdoor Split-System Air Conditioner Johnson Controls Ducted Systems 9. Leak test all refrigerant piping connections, See System charge for checking and recording including the service port flare caps, to be sure they system charge. are leak tight. Do not over-tighten (between 40 in. Coil metering devices lb and 60 in. lb maximum). NOTICE CAUTION Line set and indoor coil can be pressurized COIL UNDER PRESSURE. Verify that pressure has to 250 psig with dry nitrogen and leak tested been released by depressing the Schrader valve with a bubble type leak detector. Then release core. The coil requires a metering device to be added. the nitrogen charge. Do not use the system Refer to the outdoor unit documentation for the correct refrigerant in the outdoor unit to purge or leak TXV or piston to be used. test. 10. Evacuate the vapor line, indoor coil, and liquid line NOTICE to 500 microns or less. 11. Replace cap on service ports. Do not remove the flare caps from the service ports except when To prevent moisture and contaminates from entering the system, the coil must not be open to atmosphere necessary for servicing the system. for extended periods of time. If the coil cannot be brazed into the refrigeration system during a routine installation period, the ends must be temporarily CAUTION closed or plugged. For a short term delay, use masking tape over the ends of the copper tubing to close the tube from the air. For a longer term delay, Do not connect manifold gauges unless use plugs or caps. There is no need to purge the coil if trouble is suspected. Approximately 3/4 oz this procedure is followed. of refrigerant is lost each time a standard manifold gauge is connected. 12. Release the refrigerant charge into the system Installing a thermostatic expansion by opening the liquid line valve first. After a few valve (TXV) 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 CAUTION 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 Outdoor unit model numbers ending with an H have a valve stem 1/4 turn counterclockwise to open. factory installed hard start kit which is required when a TXV kit is installed. Outdoor unit model numbers with Do not overturn or the valve stem may break or no H ending do not require a hard start kit unless local become damaged. See Precautions during brazing regulations dictate it. of service valve. 13. Replace the plunger cap finger tight, then tighten an additional 1/12 turn (1/2 hex flat). The cap must The following are basic steps for installing a TXV kit. For be replaced to prevent leaks. detailed instructions, refer to the Installation Manual provided with the TXV kit. Important: Refer to the Technical Guide or Tabular WARNING Data Sheet for the unit to determine the correct TXV kit to use on this product. Never attempt to repair any brazed 1. Relieve the holding charge by depressing the connections while the system is under Schrader valve core on the suction manifold stub pressure. Personal injury could result. out. Installation Manual: R-410A Outdoor Split-System Air Conditioner 11 Johnson Controls Ducted Systems 2. When the holding charge is completely discharged, 6. Install the TXV equalizer line onto the vapor line by loosen and remove the Schrader valve core. hand tightening the 1/4 in. SAE coupling nut to the 3. Place a backup wrench on the distributor, and equalizer fitting and apply an additional 1/3 turn to loosen and remove the brass distributor nut. Retain seal. See Figure 9. the brass nut for use on the liquid line. Keep the PTFE washer in place and discard the sealing disk. 4. Install the TXV onto the distributor assembly with CAUTION the supplied fittings. Ensure the PTFE washer is seated in the distributor. Hand tighten and turn an Mount the TXV temperature sensing bulb after additional 1/4 turn to seal. See Figure 8. the vapor line is brazed and sufficiently cooled. Note: Do not overtighten the fittings. Failure to use a suction-line split grommet may result in TXV failure. CAUTION 7. Route the temperature sensing bulb tube for the TXV toward the vapor line header and the TXV equalizer tube connection port on the vapor line Do not over-tighten. Do not use slip joint pliers. header. This distorts the aluminum distributor and the brass fitting (potentially causing leaks). 8. Install the TXV bulb to the vapor line near the TXV equalizer tube connection port, using the bulb clamps supplied with the TXV assembly. Ensure 5. Slide the nut removed in Step 3 over the supplied that the bulb makes maximum contact. See Figure liquid line. Place the supplied PTFE washer from 9 and Figure 10 and adhere to the following: the TXV kit in place on the TXV and install the liquid a. Install the TXV bulb on the vapor line suction line to the top of the TXV. Adjust the distributor header near the TXV equalizer tube connection assembly so the liquid line aligns with the hole in port. Ensure that the bulb is installed at a 10 the access panel. See Figure 8. Hand tighten the o’clock or 2 o’clock position. liquid line and apply an additional 1/4 turn to seal. b. Insulate the TXV bulb using the thermal insulation provided to protect it from the effect of the surrounding ambient temperature. Cover CAUTION the bulb completely to insulate it. 9. When the refrigeration piping is installed, leak test the system. The Schrader valve core must not be installed into the suction line TXV equalizer Figure 9: TXV bulb and equalizer line installation line fitting. Poor system performance or system failure could result. Figure 8: TXV installation 12 Installation Manual: R-410A Outdoor Split-System Air Conditioner Johnson Controls Ducted Systems Figure 10: Correct bulb location for TXV 3. Add the negative return static to the positive supply static to determine the system total static pressure. Treat the negative return static as a positive pressure (even though it is a negative reading). 4. If there is static pressure on the blower return (-0.1), add it to a supply static (0.4) which equals a (0.5) total system static pressure. 5. Compare this value to the table for the indoor unit's static pressure against CFM or to a curve chart. Charging the system NOTICE Evacuation For cold weather charging of the system at temperatures of 55°F or below, see the Optional cold It is necessary to evacuate the system to 500 microns or weather charging procedures near the end of this less. If a leak is suspected, leak test with dry nitrogen to section. locate the leak. Repair the leak and test again. To verify that the system has no leaks, close the valve to the vacuum pump suction to isolate the pump and hold the system under vacuum. Watch the micron gauge for a few minutes. If the micron gauge indicates a steady CAUTION and continuous rise, it is an indication of a leak. If the gauge shows a rise, then levels off after a few minutes and remains fairly constant, it is an indication that the R-410A refrigerant cylinders are rose-colored. Always system is leak free but still contains moisture and may charge the system slowly with liquid R-410 refrigerant. require further evacuation if the reading is above 500 microns. The factory charge in the outdoor unit includes enough System charge charge for the unit, 15 ft (4.6 m) of interconnecting To ensure that this system performs at the published refrigerant piping, and the smallest indoor coil match-up. levels, it is important that the indoor airflow is determined Some indoor coil matches may require additional charge. and refrigerant charge is added accordingly. Refer to the Tabular Data Sheet for charge requirements. Measuring indoor airflow About this task: To determine rated airflow for a specific CAUTION match, consult the technical literature at www.simplygettingthejobdone.com. When attempting to Do not leave the system open to the atmosphere. match this airflow, select the lowest possible speed tap, measure the actual airflow, and adjust as necessary. The total system charge must be permanently stamped To measure actual airflow, it is not an acceptable method on the unit dataplate. Complete the following steps to to just check the jumper pin setting tables and to assume 0.5 in. W.C. total external static pressure. determine the total system charge: To determine indoor airflow, complete the following 1. Determine the base charge shipped in the outdoor steps: unit by referring to the Tabular Data Sheet included with the outdoor unit. (item 1) 1. Measure the static pressure with a manometer between the filter and blower. 2. Determine the charge adder for the matched indoor unit by referring to the Tabular Data Sheet. 2. On a single-piece air handler, take a second (item 2) reading in the supply air duct outside of the unit. On a gas furnace, take the second reading after 3. If the refrigerant piping is longer than 15 ft (4.6 m), the heat exchanger but before the indoor coil. calculate the charge adder for actual piping length by referring to the Tabular Data Sheet. (item 3) Installation Manual: R-410A Outdoor Split-System Air Conditioner 13 Johnson Controls Ducted Systems 4. When the charge adders for the matched indoor unit and for the refrigerant piping have been CAUTION weighed in, verify the system operation against the temperatures and pressures in the charging chart for the outdoor unit. Refer to the charging charts Compressor damage will occur if system on the outdoor unit or in the Service Application is incorrectly charged. On new system Data on www.simplygettingthejobdone.com. installations, charge the system as specified Follow the subcool or the superheat charging in the Tabular Data Sheet for the matched coil and follow guidelines in this manual. procedure in this section according to the type of indoor metering device in the system and allow 10 min after each charge adjustment for the If a calibrated charging cylinder or accurate system operation to stabilize. Record the charge weighing device is available, add refrigerant adjustment made to match the charging chart. accordingly. Otherwise, model-specific charging (item 4) charts are provided on the access panel of the unit. 5. Verify that the total system charge = (item 1) + (item 2) + (item 3) = (item 4). 6. Permanently stamp the unit data plate with the total system charge as defined in these instructions. Use this method whenever additional refrigerant is required for the system charge. WARNING Do not attempt to pump the total system charge into the outdoor unit for maintenance or service. This may cause damage to the compressor or other components. Recover and weigh the system charge into an appropriate recovery cylinder for any instances requiring evacuation. WARNING Do not attempt to pump more than the factory charge and an additional 15 ft line charge into a tube and fin outdoor unit for maintenance or service. This can cause damage to the compressor or other components. CAUTION Refrigerant charging must only be carried out by a qualified air conditioning contractor. 14 Installation Manual: R-410A Outdoor Split-System Air Conditioner Johnson Controls Ducted Systems Subcooling charging - TXV indoor Example: The liquid pressure listed at the intersection of About this task: the indoor WB and the outdoor DB is 320 psig. The outdoor unit comes equipped with subcooling charts The pressure at the liquid valve is 305 psig. It is optimized for that particular unit. Follow the instructions necessary to add refrigerant to increase the liquid on the unit. If those instructions are not readily available, pressure to 320 psig. follow the instructions below. Note: 1. Set the system running in cooling mode by setting the thermostat at least 6°F below the room Condenser subcooling is obtained by temperature and operate the system for at least 10 calculating the difference between the saturated refrigerant temperature of the min to 15 min. pressure measured at the liquid base valve 2. Refer to the Technical Guide for the indoor airflow and the liquid tube temperature as measured and verify it is correct (it must be between 350 at the liquid base valve. SCFM/ton and 400 SCFM/ton). Subcooling Temperature (TC) = Saturated 3. Measure and record the indoor wet bulb (WB) and Temperature (TS) – Liquid Temperature (T) the outdoor ambient dry bulb (DB) temperature. 4. Using the charging chart located on the unit, find the intersection of the indoor wet bulb and the CAUTION outdoor dry bulb. This is the recommended liquid pressure (and subcooling value). It is unlawful to knowingly vent, release, or 5. Measure and record the pressure at the liquid valve discharge refrigerant into the open air during pressure port and compare to the value obtained in repair, service, maintenance, or the final Step 4. disposal of this unit. 6. Add charge if the measured liquid pressure is lower than the recommended value. Remove or recover charge if the measured liquid pressure is above the recommended value. R-410A saturation properties Table 2: R-410A saturation properties Temperature Pressure Temperature Pressure Temperature Pressure Temperature Pressure Temperature Pressure °F psig °F psig °F psig °F psig °F 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 92 282 107 350 48 137 63 179 78 228 93 287 108 355 49 140 64 182 79 232 94 291 109 360 50 142 65 185 80 235 95 295 110 365 51 145 66 188 81 239 96 299 111 370 52 147 67 191 82 243 97 304 112 375 53 150 68 194 83 247 98 308 113 380 54 153 69 197 84 250 99 313 114 385 55 156 70 201 85 254 100 317 115 391 56 158 71 204 86 258 101 322 116 396 57 161 72 207 87 262 102 326. 117 401 58 164 73 211 88 266 103 331 118 407 59 167 74 214 89 270 104 336 119 412 Installation Manual: R-410A Outdoor Split-System Air Conditioner 15 Johnson Controls Ducted Systems Optional cold weather charging Electrical connections General information and grounding NOTICE The control box cover is held in place with three screws (one screw in each lower corner and one screw at the top center post). The control box can swing open by removing For better airflow, the size of the charging tent must the screw from the center of each side of the control box be at least 70 in. x 70 in. x 70 in. and must have some and allowing the control box to lower 1 in. or so into a adjustable flaps or windows to control the temperature pivotal position. inside the charging tent. The charging tent must not have a floor or floor covering. Follow the system charge procedures from Charging the system. NOTICE A flexible electrical connection must be installed in order to use the swing away function of the control 1. Assemble the charging tent. box. A rigid electrical connection requires the wiring 2. Slide the charging tent over the top of the outdoor to be disconnected in order to swing the control box unit. open. 3. Position the door zipper over the refrigerant piping so the charging tent sits evenly on the ground. The control box can then swing open from the left by 4. Make sure the distance around the outdoor unit rotating on the right side pivots for easy service of refrigeration components. If no wiring is in or routed inside of the charging tent is even for airflow. through the control box, it can be removed from the unit 5. Stake down the edges of the charging tent cover by lifting slightly, tilting the top hinge out, and lifting the to prevent the unit fan from blowing the charging bottom hinge out. During the installation, route the low tent away. voltage wiring for the thermostat along the flexible line voltage electrical connection to help facilitate the swing 6. Start the outdoor unit. away feature of the control box. See Figure 11. 7. For better temperature measurement inside the Check the electrical supply to ensure it meets the values charging tent, use a thermocouple to monitor specified on the unit nameplate and wiring label. temperature readings. Locate the thermocouple Power wiring, control (low voltage) wiring, disconnect monitor approximately 8 in. to 10 in. away from the switches, and over current protection must be supplied coil guard and 2/3 of the way above the bottom of by the installer. Wire size must be sized following NEC requirements. the coil on the opposite side from the control box. 8. Based on the outdoor ambient temperature, begin adjusting windows in order to achieve a stable temperature above 55°F inside the tent. Note that CAUTION the colder the outdoor ambient temperature is the fewer windows need removal. All field wiring must only use copper conductors and 9. Use the outdoor unit charging chart. Verify that be in accordance with Local, National, Fire, Safety the outdoor ambient temperature listed on the and Electrical Codes. This unit must be grounded with charging chart is the temperature inside the a separate ground wire in accordance with the above charging tent. codes. 10. Carefully adjust the charging tent windows until reaching the desired temperature, and allow the The complete connection diagram and schematic wiring unit to stabilize for a minimum of 15 min. Check label is located on the inside surface of the unit service the thermocouple to make sure the temperature is access panel. still maintained at the preferred temperature. If the temperature is out of range, adjust the windows by opening or closing them. 11. When the condition inside the charging tent is stabilized, follow the Charging the system procedures to adjust charge in the unit. 12. Add or remove charge and adjust the windows to maintain the preferred temperature inside the tent. 16 Installation Manual: R-410A Outdoor Split-System Air Conditioner Johnson Controls Ducted Systems Figure 11: Outdoor unit swing away control box Figure 12: Outdoor unit control box (single-phase - smaller base) Figure 13: Outdoor unit control box (single-phase - larger base) Field connections power wiring 1. Install the correct size weatherproof disconnect switch outdoors and within sight of the unit. 2. Remove the screws at the top and sides of the corner cover. Slide the control box cover down and remove from unit. 3. Run power wiring from the disconnect switch to the unit. 4. Route wires from disconnect through power wiring exit provided and into the unit control box as shown in Figure 11, Figure 12, and Figure 13. 5. Install the correct size time-delay fuses or circuit breaker, and make the power supply connections. Installation Manual: R-410A Outdoor Split-System Air Conditioner 17 Johnson Controls Ducted Systems Figure 14: Outdoor unit control box (three-phase - 4. All field wiring to be in accordance with national larger base) electrical codes (NEC) or local city codes. NOTICE A Start Assist Kit is available and recommended for long refrigerant piping applications or in areas of known low voltage problems. The kit may be required when a TXV is used (refer to the Tabular Data Sheet to determine if applicable). 5. Mount the thermostat about 5 ft above the floor, where it is 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 V control wiring (NEC Class 2) from Field connections control wiring the outdoor unit to the indoor unit and thermostat. 1. Route low voltage wiring into bottom of control box as shown in Figure 12 or Figure 13. Make low voltage wiring connections inside the low voltage NOTICE box as shown in Figure 15. 2. The complete connection diagram and schematic To eliminate erratic operation, seal the hole in wiring label is located on the inside surface of the the wall at the thermostat with permagum or unit service access panel. equivalent to prevent air drafts affecting the operation of the thermostat. 3. Replace the control box cover removed in Step 2 of the procedures. Field wiring Figure 15: Typical field wiring (air handler/electrical heat) (single-phase) 18 Installation Manual: R-410A Outdoor Split-System Air Conditioner Johnson Controls Ducted Systems Figure 16: Typical field wiring (air handler/electrical heat) (three-phase) Instructing the user Assist the user with processing warranty cards or online • Do not allow dirt to accumulate on the outdoor coils registration. Review the User’s Guide, and provide a or other parts in the air circuit. Clean as often as copy to the user and guidance on correct operation and necessary to keep the unit clean. Use a brush, vacuum maintenance. Instruct the user how to start, stop, and adjust the temperature setting. cleaner attachment, or other suitable means. When applicable, instruct the user that the compressor • The outdoor fan motor is permanently lubricated and is equipped with a crankcase heater to prevent the does not require periodic oiling. migration of refrigerant to the compressor during the OFF • If the coil needs to be cleaned, use clean water to cycle. The heater is energized only when the unit is not operating in cooling. If the main switch is disconnected wash dust, dirt, and debris from outdoor coil. for long periods of shut down, do not attempt to start the • Refer to the furnace or air handler instructions for unit until 8 h after the switch has been connected. This filter and blower motor maintenance. allows sufficient time for all liquid refrigerant to be driven out of the compressor. • The indoor coil and drain pan must be inspected and cleaned regularly to prevent odors and assure proper The installer must also instruct the user on correct operation and maintenance of all other system drainage. components. Maintenance NOTICE Do not use coil cleaners to clean outdoor coil. Cleaners containing hydrogen fluoride (HF), hydroxides, chlorides, and sulfates can greatly reduce the lifetime of the micro channel coil. CAUTION It is unlawful to knowingly vent, release, or discharge refrigerant into the open air during repair, service, maintenance, or the final disposal of this unit. Installation Manual: R-410A Outdoor Split-System Air Conditioner 19 Johnson Controls Ducted Systems Wiring diagrams Figure 17: Wiring diagram - single-phase 13.4 and 14.3 SEER2 20 Installation Manual: R-410A Outdoor Split-System Air Conditioner Johnson Controls Ducted Systems Figure 18: Wiring diagram - single-phase 15.2 SEER2 - single-stage Installation Manual: R-410A Outdoor Split-System Air Conditioner 21 Johnson Controls Ducted Systems Figure 19: Wiring diagram - single-phase 15.2 SEER2 - two-stage 22 Installation Manual: R-410A Outdoor Split-System Air Conditioner Johnson Controls Ducted Systems Figure 20: Wiring diagram - three-phase 13.4 SEER2 Installation Manual: R-410A Outdoor Split-System Air Conditioner 23 Johnson Controls Ducted Systems Start-up sheet Figure 21: Start-up sheet - page 1 24 Installation Manual: R-410A Outdoor Split-System Air Conditioner Johnson Controls Ducted Systems Figure 22: Start-up sheet - page 2 Installation Manual: R-410A Outdoor Split-System Air Conditioner 25 Johnson Controls Ducted Systems Subject to change without notice. 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