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Johnson Controls XAF Series - User Manual

Johnson Controls XAF Series
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Johnson Controls Ducted Systems
Installation Manual: XAF, XAH, and XAU
Series - Full Cased and Uncased Coils for
Cooling and Heat Pumps
XAF - full-cased upflow or downflow, XAH - full-cased
horizontal left or right, and XAU - uncased upflow or
downflow
York International Corporation, 5005 York
Drive, Norman, OK 73069
2021-07-12
5997451-UIM-A-0721
Supersedes: Nothing
A
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Johnson Controls XAF Series Specifications

General IconGeneral
BrandJohnson Controls
ModelXAF Series
CategoryHeat Pump
LanguageEnglish

Summary

General Information and Safety Guidelines

General Manual Overview

Read all sections of this manual for future reference.

Certification Information

Information regarding product certifications and standards.

General Warning on Improper Installation

General warning about improper installation causing injury or property damage.

Compliance and Code Adherence

Product must be installed in compliance with instructions and codes.

Furnace Area Storage Hazard

Warning against using furnace area for storage due to fire hazard.

Appliance Use by Persons with Reduced Capabilities

Appliance not intended for unsupervised use by persons with reduced capabilities.

Coil Inspection and Clearances

Verify Coil Pressure

Verify coil pressure using figures for XAF/XAH and XAU.

Inspect Coil for Transit Damage

Inspect coil for transit damage and document it on delivery receipt.

Check Drain Pan Integrity

Inspect the drain pan for any cracks or breakage.

Maintain Required Installation Clearances

Maintain required clearances for piping, access, drain lines, and coil removal.

Installation Overview and Metering Device Usage

Pre-Installation Review and Device Installation

Review installation aids and install the coil metering device.

Coil, Duct, and Refrigerant Line Connections

Install the coil, connect duct system, and refrigerant lines.

Condensate Drain, Air System, and Homeowner Instruction

Connect drain, adjust air, and instruct homeowner.

Adhere to Safety Codes for Coil Installation

Install the coil following national and local safety codes.

Field Installation of Piston or TXV

Install piston or TXV unless coil has factory-installed TXV or EEV.

TXV Sensing Bulb and Installation References

Note on TXV bulb timing and references for piston/TXV installation.

Coil Pressure Caution

Caution regarding coil pressure and metering device.

Installing a Piston

Piston Installation Warnings and Steps

Warnings and steps for installing piston and Schrader valve core.

Distributor Adjustment and Schrader Valve Core Installation

Adjust distributor, install Schrader valve core, and remove liquid line nut.

Piston Installation and System Testing

Install piston, verify washer, install liquid line, and leak test system.

Installing a TXV

TXV Installation Cautions and General Steps

Cautions and basic steps for TXV kit installation.

TXV Component Installation and Tightening

Install TXV onto distributor and connect liquid line.

TXV Equalizer Line and Bulb Installation

Install TXV equalizer line and route sensing bulb tube.

Insulate TXV Bulb and Leak Test System

Insulate TXV bulb and leak test the system after piping.

Using a Coil Equipped with an EEV

EEV Coils for Modulating Systems

EEV coils available for modulating systems; controls are factory installed.

Connect Communication Cable

Connect the 4-wire communication cable to furnace/blower control board.

Installing the Coil: XAF and XAH Coils

XAF;XAH Coil Installation Requirements and Flange Use

Understand installation needs, flange use, and application requirements for XAF/XAH coils.

Duct Flange Handling and Securing

Instructions for using, handling, and securing duct flanges.

Securing Coil and Horizontal Pitching Notice

Secure coil with tie plates and note on horizontal pitching.

Horizontal Applications: XAH Coils

Horizontal XAH Coil Placement and Sloping

Position horizontal XAH coils sloped 1/4 inch towards the drain plug.

Transition Angle Adjustment Steps for Furnace Use

Steps to reposition transition angle for downflow/horizontal right furnace applications.

Discard Angle for Modular Air Handlers

Note to remove and discard transition angle for modular air handlers.

Illustrations of Horizontal XAH Applications

Figures illustrate horizontal applications with furnaces and air handlers.

Condensate Blow-off Risk and Drain Pan Extension

Warning about condensate blow-off and steps to install drain pan extension.

Installing the Coil: XAU Coils

XAU Uncased Coil Installation Overview

Overview of XAU uncased coil installation for upflow/downflow furnaces.

Dimension Y vs. Z Requirement and Plenum Opening

Dimension Y requirement and cutting/bending plenum opening.

Install Furnace Plenum and Coil Shelf

Install furnace plenum and coil shelf.

Dimension References and Coil Shelf Fabrication

Referencing dimension tables and fabricating the coil shelf.

Coil Shelf Installation

Install coil shelf through plenum opening, ensuring correct pitch.

Duct Flange Folding and Duct Work Fabrication

Fold furnace duct flanges and fabricate duct work for XAU coil.

Connecting the Duct System

Critical Coil Projection: XAU Coils

Locate coil assembly ensuring minimum distance between coil top and duct top.

Duct System Options and Best Practices

Discusses options for air supply/return and best practices for duct connection.

Warning: Use 1;2-in. Screws for XAF;XAH Duct Work

Warning to use 1/2-in. screws for XAF/XAH duct work.

Connecting the Condensate Drain

Condensate Drain Connection Best Practices

Best practices for pitching, routing, and homeowner instruction for drain lines.

Auxiliary Drain Pan and Secondary Drain Use

Auxiliary drain pan requirement and secondary drain for clog warning.

Drain Connection Cautions: Trapping and Sealants

Cautions against double trapping and using sealants on drain connections.

Connecting Refrigerant Lines

Refrigerant Line Cautions and Pre-Brazing Steps

Cautions regarding coil pressure and dry nitrogen use during brazing; pre-brazing steps.

Refrigerant Line Handling and Preparation

Proper handling, connection, and preparation of refrigerant lines before brazing.

Metering Device Installation and Line Connections

Install metering device, remove cap, and make line connections.

EEV Specific Instructions and Tools

EEV specific handling, shipping, and manual tool information.

Refrigerant Line Brazing and Protection

Brazing refrigerant lines with nitrogen purge and protecting connections.

Coil Maintenance and Air System Adjustment

Post-Brazing Steps and Final Checks

Re-attach grommets, refer to outdoor manual, attach access panel, and ensure line isolation.

Coil Cleaning Precautions and Methods

Precautions and methods for cleaning the coil using water or Evap-Green.

Airflow Adjustment Procedure and Data Reference

Procedure for adjusting airflow, referencing data tables and pressure measurements.

Prepare Coil and Capture Pressure Drop Data

Prepare coil for measurements and capture pressure drop data.

Final Airflow Adjustments and Hole Sealing

Use airflow data for adjustments and seal holes after measurement.

Homeowner Instruction and Installation Verification

Post-Installation Homeowner Tasks

Tasks to perform after installation is complete.

Assist with Unit Warranty Registration

Assist homeowner with unit warranty registration.

Homeowner Instruction: Drain Pan Maintenance

Instruct homeowner on regular drain pan inspection and cleaning.

Pre-Installation Review and Task Verification

Review installation aids and verify tasks are completed during installation.

TXV Installation Checklist

Checklist for verifying correct TXV installation.

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