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INSTALLATION INSTRUCTIONS
13 SEER - SPLIT SYSTEM CONDITIONER
COOLING ONLY
2 - 5 TONS.
MOVA-24CN1-M13T, MOVC-36CN1-M13,
MOVD-48CN1-M13L, MOVA-60CN1-M13L.
R-410A Refrigerant
MAN-I-IDCO-0815
TABLE OF CONTENTS
1.0 SAFETY..................................................................................................................3
1.1 INSPECTION....................................................................................................4
1.2 LIMITATIONS....................................................................................................4
2.0 GENERAL..............................................................................................................4
3.0 UNIT INSTALLATION............................................................................................6
3.1 LOCATION.......................................................................................................6
3.2 GROUND INSTALLATION...............................................................................6
3.3 ROOF INSTALLATION.....................................................................................6
3.4 UNIT PLACEMENT..........................................................................................6
3.5 PRECAUTIONS DURING LINE INSTALLATION.............................................7
3.6 PRECAUTIONS DURING BRAZING OF LINES..............................................8
3.7 PRECAUTIONS DURING BRAZING SERVICE VALVE..................................9
3.8 UNIT MOUNTING...........................................................................................10
3.9 FACTORY-PREFERRED TIE-DOWN METHOD............................................11
4.0 ELECTRICAL CONNECTIONS...........................................................................12
4.1 GENERAL INFORMATION & GROUNDING .................................................12
4.2 FIELD CONNECTIONS POWER WIRING ....................................................12
4.3 REMOVING THE TOP PANEL AND MOTOR................................................13
5.0 EVACUATION......................................................................................................14
6.0 INTERCONNECTING TUBING............................................................................14
6.1 VAPOR AND LIQUID LINES .........................................................................14
6.2 MAXIMUM LENGTH OF LINES ....................................................................14
6.3 VERTICAL LIFT ............................................................................................14
7.0 SYSTEM OPERATION........................................................................................15
7.1 COMPRESSOR CRANKCASE HEATER (CCH)...........................................15
7.2 REVERSING VALVE INTRODUCTION .......................................................15
7.3 PROTECTION FUNCTION INTRODUCTION...............................................16
7.4 DEFROST MODE INTRODUCTION.............................................................16
8.0 CHECKING REFRIGERANT CHARGE .............................................................17
8.1 CHARGING BY LIQUID PRESSURE............................................................17
8.2 CHARGING BY WEIGHT ..............................................................................17
8.3 FINAL LEAK TESTING .................................................................................17
9.0 WARRANTY.........................................................................................................17
10.0 WIRING DIAGRAM............................................................................................18
10.1 CONTROL WIRING FOR A/C UNITS..........................................................18
10.2 CONTROL WIRING FOR H/P UNITS .........................................................20
RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION
WARNING
These instructions are intended as an aid to qualified
licensed service personnel for proper installation, adjustment and operation of this unit. Read these instructions
thoroughly before attempting installation or operation.
Failure to follow these instructions may result in improper
installation, adjustment, service or maintenance possibly
resulting in fire, electrical shock, property damage,
personal injury or death.
DO NOT DESTROY THIS MANUAL
Please read carefully and keep in a safe place for future reference by a serviceman.
2
This document is customer property and is to remain with this unit.
These instructions do not cover all the different variations of systems nor does
it provide for every possible contingency to be met in connection with installation.
All phases of this installation must comply with NATIONAL, STATE, AND LOCAL
CODES. If additional information is required please contact your local distributor.
1.0 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.
This is an attention 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 or for additional
information, consult a qualified contractor, installer or service agency.
CAUTION
This product must be installed in strict compliance with the installation instructions and any applicable local, state, and national codes including, but not
limited to building, electrical, and mechanical codes.
WARNING
FIRE OR ELECTRICAL HAZARD
Failure to follow the safety warnings exactly could result in serious injury, death
or property damage.
A fire or electrical hazard may result causing property damage, personal injury
or loss of life.
CAUTION
If using existing refrigerant lines make certain that all joints are brazed, not
soldered.
CAUTION
Scroll compressor dome temperatures may be hot. Do not touch the top of compressor; it may cause minor to severe burning.
3
1.1 INSPECTION
As soon as a unit is received, it should be inspected for possible damage during transit.
If damage is evident, the extent of the damage should be noted on the carrier's delivery
receipt. A separate request for inspection by the carrier's agent should be made in
writing. See Local distributor for more information.
Requirements For Installing/Servicing R410A Equipment
Gauge sets, hoses, refrigerant containers, and recovery system must be designed
to handle the POE or PVE type oils.
Manifold sets should be 800 PSIG high side and 250 PSIG low side with 550 PSIG
Iow side restart.
All hoses must have a 700 PSIG service pressure rating.
Leak detectors should be designed to detect R410A.
Recovery equipment (including refrigerant recovery containers) must be specifically designed to handle R410A.
Do not use an R-22 TXV.
A liquid-line filter drier is required on every unit. see the Fig.1
NOTE :
It will be more convenient to open
the Service valve after removing
the Underside Clapboard.
LARGE SERVICE VALVE
SMALL SERVICE VALVE
LIQUID-LINE FILTER-DRIER
FIELD SUPPLIED AND INSTALLED
Fig.1 Filter-Drier installation
1.2 LIMITATIONS
The unit should be installed in accordance with all National, State, and Local Safety
Codes and the limitations listed below:
1.Limitations for the indoor unit, coil and appropriate accessories must also be observed.
2.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.
3.The maximum and minimum conditions for operation must be observed to assure a system
that will give maximum performance with minimum service.
4.This unit is not designed to operate with a low ambient kit. Do not modify the control system
to operate with any kind of Iow ambient kit.
5.The maximum allowable line length for this product is 150 feet.
2.0 GENERAL
The outdoor units are designed to be connected to a matching indoor coil with braze
connect lines. Units are factory charged with refrigerant for a matching indoor coil
plus 15 feet of field supplied lines.
Matching indoor coils are available with a thermostatic expansion valve or an orifice
for the most common usage. The orifice size and/or refrigerant charge may need to
be changed for some indoor-outdoor unit combinations, elevation differences or
total line lengths.
4
W
AIR DISCHARGE: ALLOW 60”
MINIMUM CLEARANCE.
AIR INLETS
LOUVERED PANELS
ALLOW 18”
MINIMUM
CLEARANCE
SERVICE ACCESS
ALLOW 24” CLEARANCE
POWER WIRING
SEE DETAIL A
DETAIL A
NOTE: GRILL APPEARANCE
MAY VARY.
CONTROL WIRING
7/8” (22.2mm)
KNOCKOUT
1-11/32” (34.5mm)
HOLE
1-3/32” (27.8mm)
SERVICE
FITTING
LIQUID LINE
CONNECTION
DIMENSIONAL DATA
MODEL SIZE
24T/36L
48L
60L
VAPOR LINE
CONNECTION
SERVICE
FITTING
FIG.2 DIMENSIONS
Dimensions (Inches)
"H" in. [mm] "W" in. [mm] "L" in. [mm]
24-15/16[633] 23-5/8[600] 23-5/8[600]
28[710]
29-7/8[759]
28[710]
33-3/16[843] 29-1/8[740] 29-1/8[740]
Refrigerant Connection
Service Valve Size
Vapor in.
Liquid in.
3/4
3/8
7/8
3/8
7/8
3/8
NOTES: 1. T: Toshiba Compressor; L: LG Compressor.
5
3.0 UNIT INSTALLATION
3.1 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, for air
discharge and for service access. See Fig.2
NOTE
For multiple unit installations, units must be spaced a minimum of 18 inches
apart. (Coil face to coil face.)
If the unit is to be installed on a hot sun exposed roof or a black-topped ground area, the
unit should be raised sufficiently above the roof or ground to avoid taking the accumulated layer of hot air into the outdoor unit.
Provide an adequate structural support.
3.2 GROUND INSTALLATION
The unit may be installed at ground level on a solid base that will not shift or settle, causing strain on the refrigerant lines and possible leaks. Maintain the clearances shown in
Fig.2 and install the unit in a level position.
Normal operating sound levels may be objectionable if the unit is placed directly under
windows of certain rooms (bedrooms, study, etc.).
Top of unit discharge area must be unrestricted for at least 60 inches above the unit.
WARNING
The outdoor unit should not be installed in an area where mud or ice could cause
personal injury or system damage.
Elevate the unit sufficiently to prevent any blockage of the air entrances by snow in
areas where there will be snow accumulation. Check the local weather bureau for the
expected snow accumulation in your area. Isolate the unit from rain gutters to avoid any
possible wash out of the foundation.
3.3 ROOF INSTALLATION
When installing units on a roof, the structure must be capable of supporting the total
weight of the unit, including a padded frame unit, rails, etc., which should be used to
minimize the transmission of sound or vibration into the conditioned space.
3.4 UNIT PLACEMENT
1.
2.
3.
4.
6
Provide a base in the pre-determined location.
Remove the shipping carton and inspect for possible damage.
Compressor tie-down nuts should remain tightened.
Position the unit on the base provided.
CAUTION
This system uses R410A refrigerant which operates at higher pressure than
R-22. No other refrigerant may be used in this system. Gauge sets, hoses,
refrigerant containers, and recovery system must be designed to handle
R410A. If you are unsure, consult the equipment manufacturer.
The outdoor unit must be connected to the indoor coil using field supplied refrigerant
grade copper tubing that is internally clean and dry. Units should be installed only with
the tubing sizes for approved system combinations. The charge given is applicable for
total tubing lengths up to 15 feet.
NOTE
Using a larger than specified line size could result in oil return problems. Using
too small a line will result in loss of capacity and other problems caused by insufficient refrigerant flow. Slope horizontal vapor lines at least 1" every 20 feet
toward the outdoor unit to facilitate proper oil return.
3.5 PRECAUTIONS DURING LINE INSTALLATION
1. Install the lines with as few bends as possible. Care must be taken 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, care must be taken to avoid sharp bends which may cause a restriction.
2. The lines should be installed so that they will not obstruct service access to the coil,
air handling system or filter.
3. Care must also be taken to isolate the refrigerant lines to minimize noise transmission from the equipment to the structure.
4. The vapor line must be insulated with a minimum of 1/2" foam rubber
insulation. Tape and suspend the refrigerant lines as shown. DO NOT allow tube
metal-to-metal contact. See Fig. 3.
5. Use PVC piping as a conduit for all underground installations as shown in Fig. 4.
Buried lines should be kept as short as possible to minimize the build up of liquid
refrigerant in the vapor line during long periods of shutdown.
6. Pack a sealing material such as perma gum around refrigerant lines where they
penetrate a wall to reduce vibration and to retain some flexibility.
7
Suggested
optional
Sheet Metal Hanger
Insulated Vapor Line
Tape
Incorrect
Insulated Liquid Line
Fig.3 Tubing Hanger
Fig.4 Underground Installation
WEATHERPROOF
DISCONNECT
SWITCH
TO
POWER
SUPPLY
TO
24V c
ontro
INDOOR
l sign
al
BLOWER
TO
COIL
Seal opening(s) with
permagum or equivalent
NOTE:All outdoor wiring must be weather proof
Fig.5 Typical Installation
3.6 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 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.
8
CAUTION
Dry nitrogen should 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 provide. 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 necessary to displace air and prevent oxidation.
3.7 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 Fig. 6. Also, protect all painted surfaces, insulation, during
brazing. After brazing cool joint with wet rag.
The 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 Iow pressure nitrogen to the liquid line
service port.
wet rag
service valve
Fig.6 Heat Protection
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. Carefully remove the rubber plugs from the evaporator liquid and vapor connections
at the indoor coil.
4. Braze the liquid line to the evaporator liquid connection. Nitrogen should be flowing
through the evaporator coil.
5. Slide the plastic cap away from the vapor connection at the indoor coil. Braze the
vapor line to the evaporator vapor connection. Refer to the Table 1 for proper vapor
line sizing.
6. Protect the vapor valve with a wet rag and braze the vapor line connection 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 OVER TIGHTEN (between 40 and 60 inch -lbs.
maximum).
9. Evacuate the vapor line, evaporator, and the liquid line, to 350 microns or less.
9
Table 1: Refrigerant Connections and Recommended Liquid and Suction Tube
Diameters (ln.)
LIQUID
MODEL SIZE
SUCTION
Tube Diameter
Tube Diameter
24
3/8
3/4
36
3/8
3/4
48
3/8
7/8
60
3/8
7/8
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 hex wrench back out counter
-clockwise until valve stem just touches the chamfered retaining wall.
12. Replace plunger cap finger tight, then tighten an additional 1/12 turn (1/2 hex flat).
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.
See "System Charge" section for checking and recording system charge.
3.8 UNIT MOUNTING
If elevating the heat pump, either on a flat roof or on a slab, observe the following guidelines.
1.The base pan provided elevates the heat pump 2” above the base pad.
2. If elevating a unit on a flat roof , use 4”× 4”(or equivalent) stringers
positioned to distribute unit weight evenly and prevent noise and vibration
(See fig.7) .
NOTE:Do not block drain openings shown in fig.7.
3. If unit must be elevated because of anticipated snow fall, secure unit and
elevating stand such that unit and/or stand will not tip over or fall off.
NOTE: To tie down unit, see 3.9.
10
BASE PAN (BOTTOM VIEW) DO NOT
OBSTRUCT DRAIN HOLES
(SHADED)
BASE PAD
(CONCRETE OR
OTHER SUITABLE
MATERIAL)
ELEVATION ABOVE ANTICIPATED
SNOW IS NECESSARY
Fig.7 RECOMMENDED ELEVATED INSTALLATION
3.9 FACTORY-PREFERRED TIE-DOWN METHOD
Step 1: Prior to installing clear pad of debris.
IMPORTANT
Then cement pad must meet local codes and must be the proper thickness to
accommodate fasteners.
Step 2: Center and level unit onto pad.
Step 3: Using field supplied L-shaped bracket to locate holes on concrete and drill pilot
holes which is at least 1/4” deeper than fastener being used.
IMPORTANT
Self drilling screws to base pan should not exceed 3/8” long to avoid damaging
coil.
Step 4: Using conventional practices to install brackets, tighten concrete fasteners and
self-tapping screws (See Fig.8).
NOTE
NOTE: 1. One bracket for each side. For extra stability, 2 brackets for each side.
2. Do not over-tighten the concrete fastener to avoid weakening the concrete.
IMPORTANT NOTE:
These instructions are intended to provide a method to tie-down system to cement slab
as a securing procedure for high wind areas. It is recommended to check Local Codes
for tie-down methods and protocols.
11
The dimension see FIG.2
SEE DETAIL B
Brackets:
2” width, 1/16” thickness,
height as required.
Available from distributor
or in market place.
#7 X 3/8” Self Tapping Screws
(Don’t Exceed 3/8” long)
DETAIL B
1/4” Χ 1-1/2” Hex Washer Head Concrete Screws
(3/16” Pilot Hole Needed. Pilot Hole Should Be1/4” Deeper
Than The Fastener Embedment)
Fig.8 PREFERRED
TIE-DOWN
METHOD
REQUIRED
PARTS
LIST
4.0 ELECTRICAL CONNECTIONS
4.1 GENERAL INFORMATION & GROUNDING
Check the electrical supply to be sure that it meets the values specified on the unit
nameplate and wiring label.
Power wiring, control (Iow voltage) wiring, disconnect switches and over current
protection must be supplied by the installer. Wire size should be sized per requirements.
CAUTION
All field wiring must USE COPPER CONDUCTORS ONLY and be in accordance
with Local, National Fire, Safety & Electrical Codes. This unit must be grounded
with a separate ground wire in accordance with the above codes.
The complete connection diagram and schematic wiring label is located on the inside
surface of the unit service access panel and this instruction.
4.2 FIELD CONNECTIONS POWER WIRING
1. Install the proper size weatherproof disconnect switch outdoors and within sight of
the unit.
2. Remove the screws at the side of the corner panel. Slide corner panel down and
remove from unit. See Fig. 9.
3. Run power wiring from the disconnect switch to the unit.
4. Route wires from disconnect through power wiring opening provided and into the
unit control box.
5. Install the proper size time-delay fuses or circuit breaker, and make the power
supply connections.
6. Energize the crankcase heater if equipped to save time by preheating the compressor oil while the remaining installation is completed.
NOTE: When changing the motor, remove top cover first.
12
CORNER
PANEL
HIGH VOLTAGE WIRING
LOW VOLTAGE WIRING
Fig.9 Typical Field Wiring
4.3 REMOVING THE TOP PANEL AND MOTOR
1/2” nut
NOTE:
Damage will occur to condenser unit
if you remove fan nuts prior to cover removal.
5/16” nuts
Fig.10 COVER AND FAN
When motor requires changing follow the steps below:
Step 1: Go into electrical panel, disconnect motor power lines.
IMPORTANT NOTE
Disconnect main power to unit. Severe burns and electrical shock will occur if
you do not disconnect main power.
Step 2: Remove cover (be careful of motor wires)
Step 3: Be sure to place fan cover unit on the ground as indicated in Fig. 10
IMPROTANT NOTE
Do not place or lean fan blades on ground or against surface.
Step 4: Remove fan motor by removing 5/16” nuts from cover.
Step 5: Remove fan blade from motor by removing 1/2” nut and place fan on the ground.
Step 6: Reverse removal process to reinstall the fan and motor.
IMPROTANT NOTE
When connecting motor wires be sure to check motor direction.
13
5.0 EVACUATION
It will be necessary to evacuate the system to 350 microns or less. If a leak is
suspected, leak test with dry nitrogen to locate the leak. Repair the leak and test again.
To verify that the system has no leaks, simply 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 and continuous rise,
it's an indication of a leak. If the gauge shows a rise, then levels off after a few minutes
and remains fairly constant, its an indication that the system is leak free but still
contains moisture and may require further evacuation if the reading is above 500
microns.
6.0 INTERCONNECTING TUBING
6.1 VAPOR AND LIQUID LINES
Keep all lines sealed until connection is made.
Make connections at the indoor coil first.
Refer to Line Size Information in Tables 2 and 3 for correct size and multipliers to be
used to determine capacity for various vapor line diameters and lengths of run. The
losses due to the lines being exposed to outdoor conditions are not included.
The factory refrigerant charge in the outdoor unit is sufficient for the unit and 15 feet
of standard size interconnecting liquid and vapor lines. For different lengths,adjust
the charge as indicated below.
5/16” ± .4 oz. per foot
3/8” ± .6 oz. per foot
1/2” ± 1.2 oz. per foot
6.2 MAXIMUM LENGTH OF LINES
The maximum length of interconnecting line is 150 feet.
Always use the shortest length possible with a minimum number of bends.
NOTE: Excessively long refrigerant lines cause loss of equipment capacity.
6.3 VERTICAL LIFT
Keep the vertical lift to a minimum. Use the following guidelines when installing
the unit:
1. DO NOT exceed the vertical lift as indicated on Table 3.
2. It is recommended to use the smallest liquid line size permitted to minimize sys tem charge which will maximize compressor reliability.
3. Table 3 may be used for sizing horizontal runs.
LINE SIZING
TABLE 2: SUCTION LINE LENGTH/SIZE VS CAPACITY MULTIPLIER(R410A)
2 Ton
3/4" O.D.
5/8 Opt.
3/4* Std.
3 Ton
3/4" O.D.
5/8 Opt.
3/4* Std.
4 Ton
7/8" O.D.
3/4 Opt.
7/8* Std.
5 Ton
7/8" O.D.
1 1/8 Opt.
7/8* Std.
Optional
Standard
Optional
Standard
Optional
Standard
1.00
1.00
0.97
0.98
0.94
0.95
1.00
1.00
0.97
0.99
0.94
0.97
1.00
1.00
0.98
0.98
0.95
0.97
1.00
0.99
0.99
0.98
0.98
0.94
Optional
Standard
0.90
0.92
0.90
0.96
0.92
0.96
0.97
0.90
System Capacity
Suction Line Connection Size
Suction Line Run-Feet
25'
50'
100'
150'
NOTES:
* Standard size
Using suction line larger than shown in chart will result in poor oil return and is not recommended.
14
TABLE 3 :LIQUID LINE SIZE (R410A)
System
Capacity
2 Ton
Line Size
Connection Size
(Inch O.D.)
Compressor
Type
Scroll
3/8"
Rotary
3 Ton
3/8"
Scroll
4 Ton
3/8"
Scroll
5 Ton
3/8"
Scroll
Line Size
Connection And
Line Size
(Inch O.D.)
Liquid Line Size
Outdoor unit above or below indoor coil
Total Equivalent Length - Feet
25
100
125
75
50
Maximum Vertical Separation - Feet
5/16
3/8*
3/8*
25
25
25
36
50
30
29
60
30
23
60
24
16
40
NA
9
30
NA
5/16
3/8*
3/8*
1/2
3/8*
1/2
25
25
25
25
25
25
50
50
46
50
50
50
37
60
38
56
56
60
22
60
30
55
44
60
7
40
22
40
32
40
N/A
30
15
30
20
30
150
NOTES:
* Standard line size
N/A Application not recommended.
7.0 SYSTEM OPERATION
7.1 COMPRESSOR CRANKCASE HEATER (CCH) (Heat pump only)
Refrigerant migration during the off cycle can result in a noisy start up. Add a crankcase heater to minimize refrigeration migration, and to help eliminate any start up
noise or bearing “wash out”.
All heaters must be located on the lower half of the compressor shell. Its purpose is to
drive refrigerant from the compressor shell during long off cycles, thus preventing
damage to the compressor during start-up.
The crankcase heating start condition:
1.The crankcase heating start must meet two conditions:
A. Outdoor temperature <41° F.
B. Compressor stops working more than 3 hours.
2. Outdoor temperature <41° F and just connected to the power source.
The crankcase heating stop must meet condition:
Outdoor temperature >44.6° F or compressor start.
7.2 REVERSING VALVE INTRODUCTION (Heat pump only)
Reversing valve energizes at the heating conditions, and cut off at the cooling condition.
15
7.3 PROTECTION FUNCTION INTRODUCTION (Heat pump only)
Sensor T3 (condenser pipe temperature) and T4 (outdoor ambient temperature)
When open-circuit, compressor, outdoor fan motor and reverse valve will be OFF.
T3>143.6°F,compressor stop working ; T3<125.6°F,compressor start working.
When T4 < 5 °F, compressor will stop.If the electrical heater kit is installed in the
indoor unit, the outdoor unit would provide a signal to drive up the heater.
When T4 > 10.4 °F, compressor will restart.
Discharge temperature protection (optional)
When discharge temp. > 275 °F, the compressor will stop.
When discharge temp. < 194 °F, the compressor will restart.
High pressure protection (optional)
When high pressure > 638 PSIG, the compressor and outdoor fan motor will stop.
When high pressure < 464 PSIG, the compressor and outdoor fan motor will restart
(3 minutes delay necessary).
Low pressure protection
Low pressure < 21 PSIG, the compressor and outdoor fan motor will stop.
Low pressure > 44 PSIG, the compressor and outdoor fan motor will restart
(3 minutes delay necessary).
In stand-by status, the compressor will not start in low pressure protection.
Within 30 mins, if 4 protection cycles occurs.The system will be locked. It will
be restore after power cycle.
7.4 DEFROST MODE INTRODUCTION (Heat pump only)
Manual defrost mode
When the switch SW3-1 is set to “ON”, the system turns to the defrost mode.
By the logic of Shut-down conditions of defrost mode to exit the defrost mode.
Caution: Once the manual defrost mode is finished, please switch the PCB switch
back to “1”.
Start-up conditions of defrost mode:
When SW3-3 switch is set to “ON”(See in Fig 11), the mode will start up in any of
the following conditions:
1. Compressor operating, when T3 is < 30.2 °F last for 30 minutes;
2.T3 is < 28.4 °F and compressor operating for the first time after connected to the
power source.
3. When T3 is < 28.4 °F and The system standby two hours continuously .
SW3 Switch
Fig.11 SW3 Switch Location in the PCB Board
MANUAL DEFRO ST
AUTOMATIC DEFROST
RES ERVED
NOR MAL DE FROST
DEF ROSTIN G CYCL E:30MIN
D EFROSTING CYCLE:60M IN
16
When SW3-3 switch is set to “OFF”(See in Fig 11), the mode will start up in any of
the following conditions:
1. Compressor operating, when T3 is < 30.2 °F last for 60 minutes;
2.T3 is < 28.4 °F and compressor operating for the first time after connected
to the power source.
3. When T3 is < 28.4 °F and The system is on standby for two hours .
The mode will shut down in any of the following conditions:
1. The defrosted time lasting for 10 minutes;
2. T3 is ≥ 77 °F when T4 ≥ 28.4 °F;
3. Compressor stop operating;
4. T3 is ≥ 77 °F last for 60s when T4 < 28.4 °F.
8.0 CHECKING REFRIGERANT CHARGE
Charge for all systems should be checked against the Charging Chart inside the
access corner panel .
IMPORTANT:Do not operate the compressor without charge in system. Addition of
R-410A will raise pressures (vapor, liquid and discharge).
8.1 CHARGING BY LIQUID PRESSURE
In order to properly charge the system, the following conditions must be met: 1) Outdoor
temperature above 60F. 2) Indoor temperature between 70F to 100F. 3)Installation must
be complete with brazed joints and drier visually inspected. 4) The unit electrical
installation must be checked and unit powered for one (I) hour if crank case heat is used
or five (5) minutes if no crank case heat is used.
Follow these steps: 1. Run in cooling mode at least 10 minutes. 2. Measure OUTDOOR
AMBIENT TEMPERATURE within 6 inches of coil. 3. Measure SUCTION LINE
PRESSURE. 4. Find the TARGET LIQUID PRESSURE at the intersection between the
SUCTION LINE PRESSURE and the OUTDOOR AMBIENT TEMPERATURE, if falls
between rows or columns then estimate the TARGET LIQUID PRESSURE or
SUCTION LINE PRESSURE falls between rows or columns then estimate the TARGET
LIQUID PRESSURE between the rows and columns. 5. Compare the measured LIQUID
LINE PRESSURE to the TARGET LIQUID PRESSURE, add charge to raise the
pressure or recover charge to lower it. 6. After running unit for 10 minutes if the
SUCTION LINE PRESSURE changes, go back to step 2 otherwise remove test
equipment and cover the valves.
8.2 CHARGING BY WEIGHT
For a new installation,evacuation of interconnecting tubing and indoor coil is adequate;
otherwise,evacuate the entire system. The factory refrigerant charge in the outdoor
unit is sufficient for the unit and 15 feet of standard size interconnecting liquid and
vapor lines. For tube lengths over 15ft add the additional refrigerant see 6.1.
With an accurate scale (+/- 1 oz.) adjust charge difference between that shown on
the unit data plate and that calculated for the new system Installation. if the entire
system has been evacuated, add the total calculated charge.
8.3 FINAL LEAK TESTING
After the unit has been properly evacuated and charged, a halogen leak detector
should be used to detect leaks in the system. All piping within the condensing unit,
evaporator, and interconnecting tubing should be checked for leaks. If a leak is
detected, the refrigerant should be recovered before repairing the leak. The Clean Air
Act prohibits releasing refrigerant into the atmosphere.
9.0 WARRANTY
Assist owner with processing Warranty cards and/or online registration.
17
9.1 MAINTENANCE
1.. Dirt should not be allowed to accumulate on the indoor or outdoor coils or other parts
in the air circuit. Clean as often as necessary to keep the unit clean. Use a brush,
vacuum cleaner attachment, or other suitable means.
2. The outdoor fan motor is permanently lubricated and does not require periodic oiling.
3. Refer to the furnace or air handler instructions for filter and blower motor maintenance.
4. The indoor coil and drain pan should be inspected and cleaned regularly to assure
proper drainage.
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. When the
system is functioning properly and the owner has been fully instructed, secure the
owner’s approval.
10.0 WIRING DIAGRAM
CAUTION
These units must be wired and installed in accordance with all National and
Local Safety Codes.
10.1 CONTROL WIRING FOR A/C UNITS
PLUG PLATE
GROUND
L2
L1
L2
BLACK
LINE VOLTAGE
FACTORY STANDARD
FIELD INSTALLED
FACTORY OPTIONAL
POWER
L1
BLACK
RED
A2
BLACK
C
Y
YELLOW
GREEN
BLACK
BLACK
C
ORANGE
COMP
RC 1
FAN
R
S
RC 2
WHITE OR YELLOW
BLACK
GREEN
BLACK
BROWN
RED
BLACK
TO THERMOSTAT
CC
A1
LOW VOLTAGE
FACTORY STANDARD
FIELD INSTALLED
FACTORY OPTIONAL
USE COPPER CONDUCTORS ONLY
CC
COMP
RC 1
RC 2
RC 3
COMPRESSOR CONTACTOR
COMPRESSOR
RUN CAPACITOR 1
RUN CAPACITOR 2
RUN CAPACITOR 3
WARNING: CABINET MUST BE PERMANMENTLY
GOUNDED AND ALL WIRING TO CONFORM TO
I.E.C,N.E.C,C.E.C,C.L.C,AND LOCAL CODES AS APPLICABLE
REPLACEMENT WIRE MUST BE THE SAME GAUGE AND
INSULATION TYPE AS ORIGINAL WIRE
RC 3
Fig.12 Outdoor Unit Wiring Diagram for A/C Systems(208/230V 1P 60Hz).
(Exclude LG Compressor System)
18
PLUG PLATE
L1
L2
BLACK
L1
L2
LINE VOLTAGE
FACTORY STANDARD
FIELD INSTALLED
FACTORY OPTIONAL
POWER
BLACK
GROUND
RED
A2
BLACK
YELLOW
C
Y
YELLOW
HGS
GREEN
BLACK
BLACK
C
ORANGE
COMP
RC 1
FAN
R
S
RC 2
WHITE OR YELLOW
BLACK
GREEN
BLACK
BROWN
RED
BLACK
TO THERMOSTAT
CC
A1
LOW VOLTAGE
FACTORY STANDARD
FIELD INSTALLED
FACTORY OPTIONAL
USE COPPER CONDUCTORS ONLY
HGS
HOT GAS OR COMPRESSOR TOP SENSOR
CC
COMPRESSOR CONTACTOR
COMP COMPRESSOR
RC 1
RUN CAPACITOR 1
RC 2
RUN CAPACITOR 2
RC 3
RUN CAPACITOR 3
WARNING: CABINET MUST BE PERMANMENTLY
GOUNDED AND ALL WIRING TO CONFORM TO
I.E.C,N.E.C,C.E.C,C.L.C,AND LOCAL CODES AS APPLICABLE
REPLACEMENT WIRE MUST BE THE SAME GAUGE AND
INSULATION TYPE AS ORIGINAL WIRE
RC 3
Fig.13 Outdoor Unit Wiring Diagram for A/C Systems(208/230V 1P 60Hz).
(Just For LG Compressor)
THERMOSTAT
C
R
G
R
C
INDOOR UNIT
Y
BLACK
LACK
YELLO W
BLACK
LACK
R ED
D
G
GREEN
N
Y
C
OUTDOOR UNIT
Fig.14 Control Wiring for A/C Systems.
Suggestion: When choosing a thermostat, choose Intensity Thermostats.
Please refer to thermostat electrical manual for wiring schematic.
19
TABLE 4: Electrical Data:
Model
24T
Minimum Circuit Ampacity(A) Maximum Circuit Protector(A)
11.6
20
36L
29.9
35
48L
29.0
50
60L
31.1
50
NOTES: 1. T: Toshiba Compressor; L: LG Compressor.
20
TABLE 5. Troubleshooting
EF.
RD
SO
F.
SEN R DE
O
GS
S
F.
E
EN
C/H
HP P. S SOR D .
EF
EM SEN
LD
T3 T
.
O
P
N T R EF.
T EM
T4 ST CO SOR D
G
RO
EN
KIN
D E F L PC S
LEA
VE CTIVE
VAL
E
CK
DEF NG
CHE COIL LEAKI
S
SOV SOV CTION
T R I OW
RES AIRFL
IR.
. C . I.D. RHEAT
S
REF
E
E
R
SUP OPEN
CK
N
STU ATIO
TXV RCUL W
FLO
ECI
R R .D. AIR LES
. AI
B
O.D RES. O ENSA D
D
N
L OA
NCO AP.
NO E EV ARGE
H
IV
ESS
ERC GE
EXC EF. OV CHAR .
R
P
R
NDE T COM
.U
REF CIEN SSOR
E
FFI
INE OMPR USE
F
C
CK
IL
AG E
STU VOLT R CO
O
LOW TACT STAT
O
N
RM
CO
R
THE ORME
NSF ING
TRA WIR
OL
GE
TS
NTR VOLTA NTAC
CO
O
R
C
LOW TOR ACITO
C CAP
OR
NTA
CO OWER PACIT
A
R
BL
N C ACITO
I.D.
P
.
. FA
O.D R CA L DEF
SS RO
PRE ONT
ING
COM I.D. C E WIR Y
AG U P P L
OLT
S
E
H V ER
H I G P OW K M O D
C
CHE
TO
AT
WH
SYSTEM FAULTS
REFRIGERANT CIRCUIT
Head Pressure Too High
Head Pressure Too Low
Suction Pressure Too High
Suction Pressure Too Low
Liquid Refrig. Floodback
(TXV)
I.D. Coil Frosting
Compressor Runs Inadequate or
No Cooling/Heating
S
P S
S S
S S
S S S
S S
P
S
P
S
S P S
S
S
S S
S
P
P
S S
P P S P S
P P S
C
H
C
H
C
H
C
H
C
H
C
H
C
H
S P
S P
P P
S
S
P
P
P
S P
S P
P
P
P
P
P
S
S P S S
S P S S S S
S S
S
ELECTRICAL
C
H
C
Compressor Will Not Start But
O.D. Fan Runs
H
C
O.D. Fan Won’t Start
H
C
Compressor Hums But Won’t Start
H
C
I.D. Blower Won’t Start
H
DEFROST
C
Unit Won’t Initiate Defrost
H
C
Defrost Terminates on Time
H
C
Unit Icing Up
H
Compressor & O.D. Fan Won’t Start
P P
P P
P
P
P
P
S
P
P
P
S
S S
P
P
S S S
S
P
P
S
S
S
S
P
P
P P S
P P S
S P S P P
S P S
P
P
P
P
P
S P S
S P S
S
S
P
P
P
S S
S
P
P
S
P
S
P
C- Cooling H - Heating P - Primary Causes S - Secondary Causes
TABLE 6. Operational And Checkout Procedures
Final phases of this installation are the unit Operational and Checkout Procedures. To obtain proper performance,
all units must be operated and charge adjustments made in accordance with procedures found in the Service Facts
of the Outdoor Unit.
After installation has been completed, it is recommended that the entire system be checked against the following list:
1. Be sure unit suspension(if used) is secure and that
thereare no tools or loose debris in or around or on
top of the unit...................................................... [ ]
2. Properly insulate suction lines and fittings. ......... [ ]
3. Properly secure and isolate all refrigerant lines... [ ]
4. Verify that all electrical connections are tight. ..... [ ]
5.Check all duct outlets; they must be open and unrestricted. [ ]
6.Check drain lines and be sure all joints are tight............... [ ]
7.Be sure that a return air filter is installed. .......................... [ ]
8.Operate complete system in each mode to verify proper
performance. Verify operation of supplementary electric
heater. ............................................................................... [ ]
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