warning
INSTALLATION INSTRUCTIONS
13 & 14.5 SEER SERIES
CONDENSING UNITS
11⁄2 - 5 TONS FEATURING
EARTH-FRIENDLY R-410A REFRIGERANT R-410
refrigerant
NOTE: Appearance of unit may vary.
!
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.
(13 & 14.5 SEER
MODELS IN CERTAIN
MATCHED SYSTEMS)
DO NOT DESTROY THIS MANUAL
PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICEMAN
92-21354-78-01
SUPERSEDES 92-21354-78-00
TABLE OF CONTENTS
1.0 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.0 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1 Checking Product Received. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Electrical and Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.0 LOCATING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.1 Corrosive Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.2 Condenser Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 Operational Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.4 For Condensers With Space Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.5 Customer Satisfaction Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.6 Proper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.7 Unit Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.8 Factory-Preferred Tie-Down Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.0 REFRIGERANT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.0 TOOLS REQUIRED FOR INSTALLING & SERVICING R-410A MODELS . . . . . 8
5.1 Specifications of R-410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.2 Quick Reference Guide for R-410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6.0 REPLACEMENT UNITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7.0 EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8.0 REPLACEMENT UNITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.0 INTERCONNECTING TUBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.1 Vapor and Liquid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.2 Maximum Length of Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.3 Outdoor Unit Installed Above Indoor Coil. . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.4 Outdoor Unit Below Indoor Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.5 Tubing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9.6 Tubing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9.7 Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
10.0 EVACUATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
11.0 START UP AND PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
12.0 CHECKING AIRFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
13.0 CHECKING REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
13.1 Charging Using Charging Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
13.2 Charging By Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
13.3 Final Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
14.0 ELECTRICAL WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
14.1 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
14.2 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
14.3 Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
15.0 FIELD INSTALLED ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
15.1 Compressor Crankcase Heat (CCH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
15.2 Time Delay Control (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
15.3 Low Ambient Control (LAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
15.4 High and Low Pressure Controls (HPC & LPC). . . . . . . . . . . . . . . . . . . . . . 18
16.0 SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
16.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
16.2 Single-Pole Compressor Contactor (CC). . . . . . . . . . . . . . . . . . . . . . . . . . . 18
17.0 TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
17.1 Electrical Checks Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
17.2 Mechanical Checks Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
17.3 Superheat Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
17.4 Subcooling Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
17.5 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
18.0 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
18.1 PSC Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
18.2 ECM Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2
1.0 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.
! WARNING
THE MANUFACTURER’S WARRANTY DOES NOT COVER ANY DAMAGE OR
DEFECT TO THE HEAT PUMP CAUSED BY THE ATTACHMENT OR USE OF
ANY COMPONENTS. ACCESSORIES OR DEVICES (OTHER THAN THOSE
AUTHORIZED BY THE MANUFACTURER) INTO, ONTO OR IN CONJUNCTION
WITH THE HEAT PUMP. YOU SHOULD BE AWARE THAT THE USE OF UNAUTHORIZED COMPONENTS, ACCESSORIES OR DEVICES MAY ADVERSELY
AFFECT THE OPERATION OF THE HEAT PUMP AND MAY ALSO ENDANGER
LIFE AND PROPERTY. THE MANUFACTURER DISCLAIMS ANY RESPONSIBILITY FOR SUCH LOSS OR INJURY RESULTING FROM THE USE OF SUCH
UNAUTHORIZED COMPONENTS, ACCESSORIES OR DEVICES.
! WARNING
DISCONNECT ALL POWER TO UNIT BEFORE STARTING MAINTENANCE.
FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN
SEVERE PERSONAL INJURY OR DEATH.
! WARNING
DO NOT USE OXYGEN TO PURGE LINES OR PRESSURIZE SYSTEM FOR
LEAK TEST. OXYGEN REACTS VIOLENTLY WITH OIL, WHICH CAN CAUSE AN
EXPLOSION RESULTING IN SEVERE PERSONAL INJURY OR DEATH.
! WARNING
THE UNIT MUST BE PERMANENTLY GROUNDED. FAILURE TO DO SO CAN
CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR
DEATH.
! WARNING
TURN OFF ELECTRIC POWER AT THE FUSE BOX OR SERVICE PANEL
BEFORE MAKING ANY ELECTRICAL CONNECTIONS.
ALSO, THE GROUND CONNECTION MUST BE COMPLETED BEFORE MAKING
LINE VOLTAGE CONNECTIONS. FAILURE TO DO SO CAN RESULT IN ELECTRICAL SHOCK, SEVERE PERSONAL INJURY OR DEATH.
! CAUTION
The filter drier is located inside the control box. The filter drier must be
installed externally in the liquid line or the Warranty will be VOID!
3
! WARNING
THE MANUFACTURER’S WARRANTY DOES NOT COVER ANY
DAMAGE OR DEFECT TO THE
AIR CONDITIONER CAUSED BY
THE ATTACHMENT OR USE OF
ANY COMPONENTS. ACCESSORIES OR DEVICES (OTHER
THAN THOSE AUTHORIZED BY
THE MANUFACTURER) INTO,
ONTO OR IN CONJUNCTION
WITH THE AIR CONDITIONER.
YOU SHOULD BE AWARE THAT
THE USE OF UNAUTHORIZED
COMPONENTS, ACCESSORIES
OR DEVICES MAY ADVERSELY
AFFECT
THE
OPERATION
OF THE AIR CONDITIONER AND
MAY ALSO ENDANGER LIFE
AND PROPERTY. THE MANUFACTURER
DISCLAIMS
ANY
RESPONSIBILITY FOR SUCH
LOSS OR INJURY RESULTING
FROM THE USE OF SUCH
UNAUTHORIZED COMPONENTS,
ACCESSORIES OR DEVICES.
2.0 GENERAL
The information contained in this manual has been prepared to assist in the proper
installation, operation and maintenance of the air conditioning system. Improper
installation, or installation not made in accordance with these instructions, can result
in unsatisfactory operation and/or dangerous conditions, and can cause the related
warranty not to apply.
Read this manual and any instructions packaged with separate equipment required
to make up the system prior to installation. Retain this manual for future reference.
To achieve optimum efficiency and capacity, the indoor cooling coils listed in the
condensing unit specification sheet should be used.
IMPORTANT: We recommend replacement of any HVAC equipment that has been
subjected to flooding in order to avoid any risk of injury or harm.
IMPORTANT: Use all available safety precautions during the installation and servicing of any HVAC equipment.
2.1 CHECKING PRODUCT RECEIVED
Upon receiving unit, inspect it for any shipping damage. Claims for damage, either
apparent or concealed, should be filed immediately with the shipping company.
Check condensing unit model number, electrical characteristics and accessories to
determine if they are correct and match the original order from the local distributor.
Check system components (evaporator coil, condensing unit, evaporator blower,
etc.) to make sure they are properly matched.
2.2 APPLICATION
Before installing any air conditioning equipment, a duct analysis of the structure and
a heat gain calculation must be made. A heat gain calculation begins by measuring
all external surfaces and openings that gain heat from the surrounding air and
quantifying that heat gain. A heat gain calculation also calculates the extra heat
load caused by sunlight and by humidity removal.
There are several factors that the installers must consider:
•
•
•
•
4
Outdoor unit location
System refrigerant charge
Indoor unit blower speed
System air balancing
•
•
•
•
Proper equipment evacuation
Indoor unit airflow
Supply and return air duct design and sizing
Diffuser and return air grille location and sizing
2.3 (SEE FIGURE 1)
AIR DISCHARGE: ALLOW
60” MINIMUM CLEARANCE.
w
FIGURE 1
DIMENSIONS
A-00008
AIR INLETS
L
(LOUVERED
PANELS)
ALLOW 6”
MINIMUM
CLEARANCE
SERVICE ACCESS
ALLOW 24” CLEARANCE
H
NOTE: GRILLE APPEARANCE
MAY VARY.
SEE DETAIL A
DIMENSIONAL DATA
18, 24
30
Height “H” (in.) [mm]
24 /4 [616]
24 /4 [616]
273/8 [710]
353/8 [913]
Length “L” (in.) [mm]
235/8 [600]
275/8 [702]
315/8 [803]
315/8 [803]
Width “W” (in.) [mm]
235/8 [600]
275/8 [702]
315/8 [803]
315/8 [803]
13 Seer Model Size
36, 42
48, 60
18, 24, 30 36, 42, 48, 60
14.5 Seer Model Size
1
1
5
2.4 ELECTRICAL & PHYSICAL DATA (SEE TABLE 1)
TABLE 1
ELECTRICAL AND PHYSICAL DATA – 13 SEER
Electrical
Physical
Compressor
Model
Number
Phase
Frequency (Hz)
Voltage (Volts)
Rated Load
Amperes
(RLA)
Locked Rotor
Amperes
(LRA)
Fuse or HACR
Circuit Breaker
Outdoor Coil
Fan Motor Minimum
Full Load
Circuit
Amperes Ampacity
No.
(FLA)
Amperes Minimum Maximum Face Area2
Rows
Amperes Amperes Sq. Ft. [m ]
CFM
[L/s]
Refrig.
Per
Circuit
Oz. [g]
Weight
Net
Lbs. [kg]
Shipping
Lbs. [kg]
Rev. 6/2/2009
18
1-60-208/230
9/9
48
0.6
12/12
15/15
20/20
8.43
[0.78]
1
1675
[790]
75.2
[2132]
120
[54.4]
128
[58.1]
24
1-60-208/230
13.5/13.5
58.3
0.6
18/18
25/25
30/30
8.43
[0.78]
1
1665
[786]
73.8
[2092]
121
[54.9]
129
[58.5]
30
1-60-208/230
12.8/12.8
73
0.6
17/17
20/20
25/25
10.29
[0.96]
1
2075
[979]
86.08
[2440]
135
[61.2]
143
[64.9]
36
1-60-208/230
16.7/16.7
79
0.8
22/22
30/30
35/35
12.43
[1.15]
1
2690
[1269]
96
[2722]
159
[72.1]
167
[75.8]
42
1-60-208/230
17.9/17.9
112
0.8
24/24
30/30
40/40
16.39
[1.52]
1
2980
[1406]
126.4
[3583]
218
[98.9]
230
[104.3]
48
1-60-208/230
21.8/21.8
117
0.8
29/29
35/35
45/45
21.85
[2.03]
1
3175
[1498]
144
[4082]
225
[102.1]
237
[107.5]
60
1-60-208/230
26.4/26.4
134
1.2
35/35
45/45
60/60
21.85
[2.03]
1
3570
[1685]
176
[4990]
223
[101.2]
234
[106.1]
ELECTRICAL AND PHYSICAL DATA – 14.5 SEER
Electrical
Physical
Compressor
Model
Number
14AJM
Phase
Frequency (Hz)
Voltage (Volts)
Rated Load
Amperes
(RLA)
Locked Rotor
Amperes
(LRA)
Fuse or HACR
Circuit Breaker
Outdoor Coil
Fan Motor Minimum
Full Load
Circuit
Amperes Ampacity
No.
(FLA)
Amperes Minimum Maximum Face Area2
Rows
Amperes Amperes Sq. Ft. [m ]
CFM
[L/s]
Refrig.
Per
Circuit
Oz. [g]
Weight
Net
Lbs. [kg]
Shipping
Lbs. [kg]
Rev. 4/28/2009
18
1-60-208/230
9/9
48
0.8
12/12
15/15
20/20
16.39
[1.52]
1
2805
[1324]
112
[3175]
154
[69.8]
171
[77.6]
24
1-60-208/230
13.5/13.5
58.3
0.8
18/18
25/25
30/30
16.39
[1.52]
1
2805
[1324]
105.6
[2994]
154
[69.8]
171
[77.6]
30
1-60-208/230
12.8/12.8
64
0.8
17/17
25/25
25/25
16.39
[1.52]
1
3000
[1416]
112
[3175]
157
[71.2]
175
[79.4]
36
1-60-208/230
16.7/16.7
79
0.8
22/22
30/30
35/35
21.85
[2.03]
1
3570
[1685]
130.4
[3697]
181
[82.1]
201
[91.2]
42
1-60-208/230
17.9/17.9
112
2.8
26/26
30/30
40/40
21.85
[2.03]
1
3060
[1444]
145.12
[4114]
205
[92.9]
225
[102.1]
48
1-60-208/230
21.8/21.8
117
2.8
31/31
40/40
50/50
21.85
[2.03]
2
4105
[1937]
216
[6124]
246
[112.9]
269
[122]
60
1-60-208/230
26.4/26.4
134
2.8
36/36
45/45
60/60
21.85
[2.03]
2
4105
[1937]
240
[6804]
254
[115.2]
274
[124.3]
NOTE: Factory Refrigerant Charge includes refrigerant for 15 feet of standard line set.
3.0 LOCATING UNIT
MATCH ALL COMPONENTS:
3.1 CORROSIVE ENVIRONMENT
• OUTDOOR UNIT
The metal parts of this unit may be subject to rust or deterioration if exposed to a
corrosive environment. This oxidation could shorten the equipment’s useful life.
Corrosive elements include, but are not limited to, salt spray, fog or mist in seacoast
areas, sulphur or chlorine from lawn watering systems, and various chemical contaminants from industries such as paper mills and petroleum refineries.
• INDOOR COIL/METERING DEVICE
• INDOOR AIR HANDLER/FURNACE
• REFRIGERANT LINES
If the unit is to be installed in an area where contaminants are likely to be a problem, special attention should be given to the equipment location and exposure.
•
Avoid having lawn sprinkler heads spray directly on the unit cabinet.
•
In coastal areas, locate the unit on the side of the building away from the waterfront.
•
Shielding provided by a fence or shrubs may give some protection, but cannot
violate minimum airflow and service access clearances.
•
Elevating the unit off its slab or base enough to allow air circulation will help
avoid holding water against the basepan.
Regular maintenance will reduce the build-up of contaminants and help to protect
the unit’s finish.
6
! WARNING
DISCONNECT ALL POWER TO UNIT BEFORE STARTING
MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK
RESULTING IN SEVERE PERSONAL INJURY OR DEATH.
•
Frequent washing of the cabinet, fan blade and coil with fresh water will remove
most of the salt or other contaminants that build up on the unit.
•
Regular cleaning and waxing of the cabinet with an automobile polish will provide some protection.
•
A liquid cleaner may be used several times a year to remove matter that will not
wash off with water.
Several different types of protective coatings are offered in some areas. These
coatings may provide some benefit, but the effectiveness of such coating materials
cannot be verified by the equipment manufacturer.
3.2 CONDENSER LOCATION
Consult local and national building codes and ordinances for special installation
requirements. Following location information will provide longer life and simplified
servicing of the outdoor condenser.
NOTE: These units must be installed outdoors. No ductwork can be attached, or
other modifications made, to the discharge grille. Modifications will affect performance or operation.
3.3 OPERATIONAL ISSUES
•
•
•
IMPORTANT: Locate the condenser in a manner that will not prevent, impair or
compromise the performance of other equipment horizontally installed in proximity to the unit. Maintain all required minimum distances to gas and electric
meters, dryer vents, exhaust and inlet openings. In the absence of National
Codes, or manaufacturers’ recommendations, local code recommendations
and requirements will take presidence.
Refrigerant piping and wiring should be properly sized and kept as short as
possible to avoid capacity losses and increased operating costs.
Locate the condenser where water run off will not create a problem with the
equipment. Position the unit away from the drip edge of the roof whenever possible. Units are weatherized, but can be affected by water pouring into the unit
from the junction of rooflines, without protective guttering.
3.4 FOR CONDENSERS WITH SPACE LIMITATIONS
In the event that a space limitation exists, we will permit the following clearances:
Single Unit Applications: One condenser inlet air grille side may be reduced to no
less than a 6-inch clearance. Clearances below 6 inches will reduce unit capacity
and efficiency. Do not reduce the 60-inch discharge, or the 24-inch service clearances.
Multiple Unit Applications: When multiple condenser grille sides are aligned, a 6inch per unit clearance is recommended, for a total of 12 inches between two units.
Two combined clearances below 12 inches will reduce capacity and efficiency. Do
not reduce the 60-inch discharge, or 24-inch service, clearances.
3.5 CUSTOMER SATISFACTION ISSUES
•
•
The condenser should be located away from the living, sleeping and recreational spaces of the owner and those spaces on adjoining property.
To prevent noise transmission, the mounting pad for the outdoor unit should
not be connected to the structure, and should be located sufficient distance
above grade to prevent ground water from entering the unit.
3.6 PROPER INSTALLATION
Proper sizing and installation of equipment is critical to achieve optimal performance. Use the information in this Installation Instruction Manual and reference the
applicable Engineering Specification Sheet when installing this product.
IMPORTANT: This product has been designed and manufactured to meet ENERGY STAR® criteria for energy efficiency when matched with appropriate coil components. However, proper refrigerant charge and proper air flow are critical to achieve
rated capacity and efficiency. Installation of this product should follow the manufacturer’s refrigerant charging and air flow instructions. Failure to confirm proper
charge and airflow may reduce energy efficiency and shorten equipment life.
7
3.7 UNIT MOUNTING
If elevating the condensing unit, either on a flat roof or on a slab, observe the
following guidelines.
•
•
The base pan provided elevates the condenser coil 3/4” above the base pad.
If elevating a unit on a flat roof, use 4” x 4” (or equivalent) stringers positioned
to distribute unit weight evenly and prevent noise and vibration.
3.8 FACTORY-PREFERRED TIE-DOWN METHOD
INSTRUCTIONS:
IMPORTANT: These instructions are intended as a guide to securing equipment for windload ratings of “120 MPH sustained wind load” and “3-second, 150 MPH gust.” While this
procedure is not mandatory, the Manufacturer does recommend that equipment be properly secured in areas where high wind damage may occur.
STEP 1: Before installing, clear pad of any dirt or debris.
IMPORTANT: The pad must be constructed of industry-approved materials, and
must be thick enough to accommodate the concrete fastener.
STEP 2: Center basepan on pad, ensuring it is level.
STEP 3: Remove unit top panel by removing screws around the perimeter of top panel.
Disconnect fan motor leads from contactor and lay top panel aside taking care
not to damage the fan.
STEP 4: Drill 4 or 6 holes (1/4” diameter) in the unit basepan only per figure 2.
STEP 5: Select and obtain appropriate concrete or lag screws and flat washers per
figure 2.
STEP 6: Drill pilot holes in pad through the basepan clearance holes drilled in Step 4,
ensuring that the holes are at least 1⁄4” deeper than the concrete fastener being
used. Use the concrete screw or lag screw manufacturer’s recommended hole
diameter for the pilot holes.
STEP 7: Drive concrete screws or lag screws through 1⁄4” clearance holes in unit basepan
and into the pad. Use flat washers under the head of the screws. Snug screws
to basepan.
NOTE: Do not over-tighten the concrete or lag screws. Doing so can weaken or strip
the fastener and cause it to break or pull out.
STEP 8: Re-connect fan motor wire leads to contactor per the unit wiring diagram and
lower unit top onto the unit. Take care to place the fan motor wire conduit in the
slot in the top of the control box as the top is lowered onto the unit. Re-install
screws that attach unit top to the unit.
STEP 9: Finish unit installation per Sections 4 – 16 in this manual.
4.0 REFRIGERANT CONNECTIONS
All units are factory charged with Refrigerant 410A. All models are supplied with
service valves. Keep tube ends sealed until connection is to be made to prevent
system contamination.
5.0 TOOLS REQUIRED FOR INSTALLING &
5.0 SERVICING R-410A MODELS
Manifold Sets:
-Up to 800 PSIG High Side
-Up to 250 PSIG Low Side
-550 PSIG Low Side Retard
Manifold Hoses:
-Service Pressure Ratiing of 800 PSIG
Recovery Cylinders:
-400 PSIG Pressure Rating
-Dept. of Transportation 4BA400 or BW400
! 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.
8
CONCRETE PAD SPECIFICATIONS:
GREATER THAN OR EQUAL TO 2-1/2” THICK SOLID CONCRETE
DENSITY GREATER THAN OR EQUAL TO 144 LBS/FT3 OR EQUIVALENT
PAD LENGTH GREATER THAN OR EQUAL TO (UNIT LENGTH +2”)
PAD WIDTH GREATER THAN OR EQUAL TO (UNIT WIDTH +2)
FIGURE 2
TIE-DOWN KIT ASSEMBLY
(6) 1-1/2” x 1/4” CONCRETE SCREWS SNUG TO BASE PAN.
LENGTH TO PENETRATE CONCRETE 1.5” MINIMUM.
OR (6) 1-1/2” x 1/4” LAG SCREWS SNUG TO BASE PAN.
LENGTH TO PENETRATE WOOD 1.5” MINIMUM
SCREWS HAVE TO BE PLACED ON THE BASE PAN
AS SHOWN UNLESS OTHERWISE SPECIFIED.
(6) 1-1/2” x 1/4” CONCRETE SCREWS SNUG TO BASE PAN.
LENGTH TO PENETRATE CONCRETE 1.5” MINIMUM.
OR (6) 1-1/2” x 1/4” LAG SCREWS SNUG TO BASE PAN.
LENGTH TO PENETRATE WOOD 1.5” MINIMUM
SCREWS HAVE TO BE PLACED ON THE BASE PAN
AS SHOWN UNLESS OTHERWISE SPECIFIED.
VIEW A
VIEW B
IF ANY ACCUMULATOR IS UTILIZED,
ADD 3.5” TO THE “A” DIMENSION
AND 2” TO THE “C” DIMENSION
FOR THIS HOLE LOCATION ONLY.
13 SEER
MODELS
14.5 SEER
MODELS
TIE DOWN
ASSEMBLY
VIEW
TIE DOWN ASSEMBLY DIMENSIONS
L
W
A
B
C
D
E
F
18/24
A
23.63”
23.63”
2.49”
19.77”
2.41”
19.63”
CENTER LINE CENTER LINE
OF UNIT
OF UNIT
30
B
27.63”
27.63”
3.5”
22.63”
3.5”
22.63”
CENTER LINE CENTER LINE
OF UNIT
OF UNIT
B
31.63”
31.63”
5.63”
24.50”
5.63”
24.50”
CENTER LINE CENTER LINE
OF UNIT
OF UNIT
36/42/48/60
18/24/30/36/
42/48/60
5.1 SPECIFICATION OF R-410A:
Application: R-410A is not a drop-in replacement for R-22; equipment designs
must accommodate its higher pressures. It cannot be retrofitted into R-22 condensing units.
Physical Properties: R-410A has an atmospheric boiling point of -62.9°F and its
saturaton pressure at 77°F is 224.5 psig.
Composition: R-410A is an azeotropic mixture of 50% by weight difluoromethane
(HFC-32) and 50% by weight pentafluoroethane (HFC-125).
Pressure: The pressure of R-410A is approximately 60% (1.6 times) greater
than R-22. Recovery and recycle equipment, pumps, hoses and the like need to
have design pressure ratings appropriate for R-410A. Manifold sets need to range
9
up to 800 psig high-side and 250 psig low-side with a 550 psig low-side retard.
Hoses need to have a service pressure rating of 800 psig. Recovery cylinders need
to have a 400 psig service pressure rating. DOT 4BA400 or DOT BW400.
Combustibility: At pressures above 1 atmosphere, mixture of R-410A and air can
become combustible. R-410A and air should never be mixed in tanks or supply
lines, or be allowed to accumulate in storage tanks. Leak checking should
never be done with a mixture of R-410A and air. Leak checking can be performed safely with nitrogen or a mixture of R-410A and nitrogen.
5.2 QUICK REFERENCE GUIDE FOR R-410A
• R-410A refrigerant operates at approximately 60% higher pressure (1.6 times)
than R-22. Ensure that servicing equipment is designed to operate with R-410A.
• R-410A refrigerant cylinders are pink in color.
• R-410A, as with other HFC’s is only compatible with POE oils.
• Vacuum pumps will not remove moisture from oil.
• R-410A systems are to be charged with liquid refrigerants. Prior to March 1999,
R-410A refrigerant cylinders had a dip tube. These cylinders should be kept
upright for equipment charging. Post March 1999 cylinders do not have a dip tube
and should be inverted to ensure liquid charging of the equipment.
• Do not install a suction line filter drier in the liquid line.
• A liquid line filter drier is standard on every unit. Only manufacturer approved liquid line filter driers can be used. These are Sporlan (CW083S) and Alco
(80K083S) driers. These filter driers are rated for minimum working pressure of
600 psig.
• Desiccant (drying agent) must be compatible for POE oils and R-410A.
6.0 REPLACEMENT UNITS
To prevent failure of a new condensing unit, the existing evaporator tubing system
must be correctly sized and cleaned or replaced. Care must be exercised that the
expansion device is not plugged. For new and replacement units, liquid line filter
drier sould be installed and refrigerant tubing should be properly sized. Test the oil
for acid. If positive, a suction line filter drier is mandatory.
IMPORTANT: WHEN REPLACING AN R-22 UNIT WITH AN R-410A UNIT,
EITHER REPLACE THE LINE SET OR ENSURE THAT THE EXISTING LINE SET
IS THOROUGHLY CLEANED OF ANY OLD OIL OR DEBRIS.
7.0 EVAPORATOR COIL
REFER TO EVAPORATOR COIL MANUFACTURER’S INSTALLATION
INSTRUCTIONS.
IMPORTANT: The manufacturer is not responsible for the performance and operation of a mismatched system, or for a match listed with another manufacturer’s coil.
! CAUTION
Only use evaporators approved for use on R-410A systems. Use of existing R-22
evaporators can introduce mineral oil into the R-410A refrigerant forming two different liquids and decreasing oil return to the compressor. This can result in compressor vfailure.
NOTE: All units must be installed with a TEV Evaporator.
The thermostat expansion valve is specifically designed to operate with R-410A.
DO NOT use an R-22 TEV or evaporator. The existing evaporator must be
replaced with the factory specified TEV evaporator specifically designed for
R-410A.
LOCATION
Do not install the indoor evaporator coil in the return duct system of a gas or oil furnace. Provide a service inlet to the coil for inspection and cleaning. Keep the coil
pitched toward the drain connection.
10
! CAUTION
When coil is installed over a finished ceiling and/or living area, it is
recommended that a secondary sheet metal condensate pan be
constructed and installed under entire unit. Failure to do so can result
in property damage.
8.0 REPLACEMENT UNITS
To prevent failure of a new condensing unit, the existing evaporator tubing system
must be correctly sized and cleaned or replaced. Care must be exercised that the
expansion device is not plugged. Test the oil for acid. If positive, a suction line filter
drier is mandatory. For new and replacement units, a liquid line filter drier should be
installed and refrigerant tubing should be properly sized.
9.0 INTERCONNECTING TUBING
9.1 VAPOR AND LIQUID LINES
Keep all lines sealed until connection is made.
Refer to Line Size Information in Tables 2 through 4 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 refrigeration charge in the outdoor unit is sufficient for 15 feet of interconnecting lines. The factory refrigeration 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.
1/4” ± 0.2 oz. per foot
5/16” ± 0.3 oz. per foot
3/8” ± 0.5 oz. per foot
1/2” ± 1.0 oz. per foot
9.2 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. Additional compressor oil is not
required for any length up to 150 feet.
NOTE: Excessively long refrigerant lines cause loss of equipment capacity.
9.3 OUTDOOR UNIT INSTALLED ABOVE INDOOR COIL
Keep the vertical separation between coils to a minimum. However, the vertical distance can be as great as 120 feet with the condensing unit ABOVE the indoor coil.
Use the following guidelines when installing the unit:
1.
2.
3.
4.
DO NOT exceed 120 feet maximum vertical separation.
Expansion Valve Coil:
a. The vertical separation can be greater than the value in Table 3, but no
more than 120 feet.
b. No changes are required for expansion valve coils.
Always use the smallest liquid line size permitted to minimize the system
charge.
Table 3 may be used for sizing horizontal runs.
9.4 OUTDOOR UNIT BELOW INDOOR COIL
Keep the vertical separation to a minimum. Use the following guidelines when
installing the unit:
1.
2.
3.
DO NOT exceed the vertical separations as indicated on Table 4.
Always use the smallest liquid line size permitted to minimize system charge.
Table 4 may be used for sizing horizontal runs.
9.5 TUBING INSTALLATION
Observe the following when installing correctly sized type “L” refrigerant tubing
between the condensing unit and evaporator coil:
11
•
•
•
•
If a portion of the liquid line passes through a hot area where liquid refrigerant
can be heated to form vapor, insulating the liquid line is required.
Use clean, dehydrated, sealed refrigeration grade tubing.
Always keep tubing sealed until tubing is in place and connections are to be
made.
Blow out the liquid and vapor lines with dry nitrogen before connecting to the
outdoor unit and indoor coil. For an air conditioning system, any debris in the
line set could end up plugging the expansion device.
! CAUTION
The filter drier is located inside the control box. The filter drier must be
installed externally in the liquid line or the Warranty will be VOID!
•
•
•
•
•
•
•
If tubing has been cut, make sure ends are deburred while holding in a position
to prevent chips from falling into tubing. Burrs such as those caused by tubing
cutters can affect performance dramatically, particularly on small liquid line
sizes.
For best operation, keep tubing run as short as possible with a minimum number of elbows or bends.
Locations where the tubing will be exposed to mechanical damage should be
avoided. If it is necessary to use such locations, the copper tubing should be
housed to prevent damage.
If tubing is to be run underground, it must be run in a sealed watertight chase.
Use care in routing tubing and do not kink or twist. Use a tubing bender on the
vapor line to prevent kinking.
The vapor line must be insulated to prevent dripping (sweating) and prevent
performance losses. Armaflex and Rubatex are satisfactory insulations for this
purpose. Use 1/2” minimum insulation thickness, additional insulation may be
required for long runs.
Check Table 2 for the correct vapor line size. Check Tables 4 and 5 for the correct liquid line size.
9.6 TUBING CONNECTIONS
Indoor evaporator coils have only a holding charge of dry nitrogen. Keep all tube
ends sealed until connections are to be made.
•
Use type “L” copper refrigeration tubing. Braze the connections with accepted
industry practices.
•
Be certain both refrigerant service valves at the outdoor unit are closed.
TABLE 2
SUCTION LINE LENGTH/SIZE VS. CAPACITY MULTIPLIER (R-410A)
Unit Size
11⁄2 Ton
2 Ton
21⁄2 Ton
3 Ton
31⁄2 Ton
4 Ton
5 Ton
Suction Line
Connection Size
3/4" I.D.
3/4" I.D.
3/4" I.D.
7/8" I.D.
7/8" I.D.
7/8" I.D.
7/8" I.D.
5/8
5/8
5/8
3/4*
3/4
7/8*
7/8*
Suction Line
Run - Feet
3/4*
3/4*
3/4*
7/8
7/8*
1 1/8
1 1/8
25’
50’
100’
150’
---
---
7/8
---
---
---
---
Optional
1.00
1.00
1.00
1.00
1.00
1.00
1.00
Standard
1.00
1.00
1.00
1.00
1.00
1.00
1.00
Optional
---
---
1.00
---
---
---
---
Optional
0.98
0.98
0.96
0.98
0.99
0.99
0.99
Standard
0.99
0.99
0.98
0.99
0.99
0.99
0.99
Optional
---
---
0.99
---
---
---
---
Optional
0.95
0.95
0.94
0.96
0.96
0.96
0.97
Standard
0.96
0.96
0.96
0.97
0.98
0.98
0.98
Optional
---
---
0.97
---
---
---
---
Optional
0.92
0.92
0.91
0.94
0.94
0.95
0.94
Standard
0.93
0.94
0.93
0.95
0.96
0.96
0.97
Optional
---
---
0.95
---
---
---
---
NOTES:
*Standard Line Size
Using suction line larger than shown in chart will result in poor oil return and is not recommended.
12
TABLE 3
LIQUID LINE SIZE – OUTDOOR UNIT ABOVE INDOOR COIL
System
Capacity
Line Size
Line Size
Connection Size
(Inch O.D.)
(Inch I.D.)
Liquid Line Size
Outdoor Unit Above Indoor Coil
(Cooling Only - Does not apply to Heat Pumps)
25
50
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
0
14
0
0
0
0
0
0
0
0
0
0
Total Equivalent Length - Feet
75
100
125
150
8
0
0
81
0
0
N/A
0
0
0
0
35
0
0
0
0
0
24
0
0
108
0
0
N/A
0
0
9
0
54
0
0
0
0
0
125
150
N/A
53
70
N/A
16
68
N/A
17
62
7
58
N/A
30
22
53
32
79
N/A
49
68
N/A
9
65
N/A
6
58
N/A
53
N/A
24
15
52
20
76
Minimum Vertical Separation - Feet
11⁄2 Ton
3/8”
2 Ton
3/8”
21⁄2 Ton
3/8”
3 Ton
3/8”
31⁄2 Ton
3/8”
4 Ton
3/8”
5 Ton
3/8”
1/4
5/16
3/8*
1/4
5/16
3/8*
1/4
5/16
3/8*
5/16
3/8*
5/16
3/8*
3/8*
1/2
3/8*
1/2
0
0
0
29
0
0
56
0
0
0
0
0
0
0
0
0
0
0
0
0
55
0
0
98
0
0
0
0
16
0
0
0
0
0
NOTES:
*Standard Line Size
N/A - Application not recommended.
TABLE 4
LIQUID LINE SIZE – OUTDOOR UNIT BELOW INDOOR COIL
System
Capacity
Line Size
Line Size
Connection Size
(Inch OD)
(Inch I.D.)
Liquid Line Size
Outdoor Unit Below Indoor Coil
25
50
Total Equivalent Length - Feet
75
100
Maximum Vertical Separation - Feet
11⁄2 Ton
3/8”
2 Ton
3/8”
21⁄2 Ton
3/8”
3 Ton
3/8”
31⁄2 Ton
3/8”
4 Ton
3/8”
5 Ton
3/8”
1/4
5/16
3/8*
1/4
5/16
3/8*
1/4
5/16
3/8*
5/16
3/8*
5/16
3/8*
3/8*
1/2
3/8*
1/2
25
25
25
23
25
25
25
25
25
25
25
25
25
25
25
25
25
40
50
50
N/A
36
50
N/A
49
50
50
50
23
50
46
50
50
50
25
62
75
N/A
29
72
N/A
38
68
37
68
4
43
38
56
56
75
9
58
72
N/A
23
70
N/A
27
65
22
63
N/A
36
30
55
44
81
NOTES:
*Standard Line Size
N/A - Application not recommended.
13
•
•
•
•
•
•
Clean the fittings before brazing.
Remove the cap and schrader core from service port to protect seals from heat
damage.
Use an appropriate heatsink material around the copper stub and the service
valves before applying heat.
IMPORTANT: Do not braze any fitting with the TEV sensing bulb attached.
Braze the tubing between the outdoor unit and indoor coil. Flow dry nitrogen
into a service port and through the tubing while brazing.
After brazing – use an appropriate heatsink material to cool the joint and
remove any flux residue.
9.7 LEAK TESTING
•
Pressurize line set and coil through service fittings with dry nitrogen to 150 psig
maximum. Leak test all joints using liquid detergent. If a leak is found, repair
and repeat leak test procedures.
! WARNING
DO NOT USE OXYGEN TO PURGE LINES OR PRESSURIZE SYSTEM FOR
LEAK TEST. OXYGEN REACTS VIOLENTLY WITH OIL, WHICH CAN
CAUSE AN EXPLOSION RESULTING IN SEVERE PERSONAL INJURY OR
DEATH.
10.0 EVACUATION PROCEDURE
Evacuation is the most important part of the entire service procedure. The life and
efficiency of the equipment is dependent upon the thoroughness exercised by the
serviceman when evacuating air and moisture from the line set and indoor coil.
Air in the system causes high condensing temperatures and pressure, resulting in
increased power input and non-verifiable performance.
Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoric
and hydrochloric acids. These attack motor windings and parts, causing breakdown.
After the system has been leak checked and proven sealed, connect the vacuum
pump and evacuate system to 500 microns. The vacuum pump must be connected
to both the high and low sides of the system through adequate connections. Use
the largest size connections available since restrictive service connections may lead
to false readings because of pressure drop through the fittings.
IMPORTANT: Compressors (especially scroll type) should never be used to evacuate the air conditioning system because internal electrical arcing may result in a
damaged or failed compressor.
11.0 START UP AND PERFORMANCE
Even though the unit is factory charged with R410A, the charge must be checked to
the charge table attached to the service panel and adjusted, if required. Allow a
minimum of 5 minutes running. Before analyzing charge, see the instructions on the
unit service panel rating plate for marking the total charge.
•
•
The service valves are not backseating valves. To open the valves, remove the
valve cap with an adjustable wrench. Insert a 3/16” or 5/16” hex wrench into the
stem. Back out counterclockwise until it stops.
Replace the valve cap finger tight then tighten an additional 1/8 of a turn for a
metal-to-metal seal.
12.0 CHECKING AIRFLOW
The air distribution system has the greatest effect. The duct system is totally controlled by the contractor. For this reason, the contractor should use only industryrecognized procedures.
The correct air quantity is critical to air conditioning systems. Proper operation, efficiency, compressor life, and humidity control depend on the correct balance
between indoor load and outdoor unit capacity. Excessive indoor airflow increases
the possibility of high humidity problems. Low indoor airflow reduces total capacity,
and causes coil icing. Serious harm can be done to the compressor by low airflow,
such as that caused by refrigerant flooding.
14
Air conditioning systems require a specified airflow. Each ton of cooling requires
between 350 and 450 cubic feet of air per minute (CFM), or 400 CFM nominally.
Duct design and construction should be carefully done. System performance can be
lowered dramatically through bad planning or workmanship.
Air supply diffusers must be selected and located carefully. They must be sized and
positioned to deliver treated air along the perimeter of the space. If they are too
small for their intended airflow, they become noisy. If they are not located properly,
they cause drafts. Return air grilles must be properly sized to carry air back to the
blower. If they are too small, they also cause noise.
The installers should balance the air distribution system to ensure proper quiet airflow to all rooms in the home. This ensures a comfortable living space.
These simple mathematical formulas can be used to determine the CFM in a residential or light commercial system.
Electric resistance heaters can use
CFM =
volts x amps x 3.414
1.08 x temp rise
Gas furnaces can use
CFM =
BTUH
∆T x 1.08
An air velocity meter or airflow hood can give a more accurate reading of the system CFM.
13.0 CHECKING REFRIGERANT CHARGE
Charge for all systems should be checked against the Charging Chart inside the
access panel cover. Before using the chart, the indoor conditions must be within
2°F of desired comfort conditions and system must be run until operating conditions
stabilize (15 min. to 30 min.)
! CAUTION
THE TOP OF THE SCROLL COMPRESSOR SHELL IS HOT. TOUCHING THE
COMPRESSOR TOP MAY RESULT IN SERIOUS PERSONAL INJURY.
IMPORTANT: Do not operate the compressor without charge in system.
Addition of R-410A will raise pressures (vapor, liquid and discharge) and lower
vapor temperature.
If adding R-410A raises both vapor pressure and temperature, the unit is overcharged.
IMPORTANT: Use industry-approved charging methods to ensure proper system
charge.
13.1 CHARGING USING CHARGING CHART
NOTE: THIS UNIT CONTAINS R-410A REFRIGERANT.
DO NOT CHARGE WITH R-22 REFRIGERANT.
The liquid pressure method is used for charging systems in the cooling mode. The
service port on the liquid (small valve) and suction (large valve) is used for this purpose.
Verify that the outdoor unit is running in the cooling mode and the indoor air mover
is delivering the maximum airflow for this system size. Read and record the outdoor
ambient temperature. Read and record the liquid and suction pressures at the ports
on the liquid and suction valves.
If refrigerant lines are sized using the nameplate charge, the correct liquid pressure
is found at the intersection of the suction pressure and the outdoor ambient.
1. Remove refrigerant charge if the liquid pressure is above the chart value.
2. Add refrigerant charge if the liquid pressure is below the chart value.
! CAUTION
R-410A PRESSURES ARE APPROXIMATELY 60% HIGHER THAN R-22
PRESSURES. USE APPROPRIATE CARE WHEN USING THIS REFRIGERANT. FAILURE TO EXERCISE CARE MAY RESULT IN EQUIPMENT DAMAGE, OR PERSONAL INJURY.
15
If the refrigerant lines utilize extended lengths, add 4 psi to the liquid pressure values shown in the chart.
1. Remove refrigerant charge if the refrigerant liquid pressure is above the corrected chart value.
2. Add refrigerant charge if the liquid pressure is below the corrected chart value.
13.2 CHARGING BY WEIGHT
For a new installation, evacuation of interconnecting tubing and evaporator coil is
adequate; otherwise, evacuate the entire system. Use the factory charge shown in
Table 1 of these instructions or unit data plate. Note that charge value includes
charge required for 15 ft. of standard size interconnecting liquid line. Calculate actual charge required with installed liquid line size and length using:
1/4” O.D. = 0.2 oz./ft.
5/16” O.D. = 0.3 oz./ft.
3/8” O.D. = 0.5 oz./ft.
1/2” O.D. = 1.0 oz./ft.
With an accurate scale (+/– 1 oz.) or volumetric charging device, 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.
NOTE: When the total refrigerant charge volume exceeds the values in Table 7, the
manufacturer recommends installing a crankcase heater and start kit.
13.3 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.
14.0 ELECTRICAL WIRING
! WARNING
TURN OFF ELECTRIC POWER AT
THE FUSE BOX OR SERVICE
PANEL BEFORE MAKING ANY
ELECTRICAL CONNECTIONS.
ALSO, THE GROUND CONNECTION MUST BE COMPLETED
BEFORE MAKING LINE VOLTAGE
CONNECTIONS. FAILURE TO DO
SO CAN RESULT IN ELECTRICAL
SHOCK, SEVERE PERSONAL
INJURY OR DEATH.
Field wiring must comply with the National Electric Code (C.E.C. in Canada) and
any applicable local code.
14.1 GROUNDING
A grounding lug is provided near the contactor for a ground wire.
! WARNING
THE UNIT MUST BE PERMANENTLY GROUNDED. FAILURE TO DO SO
CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL
INJURY OR DEATH.
14.2 POWER WIRING
It is important that proper electrical power from a commercial utility is available at
the condensing unit contactor. Voltage ranges for operation are shown in Table 5.
Power wiring must be run in a rain-tight conduit. Conduit must be run through the
connector panel below the access cover (See Figure 1) and attached to the bottom
of the control box.
Connect power wiring to contactor located in outdoor condensing unit electrical box.
(See wiring diagram attached to unit access panel.)
Check all electrical connections, including factory wiring within the unit and make
sure all connections are tight.
DO NOT connect aluminum field wire to the contactor terminals.
TABLE 5
VOLTAGE RANGES (60 HZ)
Nameplate Voltage
208/230 (1 Phase)
16
Operating Voltage Range at Copeland
Maximum Load Design Conditions for
Compressors
187 - 253
14.3 CONTROL WIRING
(See Figure 3)
If the low voltage control wiring is run in conduit with the power supply, Class I insulation is required. Class II insulation is required if run separate. Low voltage wiring
may be run through the insulated bushing provided in the 7/8 hole in the base
panel, up to and attached to the pigtails from the bottom of the control box. Conduit
can be run to the base panel if desired by removing the insulated bushing.
A thermostat and a 24 volt, 40 VA minimum transformer are required for the control
circuit of the condensing unit. The furnace or the air handler transformer may be
used if sufficient. See the wiring diagram for reference. Use 18-gauge thermostat
wire only.
15.0 FIELD INSTALLED ACCESSORIES
15.1 COMPRESSOR CRANKCASE HEAT (CCH)
While scroll compressors usually do not require crankcase heaters, there are
instances when a heater should be added. Refrigerant migration during the off cycle
can result in a noisy start up. Add a crankcase heater to minimize refrigerate migration, and to help eliminate any start up noise or bearing “wash out.”
NOTE: The installation of a crankcase heater is recommended if the system charge
exceeds the values listed in Table 6.
All heaters are 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.
At initial start-up or after extended shutdown periods, make sure the heater is energized for at least 12 hours before the compressor is started. (Disconnect switch on
and wall thermostat off.)
TABLE 6
MAXIMUM SYSTEM CHARGE VALUES – 13 SEER
13 SEER
Model
Size
18
24
30
36
42
48
60
Compressor
Model
Number
ZP16K5E
ZP20K5E
ZP24K5E
ZP31K5E
ZP36K5E
ZP42K5E
ZP51K5E
Charge Limit
Without Crankcase
Heat (1 Phase)
9.6 lbs.
9.6 lbs.
9.6 lbs.
9.6 lbs.
12 lbs.
12 lbs.
12 lbs.
Charge Limit
Without Crankcase
Heat (3 Phase)
8 lbs.
10 lbs.
10 lbs.
10 lbs.
MAXIMUM SYSTEM CHARGE VALUES – 14.5 SEER
14.5 SEER
Model
Size
18
24
30
36
42
Compressor
Model
Number
ZP16K5E
ZP20K5E
ZP24K5E
ZP31K5E
ZP34K5E
Charge Limit
Without Crankcase
Heat (1 Phase)
9.6 lbs.
9.6 lbs.
9.6 lbs.
9.6 lbs.
12 lbs.
NOTE: Model sizes 48 and 60 have a factory installed crankcase heater.
15.2 TIME DELAY CONTROL (TDC)
The time delay (TDC) is in the low voltage control circuit. When the compressor
shuts off due to a power failure or thermostat operation, this control keeps it off at
least 5 minutes which allows the system pressure to equalize, thus not damaging
the compressor or blowing fuses on start-up.
17
FIGURE 3
CONTROL WIRING FOR GAS OR ELECTRIC HEAT
FOR TYPICAL GAS OR OIL HEAT
FOR TYPICAL ELECTRIC HEAT
15.3 LOW AMBIENT CONTROL (LAC)
This component senses compressor head pressure and shuts the heat pump fan off
when the head pressure drops to approximately 220 PSIG [1516.8 kPa]. This
allows the unit to build a sufficient head pressure at lower ambient in order to maintain system balance and obtain improved capacity. Low ambient control should be
used on all equipment operated below 70°F [21.1°C] ambient.
15.4 HIGH AND LOW PRESSURE CONTROLS (HPC & LPC)
These controls keep the compressor from operating in pressure ranges which can
cause damage to the compressor. Both controls are in the low voltage control circuit.
High pressure control (HPC) is an auto-reset which opens near 610 PSIG and
closes at 420 PSIG.
The low pressure control (LPC) is an automatic reset which opens near 50 PSIG
and closes near 95 PSIG.
16.0 SERVICE
16.1 OPERATION
Single phase units are operated PSC (no starting components). It is important that
such systems be off for a minimum of 5 minutes before restarting to allow equalization of pressure. The thermostat should not be moved to cycle unit without waiting 5
minutes. To do so may cause the compressor to go off on an automatic overload
device or blow a fuse. Poor electrical service can also cause nuisance tripping on
overloads, trip a breaker, or cause light dimming. This generally can be corrected
by adding start components. Check with factory for recommended start components, if required. For PSC type operation, refrigerant metering must be done with
fixed orifice, cap tubes or bleed type expansion valves because of low starting
torque. If non-bleed expansion valve coils (supplied by factory) are used, start components are required.
16.2 SINGLE-POLE COMPRESSOR CONTACTOR (CC)
Single-pole contactors are used on all standard single phase units up through 5
tons. Caution must be exercised when servicing as only one leg of the power supply is broken with the contactor.
18
17.0 TROUBLE SHOOTING
In diagnosing common faults in the air conditioning system, it is useful to present
the logical pattern of thought that is used by experienced technicians. The charts
which follow are not intended to be an answer to all problems, but only to guide
your thinking as you attempt to decide on your course of action. Through a series of
yes and no answers, you will follow the logical path to a likely conclusion.
Use these charts as you would a road map, if you are a beginning technician. As
you gain experience, you will learn where to establish the shortcuts. Remember
that the chart will help clarify the logical path to the problem.
17.1 ELECTRICAL CHECKS FLOW CHART
Unit Running?
YES
Repair and Recheck
NO
YES
Thermostat Problem?
Go to
Mechanical Checks
NO
Transformer Problem?
YES
Repair and Recheck
NO
Voltage on Compressor
Side of Contactor?
YES
NO
Run Capacitor
Voltage on Line
Side of Contactor?
Start Capacitor
NO
YES
Circuit Breakers
or Fuses Open
Compressor Contactor
YES
Hi Pressure Control
Compressor Winding
Grounded
Lo Pressure Control
Potential Relay
Compressor Internal
Overload Open
Compressor Winding Open
Unit Wiring and
Connections
Compressor Time-Delay
Condenser Fan
Grounded
Unit Wiring and
Connections
Grounded Capacitor
Replace Fuses
or Reset Breakers and Recheck
19
17.2 MECHANICAL CHECKS FLOW CHART
Unit Running?
YES
NO
Pressure problems?
Go to Electrical
Checks Flow Chart
High Head Pressure
Low Head Pressure
Low Suction Pressure
Dirty Condenser Coil
Low on Charge
Dirty Filters
Inoperative Outdoor Fan
Open IPR Valve
Dirty Evaporator
Overcharge
Low Ambient Temperature
Inadequate Airflow
Recirculation of
Condenser Air
Inoperative Compressor
Valves
Broken Indoor
Blower Belt
Non-condensibles
Restricted Filter-drier
Inoperative Indoor Blower
Higher than Ambient
Air Entering Condenser
Restriction in System
Low on Charge
Wrong Condenser Fan Rotation
Indoor Metering
Device Stuck
Closed
Faulty Metering Device
Indoor Metering Device
Stuck Open
Restriction in System
Restricted Filter-drier
Recirculation of
Evaporator Air
Wrong Evaporator
Blower Rotation
Inadequate Ducts
20
17.3 SUPERHEAT CALCULATION
TABLE 7
TEMPERATURE PRESSURE CHART
TEMP
(Deg. F)
R-410A
PSIG
-150
-140
-130
-120
-110
-100
-90
-80
-70
-60
-50
-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
—
—
—
—
—
—
—
—
—
0.4
5.1
10.9
14.2
17.9
22.0
26.4
31.3
36.5
42.2
48.4
55.1
62.4
70.2
78.5
87.5
97.2
107.5
118.5
130.2
142.7
156.0
170.1
185.1
201.0
217.8
235.6
254.5
274.3
295.3
317.4
340.6
365.1
390.9
418.0
446.5
476.5
508.0
541.2
576.0
612.8
1. Measure the suction pressure at the suction line service valve.
2. Convert the suction pressure to saturated temperature. See Table 7.
3. Measure the temperature of the suction line at the suction line service valve.
4. Compare the temperature of the suction line to the saturated temperature.
5. The difference between saturated temperature and suctin line temperature is the
superheat. Superheat normal range 12° to 15°.
17.4 SUBCOOLING CALCULATION
1. Measure the liquid pressure at the liquid line service valve.
2. Convert the liquid line pressure to saturated temperature. See Table 7.
3. Measure the liquid line temperature at the liquid line service valve.
4. Compare the liquid line temperature to the saturated temperature.
5. The difference between saturated temperature and liquid line temperature is the
subcooling. Subcooling normal range 9° to 12°.
TABLE 8
AIR CONDITIONING SYSTEM TROUBLESHOOTING TIPS
AIR CONDITIONING SYSTEM
TROUBLESHOOTING TIPS
INDICATORS
SYSTEM PROBLEM
Overcharge
DISCHARGE SUCTION
COMPRESSOR
SUPERHEAT SUBCOOLING
PRESSURE PRESSURE
AMPS
High
High
Low
High
High
Undercharge
Low
Low
High
Low
Low
Liquid Restriction (Drier)
Low
Low
High
High
Low
Low Evaporator Airflow
Low
Low
Low
Low
Low
Dirty Condenser
High
High
Low
Low
High
Low
Low Outside Ambient Temperature
Low
Low
High
High
Inefficient Compressor
Low
High
High
High
Low
TXV Feeler Bulb Charge Lost
Low
Low
High
High
Low
Poorly Insulated Sensing Bulb
High
High
Low
Low
High
21
17.5 GENERAL
TROUBLE SHOOTING CHART
!
WARNING
DISCONNECT ALL POWER TO UNIT BEFORE SERVICING. CONTACTOR MAY BREAK ONLY ONE SIDE. FAILURE
TO SHUT OFF POWER CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.
SYMPTOM
POSSIBLE CAUSE
Unit will not run
• Power off or loose electrical connection
• Thermostat out of calibration-set too high
• Defective contactor
• Blown fuses / tripped breaker
• Transformer defective
• High pressure control open (if provided)
Outdoor fan runs, compressor
doesn’t
Insufficient cooling
Compressor short cycles
• Run or start capacitor defective
• Start relay defective
• Loose connection
• Check for correct voltage at contactor in condensing unit
• Reset
• Check for 24 volts at contactor coil - replace if contacts are
open
• Replace fuses / reset breaker
• Check wiring-replace transformer
• Reset-also see high head pressure remedy-The high pressure
control opens at 450 PSIG
• Compressor stuck, grounded or open motor winding,
open internal overload.
• Low voltage condition
• Replace
• Replace
• Check for correct voltage at compressor check & tighten all connections
• Wait at least 2 hours for overload to reset.
If still open, replace the compressor.
• Add start kit components
•
•
•
•
•
•
•
•
Improperly sized unit
Improper indoor airflow
Incorrect refrigerant charge
Air, non-condensibles or moisture in system
• Incorrect voltage
• Defective overload protector
• Refrigerant undercharge
Registers sweat
REMEDY
Recalculate load
Check - should be approximately 400 CFM per ton.
Charge per procedure attached to unit service panel
Recover refrigerant, evacuate & recharge, add filter drier
• At compressor terminals, voltage must be ± 10% of
nameplate marking when unit is operating.
• Replace - check for correct voltage
• Add refrigerant
• Low indoor airflow
• Increase speed of blower or reduce restriction - replace air
filter
High head-low vapor pressures
• Restriction in liquid line, expansion device or filter drier
• Flowcheck piston size too small
• Incorrect capillary tubes
• Remove or replace defective component
• Change to correct size piston
• Change coil assembly
High head-high or normal vapor
pressure - Cooling mode
•
•
•
•
•
•
•
•
Low head-high vapor pressures
• Flowcheck piston size too large
• Defective Compressor valves
• Incorrect capillary tubes
• Change to correct size piston
• Replace compressor
• Replace coil assembly
Low vapor - cool compressor iced indoor coil
• Low indoor airflow
• Operating below 65°F outdoors
• Moisture in system
• Increase speed of blower or reduce restriction - replace air
filter
• Add Low Ambient Kit
• Recover refrigerant - evacuate & recharge - add filter drier
• Excessive load
• Defective compressor
• Recheck load calculation
• Replace
• TXV hunting
• Air or non-condensibles in system
• Check TXV bulb clamp - check air distribution on coil - replace
TXV
• Recover refrigerant, evacuate & recharge
• Air or non-condensibles in system
• Recover refrigerant, evacuate & recharge
High vapor pressure
Fluctuating head & vapor
pressures
Gurgle or pulsing noise at
expansion device or liquid line
22
Dirty outdoor coil
Refrigerant overcharge
Outdoor fan not running
Air or non-condensibles in system
Clean coil
Correct system charge
Repair or replace
Recover refrigerant, evacuate & recharge
18.0 WIRING DIAGRAMS
FIGURE 4
18.1 PSC DIAGRAM
SINGLE-PHASE WIRING DIAGRAM
JHB
01-19-04
90-101229-01
01
23
FIGURE 5
18.2 ECM DIAGRAM
24
CM 0509
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