Safety Labeling and Signal Words

These instructions must be read and understood
completely before attempting installation
Safety Labeling and Signal Words
DANGER,
WARNING,
CAUTION,
and NOTE
The signal words DANGER, WARNING,
CAUTION,
and NOTE are used to identify levels
of hazard seriousness. The signal word DANGER
is only used on product
labels to signify an
immediate hazard. The signal words WARNING,
CAUTION,
and NOTE will be used on product
labels and throughout
this manual and other
manual that may apply to the product.
DANGER
severe
- Immediate
personal
hazards
Signal
Words
in Manuals
The signal word WARNING
this manual in the followin(
is used throughout
manner:
The signal word CAUTION
this manual in the following
is used throughout
manner:
which will result in
injury or death.
WARNING
-Hazards
or unsafe practices which
could result in severe personal injury or death.
CAUTION
- Hazards or unsafe practices which
may result in minor personal injury or product or
property damage.
Signal Words on Product Labeling
Signal words are used in combination with
colors and/or pictures or product labels.
NOTE - Used to highlight suggestions
which will
result
in enhanced
installation,
reliability,
or
operation.
TABLE
OF CONTENTS
SAFETY CONSIDERATIONS .................
RECEIVING AND INSTALLATION .............
2
2
Step 1 - Check Equipment ...................
Step 2 - Provide Unit Support .................
Step 3 - Provide Clearances ..................
Step 4 - Field Fabricate Ductwork .............
Step 5 - Rig and Place Unit ...................
Step 6 - Provide for Condensate Disposal ......
Step 7 - Install Duct Connections ..............
Step 8 - Install Electrical Connections ..........
Wiring Diagram .............................
PRE-START-UP
............................
START-UP .................................
2
2
3
3
3
7
7
9
11
17
17
Step 1 - Check for Refrigerant Leaks ..........
17
Step 2 - Start-Up Cooling Section and Make Adj. 17
Airflow Adjustments ..........................
18
Cooling Sequence of Operations ..............
18
Maintenance ................................
22
Troubleshooting .............................
Start-Up Checklist ...........................
PERSONAL INJURY, AND/OR PROPERTY
DAMAGE HAZARD
Failure to carefully read and follow this warning
could result in equipment malfunction, property
damage, personal injury and/or death.
Installation or repairs made by unqualified
persons could result in equipment malfunction,
property damage, personal injury and/or death.
The information contained in this manual is
intended for use by a qualified service technician
familiar with safety procedures and equipped
with proper tools and test instruments.
Installation must conform with local building
codes and with the national Electrical Code
NFPA70 current edition or Canadian Electrical
Code part 1 CSA C.22.1.
28
30
5t6 01 2203 01
01/24/11
FIG. 1 - UNIT PHD3
PERSONAL INJURY AND ENVIRONMENTAL
HAZARD
Failure to relieve system pressure could result in personal injury
and/or death.
1. Relieve pressure and recover atl refrigerant before servicing
existing equipment, and before final unit disposal. Use all
service ports and open all flow-control
devices, including
solenoid valves.
2. Federal regulations require that you do not vent refrigerant
into the atmosphere. Recover during system repair or final unit
disposal.
INTRODUCTION
The PHD3 units are fully self-contained and designed for outdoor
installation. (See Fig. 1.) All unit sizes have discharge openings
for both horizontal and downflow configurations, and are factory
shipped with all downflow duct openings covered. The unit may
be installed either on a rooftop or on a ground-level cement slab.
(See Fig. 6 for roof curb dimensions.)
SAFETY
RECEIVING
CONSIDERATIONS
Installation and servicing of this equipment can be hazardous due
to mechanical and electrical components.
Only trained and
qualified
personnel
should
install, repair, or service this
equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations
must be performed by trained service personnel. When working
on this equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other safety
precautions that may apply.
Follow all safety codes. Installation must be in compliance with
local and national building codes. Wear safety glasses, protective
clothing, and work gloves. Have fire extinguisher available. Read
these instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit.
Recognize safety information. This is the safety-alert symbol /_
When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand these
signal words: DANGER, WARNING, and CAUTION. These words
are used with the safety-alert
symbol. DANGER identifies the
most serious hazards which will result in severe personal injury or
death. WARNING signifies hazards which could result in personal
injury or death. CAUTION is used to identify unsafe practices
which may result in minor personal injury or product and property
damage. NOTE is used to highlight suggestions which will result
in enhanced installation, reliability, or operation.
Step 1 m Check
AND INSTALLATION
Equipment
Identify Unit
The unit model number and serial number are stamped on the
unit identification plate. Check this information against shipping
papers.
Inspect
Shipment
Inspect for shipping
damage
before
removing
packaging
materials. If unit appears to be damaged or is torn loose from its
anchorage, have it examined by transportation inspectors before
removal. Forward claim papers directly to transportation company.
Manufacturer is not responsible for any damage incurred in
transit. Check all items against shipping list. Immediately notify the
nearest equipment distributor if any item is missing. To prevent
loss or damage, leave atl parts in original packages until
installation.
Step 2 m Provide
Unit Support
IMPORTANT: The unit must be secured to the curb by installing
screws through the bottom of the curb flange and into the unit
base rails. When installing large base units onto the common
curb, the screws must be installed before allowing the full weight
of the unit to rest on the curb. A minimum of six screws are
required for large base units. Failure to secure unit properly could
result in an unstable unit. See Warning near Rigging/Lifting
information and accessory curb instructions for more details.
For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate if required.
ELECTRICALSHOCKHAZARD
Roof Curb
Failure to follow this warning could result in personal injury or
death.
Install accessory roof curb in accordance with instructions
shipped with curb (See Fig. 6). Install insulation, cant strips,
roofing, and flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is critical
for a watertight seal. Install gasketing material supplied with the
roof curb. Improperly applied gasketing also can result in air leaks
and poor unit performance.
Curb should be level to within 1/4 in. (6.35 mm) (See Fig. 2). This
is necessary for unit drain to function properly. Refer to accessory
roof curb installation instructions for additional information as
required.
Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be more
than one disconnect switch. Turn off accessory heater power
switch if applicable.
CUT HAZARD
Failure to follow this caution may result in personal injury.
When removing access panels or performing maintenance
functions inside your unit, be aware of sharp sheet metal parts
and screws. Although special care is taken to reduce sharp
edges to a minimum, be extremely careful when handling parts
or reaching into the unit.
2
516 01 2203 01
Accessory kits are available to aid in installing a new metal base
rail unit on an old roof curb.
Accessory kit number CPADCURB001A00,
(small chassis) and
accessory
kit number CPADCURB002A00,
(large chassis)
includes roof curb adapter and gaskets for the perimeter seal and
duct openings. No additional modifications to curb are required
when using this kit.
Slab Mount
Place the unit on a solid, level concrete pad that is a minimum of
4 in. (102 mm) thick with 2 in. (51 mm) above grade. The slab
should extend approximately 2 in. (51 mm) beyond the casing on
all 4 sides of the unit. Do not secure the unit to the slab except
when required by local codes.
Step 3 m Provide
Clearances
The required minimum service clearances are shown in Fig. 4 and
5. Adequate ventilation and outdoor air must be provided. The
outdoor fan draws air through the outdoor coil and discharges it
through the top fan grille. Be sure that the fan discharge does not
recirculate to the outdoor coil. Do not locate the unit in either a
corner or under an overhead obstruction. The minimum clearance
under a partial overhang (such as a normal house overhang) is 48
in. (1219 mm) above the unit top. The maximum horizontal
extension of a partial overhang must not exceed 48 in. (1219
mm).
IMPORTANT: Do not restrict outdoor airflow. An air restriction at
either the outdoor-air
inlet or the fan discharge
may be
detrimental to compressor life.
Do not place the unit where water, ice, or snow from an overhang
or roof will damage or flood the unit. Do not install the unit on
carpeting or other combustible materials. Slab-mounted
units
should be at least 4 in. (102 mm) above the highest expected
water and runoff levels. Do not use unit if it has been under water.
Step 4 m Field-Fabricate
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached to the equipment,
and any other safety precautions that might apply.
Training for operators of the lifting equipment should include, but
not be limited to, the following:
1. Application of the lifter to the load, and adjustment
lifts to adapt to various sizes or kinds of loads.
of the
2. Instruction in any special operation or precaution.
3. Condition of the load as it relates to operation of the lifting
kit, such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work
gloves.
INSPECTION
Prior to initial use, and at monthly intervals, all rigging shackles,
clevis pins, and straps should be visually inspected for any
damage, evidence of wear, structural deformation, or cracks.
Particular attention should be paid to excessive wear at hoist
hooking points and load support areas. Materials showing any
kind of wear in these areas must not be used and should be
discarded.
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
injury or death.
Never stand beneath rigged units or lift over people.
Ductwork
Secure all ducts to roof curb and building structure on vertical
discharge units. Do not connect ductwork to unit. For horizontal
applications, unit is provided with flanges on the horizontal
openings. All ductwork should be secured to the flanges. Insulate
and weatherproof all external ductwork, joints, and roof openings
with counter flashing and mastic in accordance with applicable
codes.
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
injury/death or property damage.
When straps are taut, the clevis should be a minimum
of 36 in. (914 mm) above the unit top cover.
Fig. 3 - Slab
Fig. 2 - Unit Leveling Tolerances
A-B
B_C
A_C
Detail
[
I
I
MAXIMUM ALLOWABLE
DIFFERENCE in. (mm)
B
Mounting
2"
(50.8mm) I
1/4
(6.35)
1/4
(6.35)
1/4
(6.35)
2',
i
Ducts passing through an unconditioned space must be insulated
and covered with a vapor barrier. If a plenum return is used on a
vertical unit, the return should be ducted through the roof deck to
comply with applicable fire codes. See unit rating plate for any
required clearances around ductwork. Cabinet return-air static
shall not exceed -.25 in. wc.
Step 5 _
Rig and Place
EVAR
COIL
COND.
COIL
Unit
Rigging and handling of this equipment can be hazardous for
many reasons due to the installation location (roofs, elevated
structures, etc.).
516 01 2203
01
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FIG. 6 - ROOF CURB DIMENSIONS
/
Dashed
lines
location
for large
show
cross
support
basepan
units
A09413
SMALL/COMMON CURB
SMALL
BASE
UNIT
./
7¥
F A
LARGE
BASE
UNIT
UNIT PLACEMENT ON
COMMON CURB
A09415
LARGE CURB
* Part Numbers CPRCURB010A00 and CPRCURB011A00
is a small basepan or a large basepan.
UNIT
SIZE
Small
or
Large
Large
CATALOG
NUMBER
CPRFCURB010A00
CPRFCURB011A00
A
IN. (mm)
SMALL OR LARGE BASE UNIT
can be used on both small and large basepan
B
(small/common
base)
IN. (mm)*
A09094
units. The cross supports must be located based on whether the unit
B
(large base)
IN. (mm)*
C
IN. (mm)
D
IN. (mm)
14 (356)
16 (406)
47.8
(1214)
E
IN. (mm)
F
IN. (mm)
G
IN. (mm)
H
IN. (mm)
11 (279)
10 (254)
CPRFCURB012A00
14 (356)
11 (279)
CPRFCURB013A00
14 (356)
14 (356)
32.4 (822)
30.6 (778)
2.7 (69)
43.9
(1116)
46.1
(1170)
42.2 (1072)
NOTES:
1. Roof curb must be set up for unit being installed.
2. Seal strip must be applied, as required, to unit being installed.
3. Roof curb is made of 16-gauge
steel.
4. Attach ductwork to curb (flanges of duct rest on curb).
5. Insulated panels: 1-in. (25.4 mm) thick fiberglass 1 lb. density.
d
516 01 2203 01
FIG. 7 - RIGGING WEIGHTS
CAUTION - NOTICE TO RIGGERS
PRUDENCE - AViS AUX MANIPULATEUR
ACCESS PANELS MUST BE iN PLACE WHEN
PANNEAUX
D'ACCES
DOlT #TRE EN PLACE POUR
Use top skid as spreader
bar. / Utiliser
la palette
du haut
RiGGiNG.
MANiPULATiON.
comme
barre
de repartition
DUCTS
MINIMUM HEIGHT: 36" (914.4 ram)
HAUTEUR MINIMUM
SEAL
UNIT HEIGHT
HAUTEUR D'UNITE
STRIP
MUST
PLACE
BEFORE
UNIT ON ROOF
BE iN
PLACING
CURB
BANDE
SCELLANT
DOtT
ETRE
EN PLACE
AVANT
DE PLACER
L'UNtTE
SUR LA BASE DE TOtT
DETAIL A
VOIR DE_TAIL A
SEE DETAIL A
VOIR DETAIL A
CORNER
Unit
Ib
327
Rigging Weight
WEIGHTS
24
kg
148
-
(SMALL
J
50CY502286
CABINET)
30
Ib
340
kg
154
36
Ib
343
CORNER WEIGHTS
42
Unit
kg
156
Ib
419
Rigging Weight
kg
190
2.0
(LARGE CABINET)
48
Ib
429
kg
195
60
Ib
454
kg
206
*For 460 Volt units add 14 Ib (6,35 kg) to the rigging weight.
NOTE: See dimensional
Riqqinq/Liftinq
drawing for corner weights.
of Unit (See Fiq. 6.)
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
injury or death.
Large base units must be secured to common curb
before allowing full weight of unit to rest on curb. Install
screws through curb into unit base rails while rigging
crane is still supporting unit.
Lifting holes are provided in base rails as shown in Fig. 4 and 5.
1. Leave top shipping skid on the unit for use as a spreader
bar to prevent the rigging straps from damaging the unit. If
the skid is not available, use a spreader bar of sufficient
length to protect the unit from damage.
2. Attach shackles, clevis pins, and straps to the base rails of
the unit. Be sure materials are rated to hold the weight of
the unit. (See Fig. 7).
3. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unit is lifted level
with the ground.
After the unit is placed on the roof curb or mounting pad, remove
the top skid.
Step 6 m Provide
for Condensate
be sure to
Unit disposes of condensate water through a 3/4 in. NPT fitting
which exits through the base on the evaporator coil access side.
See Fig. 4 & 5 for location.
516 01 2203
01
Connect a drain tube using a minimum of 3/4 -in. PVC or 3/4 -in.
copper pipe (all field-supplied)
at the outlet end of the 2-in. (51
mm) trap. Do not undersize the tube. Pitch the drain tube
downward at a slope of at least 1-in. (25 mm) for every 10 ft (3.1
m) of horizontal run. Be sure to check the drain tube for leaks.
Prime trap at the beginning of the cooling season start-up.
FIG. 8 - CONDENSATE
TRAP
_,
OUTLET
1
TRAP
] ram) mini
l-in._(25
ram)rain.
Step 7 m Install
Disposal
NOTE: When installing condensate drain connection
comply with local codes and restrictions.
Condensate water can be drained directly onto the roof in rooftop
installations (where permitted) or onto a gravel apron in ground
level installations.
Install a field-supplied
2-in.
(51 mm)
condensate trap at end of condensate connection to ensure
proper drainage. Make sure that the outlet of the trap is at least 1
in. (25 mm) lower than the drain pan condensate connection to
prevent the pan from overflowing (See Fig. 8). When using a
gravel apron, make sure it slopes away from the unit.
The design
accordance
-
;
Duct Connections
and installation
of the duct system
must be
with the standards
of the NFPA for installation
in
of
non-residence
type air conditioning
and ventilating
systems,
NFPA 90A or residence-type,
NFPA 90B and/or local codes and
ordinances.
7
Select and size ductwork, supply-air
registers, and return air
grilles according to ASHRAE (American Society of Heating,
Refrigeration, and Air Conditioning Engineers) recommendations.
The unit has duct flanges on the supplyon the side of the unit.
and return-air
openings
When designing and installing ductwork, consider the following:
1. All units should have field-supplied filters or accessory filter
rack installed
in the return-air
side
of the unit.
Recommended sizes for filters are shown in Table 1.
2. Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.
IMPORTANT: Use flexible connectors between ductwork and unit
to prevent transmission
of vibration. Use suitable gaskets to
ensure weather tight and airtight seal. When electric heat is
installed, use fireproof canvas (or similar heat resistant material)
connector between ductwork and unit discharge connection. If
flexible duct is used, insert a sheet metal sleeve inside duct. Heat
resistant duct connector (or sheet metal sleeve) must extend
24-in. (610 mm) from electric heater element.
3. Size ductwork for cooling air quantity (cfm). The minimum
air quantity for proper electric heater operation is listed in
Table 2. Heater limit switches may trip at air quantities
below those recommended.
4. Seal, insulate, and weatherproof all external ductwork.
Seal, insulate and cover with a vapor barrier all ductwork
passing through conditioned spaces. Follow latest Sheet
Metal
and
Air
Conditioning
Contractors
National
Association (SMACNA) and Air Conditioning Contractors
Association
(ACCA) minimum installation standards for
residential heating and air conditioning systems.
5. Secure all ducts to building structure. Flash, weatherproof,
and vibration-isolate
duct openings
in wall or roof
according to good construction practices.
Confiqurinq Units for Downflow (Vertical) Discharqe
FIG. 9 - SUPPLY AND RETURN DUCT OPENINGS
Horizontal
Duct Covers
ELECTRICAL
SHOCK HAZARD
Failure to follow this warning could result in personal injury or
death.
Before performing service or maintenance operations on the
system, turn off main power to unit and install lockout tag.
1. Open all electrical disconnects
before starting any service work.
and
install
lockout
tag
2. Remove horizontal (metal) ductcovers to access vertical
(downflow) discharge duct knockouts in unit basepan. (See
Fig. 9.)
3. To remove downflow return and supply knockout covers,
break front and right side connecting
tabs with a
screwdriver and hammer. Push cover down to break rear
and left side tabs.
NOTE: These panels are held in place with tabs similar to an
electrical knockout. Reinstall horizontal duct covers (Fig. 9)
shipped on unit from factory. Insure openings are air and
watertight.
NOTE: The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
nonresidence-type
air conditioning
and ventilating systems,
NFPA 90A or residence-type,
NFPA 90B; and/or local codes and
ordinances.
Adhere to the following criteria when selecting, sizing, and
installing the duct system:
1. Units are shipped for side shot installation.
2. Select and size ductwork, supply-air
registers,
and
return-air grilles according to American Society of Heating,
Refrigeration and Air Conditioning Engineers (ASHRAE)
recommendations.
3. Use flexible transition between rigid ductwork and unit to
prevent transmission of vibration. The transition may be
screwed or bolted to duct flanges. Use suitable gaskets to
ensure weather-tight and airtight seal.
4. All units must have field-supplied filters or accessory filter
rack installed
in the return-air
side
of the unit.
Recommended sizes for filters are shown in Table 1.
5. Size all ductwork for maximum required airflow (either
heating or cooling) for unit being installed. Avoid abrupt
duct size increases or decreases or performance may be
affected.
6. Adequately insulate and weatherproof all ductwork located
outdoors. Insulate ducts passing through unconditioned
space, and use vapor barrier in accordance with latest
issue of Sheet Metal and Air Conditioning Contractors
National Association
(SMACNA) and Air Conditioning
Contractors
of America
(ACCA) minimum
installation
standards for heating and air conditioning systems. Secure
all ducts to building structure.
7. Flash, weatherproof, and vibration-isolate
all openings in
building structure in accordance with local codes and good
building practices.
Basepan
Downflow
Return
Knockout
8
516 01 2203 01
Step 8 --
Install Electrical
UNIT COMPONENT
3. Locate the black and yellow wires connected
side of the contactor.
Connections
DAMAGE HAZARD
Failure to follow this caution may result in damage to the unit
being installed.
1. Make all electrical connections in accordance with NEC
NFPA 70 (latest edition) and local electrical codes
governing such wiring. In Canada, all electrical
connections must be in accordance with CSA standard
C22.1 Canadian Electrical Code Part 1 and applicable
local codes. Refer to unit wiring diagram.
2. Use only copper conductor for connections between
field-supplied electrical disconnect switch and unit. DO
NOT USE ALUMINUM WIRE.
3. Be sure that high-voltage
power to unit is within
operating voltage range indicated on unit rating plate.
On 3-phase units, ensure phases are balanced within
2 percent. Consult local power company for correction
of improper voltage and/or phase imbalance.
4. Do not damage internal components when drilling
through any panel to mount electrical hardware,
conduit, etc.
4. Connect field L1 to black wire on connection 11 of the
compressor contactor.
5. Connect field wire L3 to yellow wire on connection 13 of the
compressor contactor.
6. Connect field wire L2 to blue wire from compressor.
FIG, 10 - HIGH- AND CONTROL-VOLTAGE
CONNECTIONS
HtGH VOLTAGE
/
POWER LEADS
<?=
(SEE UNIT WIRING /
LABEL)
3-PHASE SHOWN
1-PHASE USES
L=_
TWO POWER
LEADS
EQUIP GR
CONTROL
FIELD-SUPPLIED
FUSED DISCONNECT
BOX
m
/C,
Io
IO
IO
LOW-VO LTAG E
POWER LEADS
(SEE UNIT)
-WIRING LABEL
1o
IO"
IO'
ELECTRICALSHOCKHAZARD
IO
High-Voltage
Connections
The unit must have a separate electrical service with a
field-supplied, waterproof disconnect switch mounted at, or within
sight from the unit. Refer to the unit rating plate, NEC and local
codes for maximum fuse/circuit breaker size and minimum circuit
amps (ampacity) for wire sizing.
The field-supplied
disconnect may be mounted on the unit over
the high-voltage
inlet hole when the standard power and
low-voltage
entry points are used. See Fig. 4 and 5 for
acceptable location. Remove high voltage knockout.
See unit wiring label (Fig. 11-16) and Fig. 10 for reference when
making high voltage connections. Proceed as follows to complete
the high-voltage connections to the unit.
Single phase units:
1. Run the high-voltage
control box.
(L1, L2) and ground
lead into the
2. Connect ground lead to chassis ground connection.
3. Locate the black and yellow wires connected to the line
side of the contactor.
4. Connect field L1 to black wire on connection 11 of the
compressor contactor.
5. Connect field wire L2 to yellow wire on connection 23 of the
compressor contactor.
Three-phase units:
1. Run the high-voltage
control box.
(L1, L2, L3) and ground lead into the
2. Connect ground lead to chassis ground connection.
516 01 2203
01
-@
@
YE=L(Y)_
D" -@
_GRN(-G) .D= ®
®
©
O._RNLO)=
_ -@
BSU(D_I_ @
=WUT=(W_
_=
YL°(W2-2
D"
_ RED £R,,_'D"
THERMOSTAT
(TYPICAL)
_ BR,=N
(=C) _,=.
Io-
Failure to follow this warning could result in personal injury or
death.
The unit cabinet must have an uninterrupted, unbroken electrical
ground. This ground may consist of an electrical wire connected
to the unit ground screw in the control compartment, or conduit
approved for electrical ground when installed in accordance with
NEC,NFPA 70 National Fire Protection Association
(latest
edition) (in Canada, Canadian Electrical Code CSA C22.1) and
local electrical codes.
to the line
3-Phase
Only
SPLICE
BOX
Special Procedures for 208-V Operation
ELECTRICAL
SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off
main power to system. Tag the disconnect switch with
a suitable warning label. With disconnect switch open,
move black wire from transformer (3/16 in.) terminal
marked 230 to terminal marked 200. This retaps
transformer to primary voltage of 208 vac.
Control Voltage Connections
NOTE: Do not use any type of power-stealing
control problems may result.
thermostat.
Unit
Use no. 18 American Wire Gage (AWG) color-coded, insulated
(35°C minimum) wires to make the control voltage connections
between the thermostat and the unit. If the thermostat is located
more than 100 ft (30.5 m) from the unit (as measured along the
control voltage wires), use no. 16 AWG color-coded, insulated
(35 ° C minimum) wires.
Standard Connections
Locate the eight (nine on 3-phase) low voltage thermostat leads
in 24 volt splice box. See Fig. 10 for connection diagram. Run the
low-voltage leads from the thermostat, through the control wiring
inlet hole grommet (Fig. 4 and 5), and into the low-voltage splice
box. Provide a drip loop before running wires through panel.
Secure and strain relief all wires so that they do not interfere with
operation of unit. A gray wire is standard on 3-phase units for
connection to an economizer.
If an accessory electric heater is installed, low voltage leads from
heater must be connected to factory supplied control leads from
Indoor Fan Board P4 connector.
9
NOTE: If the unit 24V wires do not have a matching receptacle,
cut the 24V wires from the electric heater plug, strip the ends, and
wire nut together to match the schematic connections. If the
electric heater 24V wires do not have a matching plug, cut the
24V wires from the unit receptacle, strip the ends, and wire nut
together to match the schematic connections.
Transformer
Factory wires are provided for electric heat staging Wl and W2
(W2 and W3 on IFB). If room thermostat has only one stage of
supplemental heat, connect white and violet wires shown in Fig.
10 to second stage heat field wire.
Accessory
Protection
The transformer is of the energy-limiting type. It is set to withstand
a 30-second
overload or shorted secondary condition. If an
overload or short is present, correct overload condition and check
for blower fuse on Interface Fan Board. Replace fuse as required
with correct size and rating.
Electric
Heaters Installation
Electric heaters may be installed with the PHD3 units per
instructions supplied with electric heater package. See unit rating
plate for factory-approved
electric heater kits.
Some electric heaters have four control wires (plus common wire).
Consult unit wiring diagram and electric heater wiring diagram for
additional details.
Table
UNIT SIZE
NOMINAL
CAPACITY
SHIPPING
24
(ton)
WEIGHTS (Ib)
(kg)
COMPRESSOR
1 - Physical
Data
- Unit
30
PHD3
36
42
2
2.5
3
3.5
4
5
340
154
343
156
419
190
429
195
454
206
10,0
4.5
9.6
4.4
12.3
5.6
QUANTITY
1
TYPE
SCROLL COMPRESSOR
R-410A
(R-410A)
Quantity
Quantity (kg)
METERING
60
327
148
REFRIGERANT
Refrigerant
48
(Ib)
8.3
3.8
10,2
4.6
7.9
3.6
DEVICE ID
TXV
0.032 (2)
.81
0.035 (2)
.89
0.037 (2)
.94
0.038 (Left OD Coil)
0.040 (Right OD Coil)
.97/1.02
0.046 (2)
1.2
0.052 (2)
1.3
OUTDOOR COIL
Rows... Fins/in.
face area (sq. ft.)
2...21
11.9
2...21
11.9
2...21
11.9
2...21
13.6
2...21
13.6
2...21
17.5
OUTDOOR FAN
Nominal Airflow (CFM)
Diameter Motor HP (RPM)
2000
24
1/5 (810)
2700
24
1/5 (810)
2700
24
1/5 (810)
3100
26
1/5 (810)
3100
26
1/5 (810)
3500
26
1/5 (810)
INDOOR COIL
Rows... Fins/in.
face area (sq. ft.)
3...17
3.7
3...17
3.7
3...17
3.7
3...17
4.7
3...17
4.7
3...17
5.7
INDOOR BLOWER
Nominal Cooling Airflow (CFM)
Size (in.)
(mm)
Motor (H P)
800
10x10
254x254
1/2
1000
10x10
254x254
1/2
1200
1 lx10
279x254
3/4
1400
1 lx10
279x254
3/4
1600
1 lx10
279x254
1.0
1800
1lx10
279x254
1.0
ORIFICE OD (in.)
(mm)
HIGH-PRESSURE
SWITCH
Cutout
Reset (Auto)
LOSS-OF-CHARGE/LOW-PRESSURE
(psig)
650+15
420+25
SWITCH
20+5
45+10
(Liquid
Line) (psig)
Cutout
Reset (Auto)
RETURN-AIR
FILTERS*t
throwaway
(in.)
(mm)
20x20x1
508x508x25
20x24x1
508x610x25
24x30x1
610x762x25
24x36x1
610x914x25
*Required filter sizes shown are based on the larger of the ARI (Air conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 ft/minute
for throwaway type or 450 ft/minute for high-capacity
type. Air filter pressure drop for non-standard
filters must not exceed 0.08 IN. W.C.
If using accessory filter rack refer to the filter rack installation instructions for correct filter size and quantity.
S For 460 volt units, add 14 Ib (6.4 kg) to the weight.
Table
SIZE
AIRFLOW
10
(CFM)
2 - Minimum
Airflow
for
Reliable
Electric
Heater
Operation
(CFM)
24
30
36
42
48
60
800
1025
1250
1400
1710
1800
516 01 2203 01
FIG. 11 - CONNECTION
WIRING SCHEMATICS
CONNECTION WIRING
DANGER
ELECTRICAL
C)
o
•
0
COMP
_BLN_
IF
ORN=
BLH
L
FIELD
BLK
_
i ,_BLK_
_
_BLK
SUPPLY_
DR ..........
_BLN_
....................
YEL
EQUIP
_
F_ EL_x
COMPRESSORMOTOR
DEFROST BOARD
DEHUMIDIFICATION
MODE
DEFROST TEMPERATURE SWITCH
DEFROST RELAY
ACCESSORY OR OPTIONAL
HPS
HIGH
TO
INDICATE
COMMON
OTENTI
L ONL
:
'IRINGTO REPRESENT WIRING
NOT
IFB
HR
IFM
LPS
OFM
RVS
STD
TRAN
T STAT
INDOOR FAN BOARD
HEATER
INDOOR RELAY
FAN MOTOR
LOW PRESSURE SWITCH
OUTDOOR
FAN MOTOR
REVERSING
VALVE
STANDARD MODE
TRANSFORMER
THERMOSTAT
DE
USED_
LK%
BLK_B•
OFM
BLK_
COLOR 0
B__VEL_d
_
!
C
\
GNB
flLK
BLU
/
NW__P=---_%,,_BRN___
COMPRESSOR FLLG_
_
BLUE
GGRRY
N GGRRAE'EN
--
_i,_
UL['
--YEL
BLACK
BRNBROWR
YEL
=
D8
DEHUM
DFT
DR
CAP
CCH
SCHEIWATIC
208/230
1 60
IF SED_
TERMINAL (MARKED)
TERMINAL (UNMARKED)
SPLICE (IF
USED)
SPLICE (MARKED)
CONTACTOR
CAPACITOR,
COMP
CRANK CASE HEATER
DIAGRAM
SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING
NOTES:
I
IF ANY OF THE ORIGINAL WIRES FURNISHED ARE
REPLACED, THEY MUST BE REPLACED WITH THE
SAME WIRE OR ITS EQUIVALENT
R SEE PRICE PAGES FOR THERMOSTATS
3 USE 75 DEG COPPER CONDUCTORS
FOR FIELD
INSTALLATION
4 SEE INSTALLATION
INSTRUCTIONS
FOR PROPER HEATING AND COOLING CONNECTIONS
FOR YOUR UNIT
INDOOR FAN MOTOR PLUGS
"DO NOT DISCONNECT
UNDER LOAD"
S CCH NOT USED ON ALL UNITS
B THIS FUSE IS MANUFACTURED RY LITTELFUSE,
PIN 257003
7 UNIT FACTORY SHIPPED IN STD MODE
LEGEND
/_ FIELD SPLICE
208/230-1-60
CO_ P
ORN
ORANGE
RED
RED
wHTV[O VIOLETwHITE
YEL
YELLOW
IFM
..........
..................
PRESSURE SWITCH
/
--YE?
''
I
_
_" _
?
PRIMARY
2081_30V
_
*_
_
#._,_
SECONDARY
24V
\
L_I
/
_
_
_
I
I
TRAM
1 2 3 4 5
RED
BRN
FOR WIRING
WITH
ELECTRIC
HEATERS
SEE SCHEMATIC
ON HEATER
ACCESSORY
II _
i_IIi
_
.....
•
_;L
I
/I
;
--
----
fL
I
I
I
_
l_i_
I
i
I
TSTAT
"
/ _,
R LRED
I
_
4_
i
i
I
I
FF"_'''-_'_-,-,
_I
g
_#I
I
_
I L1
I
LR[
I
I
,,
'
,
I
,
_
I
I
I
I
1
I
I
G
I
I
I
SEE NOTE
j L_N
V
Z_
J L
, '
I
[
]
_
I
! [11
_
'
] [
RED
j
I_
!BNL<
BL_pj
I
__gl
_BLU'J
_GRN--
W
ii
ill
6_
,11
_
I
1
IFM SPEED TAP
M
SEE
NOTE
4
LI
:i
j
o
I
........................................
......
t...... ......................
I
]
ELECTRIC
HEATER
CONNECTOR
I_
IV
ELECTRIC
HEAT
BR BNR
/1/
_/HT4_<I(2_HT
/I
HRI ISK,I_
_RI_
,R_,2,3_4(_,w_n
W
VlOd_<,<'{VlO _>
Ii_
__.o K,_
•
BRN
BRN•
I
|
I
DEFROST
DR
q l
_
II
BOARD (DB)_
CTD
_
I_
_
_
p _
PI
_
DIP
COOLING
_
ENERGIZED
HEATING
ENERGIZED
FAN
LOGIC
SWITCH
SETTINGS
DEFAULT
so _I_UTES 60 _NUTES _0 M_NUTES_zo MINUTES
50
1 _ 3 _0 t _
; T+RO
DE
LOGIC
ENERGIZED
,
FIELD SELECTABLE OPTIONS FOR TI_E
BETWEEN DEFROST CYCLES (MINUTES)
516 01 2203
01
BR
PNI_
3 {ID_
BL
_
BLU
HPS
LPS
+BLN_BLI_BLU_BLU_
•
I
s_o_
UM
_
JU._EREO
_E_PINB
lOBE
ME_AL
O_JECTI
FIELD
SPEED
UP
CYCLE
I) MOMENTARILY
SHORT PINS AND RELEASE TO BYPASS
COMPRESSOR
OFF DELAY
21 SHORT
FOR S+ SEC
AND RELEASE
FOR FORCED DEFROST
3) PERMANENT SHORT WILL BE IGNORED
DE ENERGIZED
FAN
_
_"
p2 _
_WR/
[
_S_
_U ..........................................................
_N
RI
,_
DEFROST WILL
DEFROST WILL
TERMINATE
TERMINATE
IN 30 SEC
IF DFT OPEN
NORMALLY IF DFT IS CLOSED
PERIOD
THE COMPRESSOR WILL SHUT OFF FOR 50 SEC
INITIATION
AND TERMINATION
IN THE "QUIET
POSITION
ON DEFROST
SHIFT"
ON
11
FIG. 12 - LADDER WIRING SCHEMATICS
LADDER WIRING
DANGER
ELECTRICAL
208/230-1-60
DIAGRAM
SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING
L1
I
G/Y
USE COPPER CONDUCTORSONLY
FIELD SUPPLY
208/230 VAC, 60 HZ, 1PH
LK
11
L2
EL
23
C
USED
YEL
BLK
IF
USED_E
..............................................
BLU
YEL_
1!
230
TRAN
COM
PRIMARY 208/230V
BLK __A-A_L_L_},O
T 'STAT
DB
PS _
P3 2C_
24VAC R
Z_RE
: .....
D
OP1
I IIRII 3A
T_O_pq
2
lie
_Z]) P 1
YEL
DFT
IFB
--PN_
BLU
YO-
II
ORN
Y
23
YEL
3HYI/Y
n
RE_
©P 8.0
4DP_ 7,R
WH_ OP1
S
O P1 _ I1_11
DN
OP1
,IFB
C
6,W_
YE_
XDP 5.Y
BRN
_DPI
&C
5IIy2/DN II
P2
W
4_ P1 6IIW2II
V
4_ P1 711W3
II
T2
40 _
DB C
o
P_ _C>
0
DB C
RVS
ORN
-- BRN
P2
P2
OY
P2
2IIV
S
II C
IlWll
O
4 II RII 0
YEL
--WHT
SEE NOTE 4
RED
LOW0
die--SEE
ACC_SSOR_E____
_
....
12
[LECTRIC HEATER
CONNECTOR
HIGHO
IFB
}COM
NOTE 7
UNIT COMPONENT ARRANGEMENT
STD_
DEHUM
E ECTRIC HEAT
\
IFM
IF5
PI 2
SECTION
O_T_OOR FAX
516 01 2203 01
FIG. 13-
DANGER
ELECTRICAL
CONNECTION
WIRING SCHEMATICS
-208/230-3-60
SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING
NOTES
1
IF
2
BE REPLACED WITH THE SAME 91RE WR ITS
SEE PRICE PACES FOR THERMOSTATS
3
USE 75
ANY OF THE
DEC
OR[CIRAL
WIRES
FURNISHED
COPPER CONDUCTORS
SEE INSTALLATION
INSTRUCTIONS
ARE REPLACED,THEY
CCH
FOR PROPER HEATING
FOR YOUR UNIT
INDOOR FAN
THIS FUSE IS MANUFACTURED
MOTOR PLUGS
SN LITTELEUSE,
D
REMOVE YELLOW SPLICE
WHEN ECONOMIZER
K
AND CONNECT TW RELAY RI AS SHOWN
WHEN ECONOMIZER
AND ECONOMIZER RELAYS
THE
YELLOW
KIT
REQUIRED
AND SLACK
WITH
WIRES
IF USED_
INSTALLATION
5
WIRE
TO RELAY
ECWNOMIZER
AND COWLING
"DO ROT DISCONNECT
P/N _DIOO3
FUEL
R
DEHNM
FEATURE CANNOT SE USED WHEN ECONWMIZER
SHIPPED
IN
STD
IS
BLH
\
DR
BLK
ARE USED
L1
FIELD
RELAY
WHEN ECONOMIZER
AND ECONOMIZER RELAYS ARE NSED,]NSTALL
AS SHOWN ONTO THE COILS OF RELAY R AND RELAY R]
FACTORY
RELAYS
LOAD"
ARE USED,CONNECT
R AS SHOWN
AND HEAT PUMP/DUAL
IF USED_
CORRECTIONS
UMBER
ANS ECONOMIZER
8
UNIT
WUST
EOU[VALENT
FOR FIELD
_
IF
WIRES
BLK
BLU
BLK
L3
UNITS
BRN
L2
INSTALLED
BLK
MODE
EQUIP
GND
YE_
L)
CD
o
BLU
.Jl_"
BLACK
BLUE
BROWN
GRY
GRAY
ORN
PNK
RED
VIO
GRN
WHT
YEL
ORANGE
PINK
RED
VIOLET
GREEN
WHITE
YELLOW
C
CAW I
CCH
COMP
DB
DH
DEHUM
DFT
DR
ECON
EQUIP
_SEE
NOTE I
_I
I
_BLK
........
BLK
_
.....
I
\_
7
YEL
_
......
T
...............................................
YEL .........................................
Rj
!i L
COOLI%
UNIT
COMPONENT ARRANGEMENT
FAN LOGIC
i
I
TI+9o
ENERGIZED BE ENERGIZED
OUTDOOR FAN
SECTION
FHEATIND FAk LOGIC
ENERBIZEB DE ENERGIZED
COMPRESSOR
SECTION
INDOOR FAN
SECTIO_
CONTROL
BOX AREA
DIP
SINGLE PT
CONNECT[O_
30 MINUTES
ELEC
SWITCH
DEFA(LT
60 _[NUTES
90 MINUTES
SETTINGS
20
I)
OR
OR
2)
3)
CWMP
516 01 2203
E_
01
NE L
I_4vBoX
SPLICE
24V PO_IER
_NTRY
TEST
FIELD
PINS
SPEED
(USE
UP
METAL
CYCLE
MOMENTARILY
SHORT PINS AND RELEASE TO BYPASS
COMPRESSOR OFF DELAY
SHORT FOR 5+ SEC
AND RELEASE FOR FORCED DEFROST
PERMANENT SHORT WILL BE IGNORED
DEFROST
DEFROST
90
DISCON_IECT
_ER
JUMPERED
OBJECT)
MINUTES
HEAT
0£
N
SFL_B_
uM
_
WILL
WILL
TERMINATE
TERMINATE
IN 30 SEC
IF DFT OPEN
NORMALLY IF DFT IS CLOSED
+
FIELD SELECTABLE
OPTIONS
FOR TIME
BETWEEN DEFROST CYCLES (MINUTES>
PERIOD
THE COMPRESSOR WILL SHUT OFF FOR 50 SEC
INITIATION
AND TERMINATION
IN THE "QUIET
POSITION
ON OEFROST
SHIFT"
ON
13
FIG. 14 - LADDER WIRING SCHEMATICS
LADDER WIRING
DANGER
ELECTRICAL
L1
- 208/230-3-60
DIAGRAM
SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING
I
USE COPPER CONDUCTORS ONLY
FIELD S PPLY
BLK
I L3
G#Y
L
L2
BLU
YEL
11
23
c
11
13
ZF USED
YEL
YEL
BLK
BLU
11
230
TRAN
COM
BLK
YEL
IFB
24VAC R
T 'STAT
DB
DFT
10 _
P3
4:]_PI
R -
15
YEL
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HIOHO
ACCESSORY
ELECTRIC
HEAT
_,,
x
I
ELECTRIC
HEATER
CONNECTOR
•
.......................................
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50EZ500356
14
516 01 2203 01
FIG. 15 - CONNECTION
WIRING DIAGRAM 460-3-60
DANGER" ELECTRICAL SHOCK HAZARD DISCONNECT
NOTES:
1. IF ANYOF THE ORIGINALWIRES FURNISHEDAREREPLACED,
THEY NUGTBE REPLACED
WITHTHE SANEWIREOR ITS EOUIVALENT.
IF
2, SEEPRICE PAGESFORTNERNOSTATD,
3, USE 75 DEG. COPPER
CONDUCTORS
FORFIELD INSTALLATION.
4. SEE INSTALLATIONINSTRUCTIONS
FORPROPERHEATINGANDCOOLINGCONNECTIONS
FORYOURUNIT. INDOORFAN MOTOR
PLUGS
- 'DO NOTDISCONNECT
UNDERLOAD"
5, THESEFUSESAREMANUFACTURED
BY COOPER
BUGSNANN.
FIELD L1 ,_
PiN FNO-R-S.
_'--eLK6, THIS FUSE IS MANUFACTURED
BY LITTELFUGE,PIN 257003.
7. RENOVEYELLOW
SPLICE WHENECONOMIZER
ANDECORONIZER
SUPPL
Y._ L_____._yE L
RELAYSAREUSEDANDCONNECT
TO RELAYR1 AS SHOWN.
8. WHENECONOMIZER
ANDECONOMIZER
RELAYSAREUSED,
L2
CONNECT
THE YELLOWANDBLACKWIRESTO RELAY "R' AS
SHOWN,
RELAYliT REOURED
WITHECONOMIZER
ANDHEAT
PUMP/DUAL
FUEL UNITS.
EQUIP_GND
9. WHENECONONIZER
ANDECONONIZER
RELAYSAREUSED, INSTALL
___
WIRES kS SHOWN
ONTOTHE COILS OF RELAYR ANDRELAYRt.
tO.DEHUNFEATURE
CANNOTBE USEDWHENECONOMIZER
IS INSTALLED.
UNIT FACTORY-SHIPPEDIN STD NOUE.
POWERBEFORE SERVICING
SCHEMATIC
460-3-60
CCH
OFM
OFR
BLK
\
COLORCODE
BLK
BLU
BRN
GRY
GREEN
ORANGE
PINK
vIo ff&ET
PNK
RED
COMP
LEGEND
AT
C
CAP 1
CCH
COMP
DE
DFT
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ECON
EQUIP
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GND
HPS
HR
IFB
IFW
AUTO TRANSFORMER
LPS
460V - 230V
OFN
CORTACTOR
OFR
CAPACITOR. CONP
RVS
CRANKCASE HEATER
TRAN
COMPRESSOR
MOTOR
T-STAT
DEFROSTBOARD
R
DEFROSTTEMPERATURE R1
SWITCH
STD
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YEL
WHITE
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o TERMINAL (UNMARKED)
•
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-- FACTORY WIRING
- - FIELD CONTROLWIRING
--- FIELD POWERWIRING
--ACCESSORY
OR OPTIONAL
WIRING
BLACK
BLUE
BROWN
GRAY
RED ,II
DEFROSTRELAY
ECONOWIZER
EQUIPMENT
FUSE
GROUND
HIGH PRESSURESWITCH
HEATERRELAY
INDOOR FAN BOARD
INDOOR FAN MOTOR
LOW PRESSURE SWITCH
OUTDOOR FAN NOTOR
OUTDOORFAN RELAY
REVERSINGVALVE
TRANSFORMER
THERMOSTAT
ECONRELAY
E_ONRELAY
STANDARD
MODE
FUI 5 AMP
ELK
_1
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NOTE 4
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J _,
_
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FOR WIRING WITH
ELECTRIC HEATERS
SEE SCHEMATIC
ON HEATER ACCESSORY,
r:r-
-
_
L
_
,-
-
-BRN
Y;L
-
4
/
P1
DEFAULT
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-
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516 01 2203
,
i-
_
',
J i
ENE_ED
HEATING FAN LOGIC
'_,
01
-
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HPS
.... LPS _.--RLU----------_--n
LK-----o-_-_
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JUMPERED
OBJECT}
TEST
FIELD
PINS
(USE METAL
SPEED-UP
CYCLE
1) MOMENTARILY SHORT PINS AND RELEASE TO BYPASS
COMPRESSOR OFF DELAY.
21 SHORT FOR 5+ SEC, AND RELEASE FOR FORCED DEFROST,
5) PERMANENT SHORT WILL BE IGNORED,
COOLING FAN LOGIC
i
P3_'_
DIP SWITCH SETTINGS
.L,_I
*-- - _ --_,
-_T
-BLU
,,"
L
DEFROST BOARD (DB) I'_
CTD
,_--'-r-- _
NOTE 7X
, -_-'
DEFROST
WILL TERMINATEIN 30 SEC, IF DFT OPEN.
DEFROST
WILL TERMINATENORMALLY
IF DFT IS CLOSED,
FIELD SELECTABLEOPTIONS FOR TIME PERIOD
BETWEENDEFROSTCYCLES (MINUTES)
THE COMPRESSOR
WILL SHUTOFF FOR 30 SEC, ON DEFROST
INITIATIONAND TERMINATIONIN THE 'QUIET SHIFT' ON
POSITION
15
FIG. 16 - LADDER WIRING DIAGRAM 460-3-60
DANGER" ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE SERVICING
USE COPPER CONDUCTORS ONLY G)Y
FIELD SUPPLY
.j_
460 VAC, 60 HZ, 3PH
11q
L3
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1
CCH
C
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NOTES
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NOTE
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l,--YEL.--c---4
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HEATER
l_Vl e
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I 50EZSOOS54 I E
516 01 2203 01
PRE-START-UP
FIRE, EXPLOSION,
ELECTRICAL
START-UP
SHOCK HAZARD
Failure to follow this warning could result in personal injury,
death or property damage.
1. Follow
recognized
safety
practices
and wear
protective
goggles when checking
or servicing
refrigerant system.
2. Relieve and recover all refrigerant from system before
touching or disturbing compressor plug if refrigerant
leak is suspected around compressor terminals.
3. Do not remove compressor plug until all electrical
sources are disconnected and tagged.
4. Never attempt to repair soldered connection
refrigerant system is under pressure.
while
5. Do not use torch to remove any component. System
contains oil and refrigerant under pressure.
To remove a component, wear protective goggles and
proceed as follows:
a. Shut off electrical power to unit and install lockout
tag.
b. Relieve and reclaim all refrigerant from system using
both high- and low-pressure ports.
c. Cut component connecting tubing with tubing cutter
and remove component from unit.
d. Carefully unsweat remaining tubing stubs when
necessary. Oil can ignite when exposed to torch
flame.
Use the Start-Up Checklist supplied at the end of this book and
proceed as follows to inspect and prepare the unit for initial
start-up:
1. Remove all access panels.
2. Read and follow instructions on all DANGER, WARNING,
CAUTION, and INFORMATION
labels attached to, or
shipped with, unit.
3. Make the following inspections:
a. Inspect for shipping and handling damages such as
broken lines, loose parts, disconnected wires, etc.
b. Inspect for oil at all refrigerant tubing connections and on
unit base. Detecting oil generally indicates a refrigerant
leak. Leak-test all refrigerant tubing connections using
electronic leak detector, or liquid-soap
solution. If a
refrigerant leak is detected, see following Check for
Refrigerant Leaks section.
c. Inspect all field and factory-wiring
connections. Be sure
that connections are completed and tight. Ensure wires do
not touch refrigerant tubing or sharp sheet metal edges.
d. Inspect coil fins. If damaged during shipping and handling,
carefully straighten fins with a fin comb.
4. Verify the following conditions:
a. Make sure that outdoor-fan blade is correctly positioned in
fan orifice.
b. Make sure that air filter(s) is in place.
c. Make sure that condensate drain pan and trap are filled
with water to ensure proper drainage.
d. Make sure that all tools and miscellaneous loose parts
have been removed.
5. Each unit system has 2 Schrader-type ports, one low-side
Schrader fitting located on the suction line, and one
high-side
Schrader fitting located on the compressor
discharge line. Be sure that caps on the ports are tight.
516 01 2203
01
Checking Cooling and Heating Control Operation
Start and check the unit for proper control operation as follows:
(1 .) Place room thermostat SYSTEM switch or MODE
control in OFF position. Observe that blower motor
starts when FAN mode is placed in FAN ON
position and shuts down when FAN MODE switch
is placed in AUTO position.
(2.) Thermostat:
When the room temperature rises to a point that is
slightly above the cooling control setting of the
thermostat, the thermostat completes the circuit
between thermostat terminal R to terminals Y, O
and G.These completed circuits through the
thermostat connect contactor coil (C) (through unit
wire Y) and Indoor Fan board (through unit wire G)
across the 24-v. secondary of transformer (TRAN).
(3.) Place system switch or MODE control in HEAT
position. Set control above room temperature.
Observe that compressor, outdoor fan, and indoor
blower motors start. Observe that heating cycle
shuts down when control setting is satisfied.
(4.) When using an automatic changeover room
thermostat place both SYSTEM or MODE control
and FAN mode switches in AUTO positions.
Observe that unit operates in Cooling mode when
temperature control is set to "call for Cooling"
(below room temperature), and unit operates in
Heating mode when temperature control is set to
"call for Heating" (above room temperature).
NOTE: Once the compressor has started and then has stopped,
it should not be started again until 5 minutes have elapsed. The
defrost board has a built-in 5 minute delay between cycles. The 5
minute compressor delay also applies to heat pump heating
mode.
Step 1 m Check
for Refrigerant
Leaks
Proceed as follows to locate and repair a refrigerant leak and to
charge the unit:
1. Locate leak and make sure that refrigerant system pressure
has been relieved and reclaimed from both high- and
low-pressure ports.
2. Repair leak following Refrigerant Service procedures.
NOTE: Install a bi-flow filter drier whenever the system has been
opened for repair.
3. Add a small charge of R-410A
and leak-test unit.
refrigerant vapor to system
4. Recover refrigerant from refrigerant system and evacuate to
500 microns if no additional leaks are not found.
5. Charge unit with R-410A refrigerant, using an electronic
scale. Refer to unit rating plate for required charge.
Step 2 m Start-Up
Adjustments
Complete the required procedures given in the Pre-Start-Up
section before starting the unit. Do not jumper any safety devices
when operating the unit. Do not operate the unit in Cooling mode
when the outdoor temperature is below 40°F (4°C) (unless
accessory low-ambient kit is installed).
IMPORTANT: Three-phase,
scroll compressors
are direction
oriented. Unit must be checked to ensure proper compressor
3-phase power lead orientation. If not corrected within 5 minutes,
the internal protector will shut off the compressor. The 3-phase
power leads to the unit must be reversed to correct rotation. When
turning backwards, the difference between compressor suction
and discharge pressures may be near zero.
1"7
Sequence of Operation
a. CONTINUOUS FAN
(1.) Thermostat closes circuit R to G energizing the
blower motor for continuous fan.
b. COOLING MODE
(1.) If indoor temperature is above temperature set
point, thermostat closes circuits R to G, R to Y and
R to O-The unit delivers cooling airflow.
c. ELECTRIC HEATING MODE
(1 .) Thermostat closes circuit R to W/W1, or W2 and R to
G. There are no on or off delays.
d. HEAT PUMP HEATING MODE
(1.) Thermostat closes circuits R to G and R to Y. The
compressor, indoor and outdoor fans are energized.
e. HEAT PUMP HEATING WITH AUXILIARY ELECTRIC
HEAT
(1.) Thermostat closes circuits R to G, R to Y and R to
W/W1 or W2. The compressor, indoor and outdoor
fans are energized, as well as the electric heat
relays.
f. DEFROST MODE
The defrost mode is automatically energized by the defrost
board during heating mode. The defrost board energizes
"O" (reversing valve) and "W2" (electric heat). It also deenergizes the outdoor fan. When defrost is complete, unit
will return to heating mode. If room thermostat is satisfied
during defrost, unit will shut down and restart in defrost on
next call for heat.
Checking and Adjusting Refrigerant Charge
The refrigerant system is fully charged with R-410A
and is tested and factory sealed.
refrigerant if actual temperature is more than 2°F (1.1°C)
higher than proper liquid line temperature,
or remove
refrigerant if actual temperature is more than 2°F (1.1°O)
lower than required liquid line temperature.
NOTE:
If the problem causing the inaccurate readings is a
refrigerant leak, refer to Check for Refrigerant Leaks section.
Airflow Adjustments
UNIT OPERATION HAZARD
Failure to follow this caution may result in unit damage.
For cooling operation, the recommended airflow is 350 to
450 cfm for each 12,000 Btuh of rated cooling capacity.
For heating operation, the airflow must produce
a
temperature rise that falls within the range stamped on the
unit ratin,q plate.
NOTE:
Be sure that all supply-and return-air grilles are open,
free from obstructions, and adjusted properly.
ELECTRICAL
SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Disconnect electrical power to the unit and install lockout
tag before changing blower speed.
refrigerant
NOTE: Adjustment of the refrigerant charge is not required unless
the unit is suspected of not having the proper R-410A charge.
A subcooling charging chart is attached to the inside of the
compressor access panel. The chart includes the required liquid
line temperature at given discharge line pressures and outdoor
ambient temperatures.
This unit has the field-selectable capability to run two different
cooling fan speeds: A normal cooling fan speed (350-400
CFM/Ton) and an enhanced dehumidification fan speed (As low
as 320 CFM/Ton) for use with either a dehumidistat
or a
thermostat that supports dehumidification.
FIG. 17 - INTERFACE FAN BOARD (IFB)
HiGH
An accurate thermocouple- or thermistor-type thermometer, and
a gauge manifold are required when using the subcooling
charging method for evaluating the unit charge. Do not use
mercury or small dial-type thermometers because they are not
adequate for this type of measurement.
NOTE:
Allow system to operate for a minimum of 15 minutes
before checking or adjusting refrigerant charge.
IMPORTANT:
When evaluating the refrigerant charge, an
indicated adjustment to the specified factory charge must always
be very minimal. If a substantial adjustment is indicated, an
abnormal condition exists somewhere in the cooling system, such
as insufficient airflow across either coil or both coils.
_
LOW
COM
©
07
09
0LO
08
ALO
R13
08
Rll
Q1
D2
QC1
U
??0000c
0
Proceed as follows:
1. Remove caps from low- and high-pressure service fittings.
2. Using hoses with valve core depressors, attach low- and
high-pressure
gauge hoses to low- and high-pressure
service fittings, respectively.
3. Start unit and let run until system pressures stabilize.
4. Measure and record the following:
a. Outdoor ambient-air temperature (°F [°C] db).
b. Liquid line temperature (°F [°C]) at TXV.
c. Discharge (high-side) pressure (psig).
d. Suction (low-side) pressure (psig) (for reference only).
5. Using Cooling Charging Charts compare outdoor-air
temperature (°F [°C] db) with the discharge line pressure
(psig) to determine desired system operating liquid line
temperature (See Fig. 18).
6. Compare actual liquid line temperature with desired liquid
line temperature. Using a tolerance of _+2°F (+1.1°O), add
18
Om00O0
,w.l
JW5
R2
R3R_pR
2 Jw3R
_U
R
_ _
W2
Y
C
W
p4
W3 W3
W2
W2
C
JW4
1
W3
W2
Y2OHG
Y1
C
R
The cooling speed is marked "LOW" on the interface fan board
(IFB) (Fig. 17). The factory-shipped settings are noted in Table 4.
There are 4 additional speed tap wires available for use in either
electric heating or cooling (For color coding on the indoor fan
motor leads, see Table 3). The additional 4 speed tap wires are
516 01 2203 01
shipped loose with vinyl caps and are located in the control box,
near the interface fan board (IFB) (Fig. 17).
Single Cooling Fan Speed Set-up (Dehumidification
feature
not used)
Table
3 - Color
Coding
3. Connect the desired speed tap wire to the "LOW" terminal
on the interface fan board (IFB).
NOTE:
If accessory electric heat is installed, and the
electric heat fan speed is chosen to be the same as the
normal cooling fan speed, the dry airflow must meet or
exceed the minimum airflow speed specified in Table 2 for
the specific size unit.
Two Cooling
used_
Fan Speeds Set-up (Dehumidification
Fan Motor
Leads
Orange = Med-High Speed
Red = Med Speed
Pink = Med-Low Speed
Blue = Low Speed
To change cooling speed:
1. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 3 for color coding). Add the wet coil
pressure drop in Table 5 to the system static to determine
the correct cooling airflow speed in Table 4 that will deliver
the nominal cooling airflow as listed in Table 1 for each size.
2. Remove the current speed tap wire from the "LOW" terminal
on the interface fan board (IFB) (Fig. 17) and place vinyl
cap over the connector on the wire.
for Indoor
Black = High Speed
Single
This
Speed
unit
cooling
Cooling
can
also
and a higher
1. Using
"STD"
With
speed
Fig. 17, move
position
2. See Table
Higher
be configured
Electric
to
Heat Speed
operate
for an accessory
the two
pin DEHUM
to the "DEHUM"
2 for minimum
with
single
electric
speed
heater.
jumper
from the
position.
airflow
for electric
heat operation.
Add electric heater and filter pressure
drop to duct system
static pressure to determine
total external static pressure.
3. Select
airflow
speed tap from
from Table 2.
Table
4 that
4. Remove
the vinyl cap off of the
(Refer to Table 3 for color coding).
will achieve
desired
speed
5. Connect the desired speed tap wire to the "HIGH"
on the interface fan board (IFB).
required
tap
wire
terminal
feature
IMPORTANT: Dehumidification control must open control circuit
on humidity rise above set point.
Use of the dehumidification
cooling fan speed requires use of
either a 24 VAC dehumidistat or a thermostat which includes
control of a 24 VAC dehumidistat connection. In either case, the
dehumidification control must open the control circuit on humidity
rise above the dehumidification
set point. Dehumidification
controls are available with the reverse logic; these must not be
used.
1. Using Fig. 16, move the two pin DEHUM jumper from the
"STD" position to the "DEHUM" position.
2. Remove fan speed tap wire from the "LOW" terminal on the
interface fan board (IFB) (Fig. 17).
3. Determine correct normal cooling fan speed for unit and
application. Add the wet coil pressure drop in Table 5 to the
system static to determine the correct cooling airflow speed
in Table 4 that wilt deliver the nominal cooling airflow as
listed in Table 1 for each size.
NOTE: If accessory electric heat is installed, the dry airflow
must meet or exceed the minimum airflow speed specified
in Table 2 for the specific size unit. The electric heat fan
speed will be the same as the normal cooling fan speed.
UNIT OPERATION HAZARD
Failure to follow this caution may result in unit component
damage or improper operation.
To use this mode, a speed connection must be made on the
"HIGH" terminal that meets or exceeds the minimum airflow
found in Table 2.
ELECTRICAL
SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Disconnect electrical power to the unit and install lockout
tag before changing blower speed.
Continuous
Fan Operation
When the DEHUM feature is not used, the continuous fan speed
will be the same as cooling fan speed. When the DEHUM feature
is used, the continuous fan will operate on IFB "LOW" speed
when the DH control lead is not energized, or IFB "HIGH" speed
when the DH lead is energized. (See Figure 17).
4. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 3 for color coding) for the normal cooling fan
speed and place desired speed tap wire on "HIGH" on the
interface board.
5. Refer to airflow tables (Table 4) to determine allowable
speeds for the dehumidification cooling fan speed. In Table
10, speeds that are not allowed for dehumidification cooling
are shaded.
6. Remove the vinyl cap off of the desired speed tap wire
(Refer to Table 3 for color coding) for the dehumidification
cooling fan speed and place desired speed tap wire on the
"LOW" connection on the interface board (IFB). Verify that
static pressure is in the acceptable range for the speed tap
to be used for dehumidification cooling.
7. Use any spare vinyl plugs to cap any unused speed tap
wires.
516 01 2203
01
19
FIG. 18-
TYPICAL HEAT PUMP OPERATION,
COOLING MODE
I_DCX)a
CO_L
LEGEND
HPS _ High Pressure Swteh
LCS - Loss of Charge Switch
Piston Metering Device
Arrow indicates;dira_ion of flew
FIG. 19 - TYPICAL HEAT PUMP OPERATION, HEATING MODE
INDOORCOIL
TX_ ' in Bypass
Position
LCS
Metering
Position
LEGEND
HPS - High Pressure
Switch
LCS - Loss of Charge
Piston
]
20
Metering
Arrc_d indicates
Switch
Device
direction
of flow
516 01 2203 01
Step 3 --
Defrost
If defrost thermostat is closed, speed-up
pins (J1) must be
shorted by placing a flat head screw driver in between for 5 sec
and releasing, to observe a complete defrost cycle. When the
Quiet Shift switch is selected, compressor will be turned off for two
30 sec intervals during this complete defrost cycle, as explained
previously. When Quiet Shift switch is in factory default OFF
position, a normal and complete defrost cycle will be observed.
If defrost thermostat is in open position, and speedup pins are
shorted (with a flat head screw driver) for 5 sec and released, a
short defrost cycle will be observed (actual length is dependent
upon the selected Quiet Shift position). When Quiet Shift switch is
in ON position, the length of defrost is 1 minute (30 sec
compressor
off period followed by 30 sec of defrost with
compressor
operation).
On return
to heating
operation,
compressor will again turn off for an additional 30 sec and the
outdoor fan for 40 sec. When the Quiet Shift is in OFF position,
only a brief 30 sec. cycle will be observed.
Control
Quiet Shift
Quiet Shift is a field-selectable
defrost mode, which will eliminate
occasional noise that could be heard at the start of defrost cycle
and restarting of heating cycle. It is selected by placing DIP switch
3 (on defrost board) in ON position.
When Quiet Shift switch is placed in ON position, and a defrost is
initiated, the following sequence of operation will occur. Reversing
valve will energize, outdoor fan will turn off, compressor will turn
off for 30 sec and then turn back on to complete defrost. At the
start of heating after conclusion of defrost reversing valve will
de-energize, compressor will turn off for another 30 sec, and the
outdoor fan will stay off for 40 sec, before starting in the Heating
mode.
Defrost
The defrost control is a time/temperature control which includes a
field-selectable
time period (DIP switch 1 and 2 on the board)
between defrost cycles of 30, 60, 90, or 120 minutes (factory set
at 60 minutes). To initiate a forced defrost, two options are
available depending on the status of the defrost thermostat.
NOTE: Unit will remain in defrost until defrost thermostat reopens
at approximately 65°F (18°C) coil temperature at liquid line or
remainder of defrost cycle time.
FIG. 20 - DEFROST CONTROL
8
-11
--4
O
%
©
33
8
r
r
r
r
r
r
r
r
$
_Defrost
Speedup
Pins
516 01 2203
01
Quiet
Shift
_
:1
_
1
_
:1
j
:1
c
c
c
c
c
c
c
-XCC
--Cl)-
interval
DIP switches
21
MAINTENANCE
To ensure continuing high performance, and to minimize the
possibility of premature equipment failure, periodic maintenance
must be performed on this equipment. This heat pump unit should
be inspected at least once each year by a qualified service
person. To troubleshoot unit, refer to Table 9.
NOTE:
TO EQUIPMENT OWNER:
about the availability of a maintenance
Consult your local dealer
contract.
PERSONAL INJURY AND UNIT DAMAGE HAZARD
Failure to follow this warning could result in personal injury or
death and unit component damage.
The ability to properly perform maintenance
on this
equipment requires certain expertise, mechanical skills, tools
and equipment. If you do not possess these, do not attempt
to perform any maintenance on this equipment, other than
those procedures recommended in the Owner's Manual.
ELECTRICAL
2. Use extreme caution when removing panels and parts.
3. Never place anything combustible either on or inn
contact with the unit.
CUT HAZARD
Failure to follow this caution may result in personal injury.
When removing access panels or performing maintenance
functions inside your unit, be aware of sharp sheet metal
parts and screws. Although special care is taken to reduce
sharp edges to a minimum, be extremely careful when
handling parts or reaching into the unit.
UNIT OPERATION HAZARD
follow
this
caution
may
result
in improper
Errors made when reconnecting wires may cause improper
and dangerous
operation.
Label all wires prior to
disconnecting when servicing.
maintenance
1. Inspect air filter(s)
necessary.
requirements
for this equipment are
each month. Clean
or replace when
2. Inspect indoor coil, drain pan, and condensate drain each
cooling season for cleanliness. Clean when necessary.
3. Inspect blower motor and wheel for
cooling season. Clean when necessary.
22
IMPORTANT: Never operate the unit without a suitable air filter in
the return-air duct system. Always replace the filter with the same
dimensional size and type as originally installed. See Table 1 for
recommended filter sizes.
Inspect air filter(s) at least once each month and replace
(throwaway-type)
or clean (cleanable-type)
at least twice during
each cooling season and twice during the heating season, or
whenever the filter becomes clogged with dust and lint.
Indoor Blower and Motor
NOTE: All motors are pre-lubricated.
these motors.
Do not attempt to lubricate
SHOCK HAZARD
1. Turn off electrical power to the unit and install a lockout
tag before performing any maintenance or service on
this unit.
The minimum
as follows:
Step 1 m Air Filter
NOTE:
460 volt units have a stepdown autotransformer
that
supplies approximately 230 volts to a nominal 230 volt indoor
blower motor.
For longer life, operating economy, and continuing efficiency,
clean accumulated dirt and grease from the blower wheel and
motor annually.
Failure to follow these warnings could result in personal injury
or death:
Failure to
operation.
4. Check electrical connections for tightness and controls for
proper operation each cooling season. Service when
necessary.
cleanliness
each
ELECTRICAL
SHOCK HAZARD
Failure to follow this warning could result in personal injury or
death.
Disconnect and tag electrical power to the unit before cleaning
and lubricating the blower motor and wheel.
To clean the blower motor and wheel:
1. Remove and disassemble blower assembly as follows:
a. Remove blower access panel.
b. Disconnect 5 pin plug and 4 pin plug from indoor blower
motor. Remove capacitor if required.
c. On all units remove blower assembly from unit. Remove
screws securing blower to blower partition and slide
assembly out. Be careful not to tear insulation in blower
compartment.
d. Ensure proper reassembly by marking blower wheel and
motor in relation to blower housing before disassembly.
e. Loosen setscrew(s) that secures wheel to motor shaft,
remove screws that secure motor mount brackets to
housing, and slide motor and motor mount out of housing.
2. Remove and clean blower wheel as follows:
a. Ensure proper reassembly by marking wheel orientation.
b. Lift wheel from housing. When handling and/or cleaning
blower wheel, be sure not to disturb balance weights (clips)
on blower wheel vanes.
c. Remove caked-on dirt from wheel and housing with a
brush. Remove lint and/or dirt accumulations from wheel
and housing with vacuum cleaner, using soft brush
attachment. Remove grease and oil with mild solvent.
d. Reassemble wheel into housing.
e. Reassemble motor into housing. Be sure setscrews are
tightened on motor shaft flats and not on round part of shaft.
Reinstall blower into unit. Reinstall capacitor if required.
f. Connect 5 pin plug and 4 pin plug to indoor blower motor.
g. Reinstall blower access panel.
3. Restore electrical power to unit. Start unit and check for
proper blower rotation and motor speeds during cooling
cycles.
516 01 2203 01
FIG. 21 - UNIT ACCESS PANELS
Step 3 m Outdoor
Fan
Keep the condenser fan free from all obstructions to ensure
proper cooling operation. Never place articles on top of the
unit. Damage to unit may result.
1. Remove 6 screws holding outdoor grille and motor to top
cover.
2. Turn motor/grille assembly upside down on top cover to
expose fan blade.
3. Inspect the fan blades for cracks or bends.
4. If fan needs to be removed, loosen setscrew and slide fan
off motor shaft.
5. When replacing fan blade, position
position as before.
6. Ensure that setscrew
shaft when tightening.
blade back to same
engages the flat area on the motor
7. Replace grille.
Step 2 m Outdoor Coil, Indoor
Condensate
Drain Pan
Coil, and
Inspect the condenser coil, evaporator coil, and condensate drain
pan at least once each year.
The coils are easily cleaned when dry; therefore, inspect and
clean the coils either before or after each cooling season.
Remove all obstructions,
including weeds and shrubs, that
interfere with the airflow through the condenser coil.
Straighten bent fins with a fin comb. If coated with dirt or lint, clean
the coils with a vacuum cleaner, using the soft brush attachment.
Be careful not to bend the fins. If coated with oil or grease, clean
the coils with a mild detergent-and-water
solution. Rinse coils
with clear water, using a garden hose. Be careful not to splash
water on motors, insulation, wiring, or air filter(s). For best results,
spray condenser coil fins from inside to outside the unit. On units
with an outer and inner condenser coil, be sure to clean between
the coils. Be sure to flush all dirt and debris from the unit base.
Inspect the drain pan and condensate drain line when inspecting
the coils. Clean the drain pan and condensate drain by removing
all foreign matter from the pan. Flush the pan and drain trough
with clear water. Do not splash water on the insulation, motor,
wiring, or air filter(s). If the drain trough is restricted, clear it with a
plumbers snake or similar probe device.
516 01 2203
01
23
Table
4 - Dry Coil Air Delivery*
- Horizontal
and Downflow
Discharge
- Unit PHD3
MOTOR
WIRE
EXTERNAL STATIC PRESSURE (in. W.C.)
SPEED
COLOR
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Low
Blue
CFM
754
650
Med-Low
Pink
CFM
777
675
24
Medium 1
Red
CFM
774
684
Med-High
Orange
CFM
_9
, 91
, 840i
759
667
577_,
_,
Black
High
CFM
Low
Blue
CFM
Med-Low
Pink
CFM
973
887
823
30
Medium
Red
CFM
_88
, _023
954
881
800
23
_:658
Med-High 1
Orange
CFM
_!'4_
, _64
996
915
840
58
_687
Black
High
CFM
Low
Blue
CFM
1168
1093
1021
961
828
Med-Low
Pink
CFM
_2_
, _223
1154
1090
1027
977
89_::
36
Medium 1
Red
CFM
!354
, !2_
, !228
1158
1102
1046
981
Med-High
Orange
CFM
_686,
!5_8
,! _89:,
!'4_,
_37_,
_8_
Black
High
CFM
_63_
,[ _8_'
_51'
_488'
_'4_'
!_
_:277
Low
Blue
CFM
1295
1234
1182
1126
955
Med-Low
Pink
CFM
1345
1282
1235
1194
1140
42
Medium
Red
CFM
1358
1323
1282
1234
Med-High _
Orange
CFM
_545
,i _'48_: , !4_9: :, !'4_
1362
1313
1278
Black
High
CFM
Low
Blue
CFM
1402
1351
1311
Med-Low
Pink
CFM
1457
1404
1367
1318
1284
_23_
48
Medium _
Red
CFM
_ _8'
_69_:'
_64_'
;1601
1553
1512
1465
Med-High
Orange
CFM
_2_'49 :,!_2_,
_6_,
_8,
1980,
_
_'cJ0_:
Black
High
CFM
_'99_
Low
Blue
CFM
Med-Low
Pink
CFM
1678
1635
1602
60
Medium _
Red
CFM
_8_
, _89_
, _858
, _824
,
8_
, _ &9
1720
Med-High
Orange
CFM
_1'31,
_088,
_68,
_8_8,
_882,
_41
1888,
Black
CFM
248_
2488
i 23:_ : 12286
High
* Air delivery values are without air filter and are for dry coil (See PHD3 Wet Coil Pressure Drop Table).
1 Factory-shipped
cooling speed
NOTE: Deduct field-supplied
air filter pressure drop and wet coil pressure drop to obtain external static pressure available for ducting.
Shaded areas indicate speed/static combinations that are not permitted for dehumidification
speed.
UNIT SIZE
Table
UNIT SIZE
500
600
0.06
24
30
36
42
48
60
700
0.07
800
0.08
0.12
Table
UNIT
SIZE
5 - PHD3
900
0.09
0.15
Coil
Pressure
0.23
0.11
Air
0.26
0.07
0.35
0.1
0.11
-- Downflow
EXTERNAL
0.4
Discharge
STATIC PRESSURE
0.5
0.6
,
,
563
564
,
,
_6
_80
,
,
_::
828
_
,
,
,
,
,
_;Q
898
,i
,
687
762
84_
1140
_ __
857
1169
1231
1130
1188
1427
, _1,864
,',1_02::
1381
,! _ 9 _
, ',_803
1689
_68
_68
1640
, _785
_,874
(in. W.C.)
CFM (S.C.F.M)
1300
1400
0.27
0.18
0.04
Delivery
Drop
0.9
1500
1600
1700
1800
1900
2000
0.15
0.14
0.21
0.17
0.1
0.22
0.17
0.28
0.23
0.31
0.36
-- High
Speed
(in.W.C.)
0.1
0.2
0.3
0.7
0.8
0.9
1.0
42
1527
1630
1466
1593
1401
1556
1339
1526
1274
1487
1228
1442
1187
1405
1142
1365
1098
1322
1065
1288
48
2265
2185
2088
2000
1891
1791
1650
1508
1331
1089
60
2286
2222
2144
2068
1986
1905
1820
1737
1635
1531
36
Table
FILTER SIZE
in. (mm)
20X20X1
(506X506X25)
20X24X1
(508X610x25)
700
800
900
1000
1100
1200
0.05
0.07
0.08
0.1
0.12
0.13
0.14
0.15
.09
.10
.11
.13
0.04
0.05
0.06
0.07
500
0.00
0.00
0.00
0.00
0.00
600
0.00
0.00
0.00
0.00
0.00
700
0.00
0.00
0.00
0.00
0.02
800
0.00
0.00
0.00
0.02
0.04
1100
0.00
0.00
0.00
0.00
0.02
1200
0.00
0.00
0.00
0.02
0.03
1300
0.00
0.01
0.01
0.03
0.04
1400
0.01
0.02
0.02
0.04
0.05
1500
0.02
0.03
0.03
0.05
0.06
(in. W.C.)
1400
.14
.15
.16
0.07
0.08
0.09
0.1
0.06
0.07
0.07
Pressure
1500
Pressure
24-36
1000
0.00
0.00
0.02
0.06
0.08
Heat
1600
0.03
0.04
0.04
0.06
0.07
Drop Table
CFM
1300
8 - Electric
Heat
Small
Cabinet:
900
0.00
0.00
0.00
0.04
0.06
Electric
5kw
7.5 kw
10 kw
15 kw
20 kw
Pressure
600
Table
5kw
7.5 kw
10 kw
15 kw
20 kw
7 - Filter
500
24X30X1
(610X762x25)
24X36X1
(610X914X25)
24
Coil
STANDARD
1100
1200
1000
0.1
0.19
0.07
6 - Wet
Wet
0.8
1600
1700
1800
1900
2000
2100
2200
2300
0.08
0.09
0.09
0.10
0.11
0.12
0.13
0.14
0.14
Drop
cfm
Table
1100
0.00
0.02
0.04
0.08
0.09
Drop
Large
Cabinet
42-60
1700
1800
0.04
0.05
0.05
0.06
0.05
0.06
0.07
0.08
0.08
0.09
Table
cfm
1900
0.06
0.07
0.07
0.09
0.10
1200
0.00
0.03
0.06
0.10
0.11
1300
0.02
0.05
0.07
0.12
0.13
1400
0.04
0.07
0.09
0.14
0.15
1500
0.06
0.08
0.10
0.16
0.17
1600
0.07
0.09
0.11
0.18
0.19
(in. W.C.)
2000
0.07
0.08
0.08
0.10
0.11
2100
0.08
0.09
0.09
0.11
0.12
2200
0.09
0.10
0.10
0.12
0.13
2300
0.10
0.11
0.11
0.13
0.14
2400
0.11
0.12
0.12
0.14
0.15
2500
0.12
0.13
0.13
0.15
0.16
516 01 2203 01
O1
03
o
"11
Fo
Fo
o
Co
o
Required
Subcooling
Outdoor
Model
°F(°C)
Ambient
Required
Temperature
°F(°C)
Required
Sizt
Liquid
Subcoolin_
Line Temperature
85 (29)
95 (35)
105 (41)
115 (46)
(psig)
Subcooling
(R-410A)
I
Required
Pressur_
75 (24)
for a Specific
!°F!
5
10
15
20
25
Pressure
(kPa)
Subcoolin_
!°C!
C)
o
3
6
8
11
14
O
r-"
i
189
66
61
56
51
46
41
1303
19
16
13
11
8
5
Z
024
15 (8.5)
15 (8.5)
15 (8.3)
15 (8.2)
14 (7.9)
196
68
63
58
53
48
43
1351
20
17
15
12
9
6
030
18 (10)
18 (10)
17 (9.4)
17 (9.4)
17 (9.4)
203
71
66
61
56
51
46
1399
21
19
16
13
10
8
"1"
73
68
63
58
53
48
1448
23
20
17
14
11
9
_>
65
60
55
50
1496
24
21
18
15
13
10
o
18 (10)
18 (9.8)
16 (8.7)
15 (8.4 !
14 (7.8)
042
17 (9.3)
17 (9.3)
17 (9.2)
16 (8.9)
15 (8.5)
217
75
70
048
20 (11.2)
20 (10.9)
19 (10.5)
18 (10.1)
17 (9.5)
224
77
72
67
62
57
52
1544
25
22
19
16
14
11
060
19 (10.6)
19 (10.4)
18 (10.1)
18 (9.7)
17 (9.4)
231
79
74
69
64
59
54
1593
26
23
20
18
15
12
238
81
76
71
66
61
56
1641
27
24
21
19
16
13
245
82
77
72
67
62
57
1689
28
25
22
20
17
14
252
84
79
74
69
64
59
1737
29
26
23
21
18
15
260
86
81
76
71
66
61
1792
30
27
25
22
19
16
268
88
83
276
90
85
78
80
73
75
68
70
63
65
1848
1903
31
32
29
30
26
27
23
24
20
21
17
19
284
92
87
82
77
72
67
1958
33
31
28
25
22
20
O
292
94
89
84
79
74
69
2013
35
32
29
26
23
21
O
300
96
91
86
81
76
71
2068
36
33
30
27
24
22
309
98
93
r-"
Z
318
100
95
88
90
83
85
78
80
73
75
2130
2192
37
38
34
35
31
32
28
29
26
27
23
24
327
102
97
92
87
82
77
2254
39
36
33
31
28
25
336
104
99
94
89
84
79
2316
40
37
34
32
29
26
345
106
101
96
91
86
81
2378
41
38
35
33
30
27
354
108
103
98
93
88
83
2440
42
39
36
34
31
28
364
110
105
100
95
90
85
2509
43
40
38
35
32
29
374
112
107
102
97
92
87
2578
44
41
39
36
33
30
384
113
108
103
98
93
88
2647
45
42
40
37
34
31
394
115
110
105
100
95
90
2716
46
44
41
38
35
32
404
117
112
107
102
97
92
2785
47
45
42
39
36
33
414
119
114
109
104
99
94
2854
48
46
43
40
37
34
424
121
116
111
106
101
96
2923
49
47
44
41
38
35
434
123
118
113
108
103
98
2992
50
48
45
42
39
36
444
124
119
114
109
104
99
3061
51
48
46
43
40
37
454
126
121
116
111
106
101
3130
52
49
47
44
41
38
464
128
123
118
113
108
103
3199
53
50
48
45
42
39
474
129
124
119
114
109
104
3268
54
51
48
46
43
40
484
131
126
121
116
111
106
3337
55
52
49
47
44
41
494
132
127
122
117
112
107
3406
56
53
50
47
45
42
504
134
129
124
119
114
109
3475
57
54
51
48
46
43
514
136
131
126
121
116
111
3544
58
55
52
49
46
44
524
137
132
127
122
117
112
3612
58
56
53
50
47
45
534
139
134
129
124
119
114
3681
59
56
54
51
48
45
i
036
210
Charqinq
1- Measure
Procedure
Discharge
line pressure
2- Measure
the Liquid
device to it.
3- Insulate
line temperature
the temperature
doesn't
affect
4- Refer
to the required
the Outdoor
by attaching
sensing
a gauge
by attaching
device
to the service
a temperature
so that the Outdoor
port.
sensing
Ambient
the reading.
Ambient
5- Interpolate
Subcooling
in the table
based
on the model
size
and
temperature.
if the Outdoor
ambient
temperature
lies in between
the table
values.
6- Find the Pressure
Pressure
temperature
for
Charge
9 - Remove
from
if the
Discharge
the Pressure
a required
charge
50EZ500317
,Ji
in the table
of the Compressor
7- Read across
8- Add
Value
line.
reading
temperature
if the measured
I
to the the measured
to obtain
the Liquid
line
Subcooling
measured
REV 2.0
corresponding
is higher
temperature
than
is lower
the table
than
value.
the table
value.
Y
I:D
r-"
rn
i
(/)
(=
I:D
o
Step 4 _
Electrical
Controls
and Wiring
Inspect and check the electrical controls and wiring annually. Be
sure to turn off the electrical power to the unit.
Remove access panels to locate all the electrical controls and
wiring. Check all electrical connections for tightness. Tighten all
screw connections. If any discolored or burned connections are
noticed, disassemble the connection, clean all the parts, restrip
the wire end and reassemble the connection properly and
securely.
After inspecting the electrical controls and wiring, replace all the
panels. Start the unit, and observe at least one complete cooling
cycle to ensure proper operation. If discrepancies are observed in
operating cycle, or if a suspected malfunction has occurred, check
each
electrical
component
with
the
proper
electrical
instrumentation. Refer to the unit wiring label when making these
checkouts.
Step 5 m Refrigerant
Circuit
Inspect all refrigerant tubing connections and the unit base for oil
accumulation
annually. Detecting
oil generally
indicates a
refrigerant leak.
If oil is detected or if low performance is suspected, leak-test all
refrigerant tubing using an electronic leak detector, or liquid-soap
solution. If a refrigerant leak is detected, refer to Check for
Refrigerant Leaks section.
If no refrigerant
leaks are found and low performance
is
suspected, refer to Checking and Adjusting Refrigerant Charge
section.
FIG. 23 - REFRIGERANT
CIRCUIT
Step 8 _
Pressure
Switches
Pressure switches are protective devices wired into control circuit
(low voltage). They shut off compressor if abnormally high or low
pressures are present in the refrigeration circuit. These pressure
switches are specifically
designed to operate with R-410A
systems.
R-22 pressure switches
must not be used as
replacements for the R-410A system.
Step 9 _
Loss of Charge
Switch
This switch is located on the liquid line and protects against low
suction pressures caused by such events as loss of charge, low
airflow across indoor coil, dirty filters, etc. It opens on a pressure
drop at about 20 psig. If system pressure is above this, switch
should be closed. To check switch:
1. Turn off all power to unit.
2. Disconnect leads on switch.
3. Apply ohm meter leads across switch. You should
continuity on a good switch.
have
NOTE:
Because these switches are attached to refrigeration
system under pressure, it is not advisable to remove this device
for troubleshooting
unless you are reasonably certain that a
problem exists. If switch must be removed, remove and recover
all system charge so that pressure gauges read 0 psi. Never open
system without breaking vacuum with dry nitrogen.
Step 10 _
High-Pressure
Switch
The high-pressure
switch is located in the discharge line and
protects against excessive condenser coil pressure. It opens at
650 psig.
High pressure may be caused by a dirty outdoor coil, failed fan
motor, or outdoor air recirculation.
To check switch:
1. Turn off all power to unit.
2. Disconnect leads on switch.
3. Apply ohm meter leads across switch. You should
continuity on a good switch.
Step 11 m Copeland
Refrigerant)
Scroll Compressor
have
(R-410A
The compressor used in this product is specifically designed to
operate with R-410A refrigerant and cannot be interchanged.
EXPLOSION
HAZARD
Failure to follow this warning could result in personal injury,
death or property damage.
Wear safety glasses and gloves when handling refrigerants.
Keep torches and other ignition sources away from refrigerant
and oils.
Step 6 m Indoor
Airflow
The heating and/or cooling airflow does not require checking
unless improper performance is suspected. If a problem exists, be
sure that all supply-air
and return-air grilles are open and free
from obstructions, and that the air filter is clean. When necessary,
refer to Indoor Airflow and Airflow Adjustments section to check
the system airflow.
Step 7 _
Metering
Devices-TXV
& Piston
This unit uses 2 types of metering devices. The outdoor metering
device is a fixed orifice and is contained in the brass hex-body in
each liquid line feeding the outdoor coils. The indoor metering
device is a TXV type device.
2d
The scroll compressor pumps refrigerant throughout the system
by the interaction of a stationary and an orbiting scroll. The scroll
compressor has no dynamic suction or discharge valves, and it is
more tolerant of stresses caused by debris, liquid slugging, and
flooded starts. The compressor is equipped with an internal
pressure relief port. The pressure relief port is a safety device,
designed to protect against extreme high pressure. The relief port
has an operating range between 550 and 625 psi differential
pressure.
516 01 2203 01
Step 12 m Refrigerant
System
This step covers the refrigerant system of the PHD3, including the
compressor oil needed, servicing systems on roofs containing
synthetic materials, the filter drier and refrigerant charging.
Refrigerant
PROPERTY
HAZARD,
PERSONAL
ENVIRONMENTAL HAZARD
INJURY
OR
Failure to follow this warning could result in property damage or
personal injury or death.
This system uses R-410A refrigerant which has higher
operating pressures than R-22 and other refrigerants. No other
refrigerant may be used in this system. Gauge set, hoses, and
recovery system must be designed to handle R-410A. If you are
unsure consult the equipment manufacturer.
Compressor
Oil
The Copeland scroll compressor uses 3MAF POE oil. If additional
oil is needed, use Uniqema RL32-3MAF. If this oil is not available,
use Copeland Ultra 32 CC or Mobil Arctic EAL22 CC. This oil is
extremely hygroscopic, meaning it absorbs water readily. POE oils
can absorb 15 times as much water as other oils designed to
HCFC and CFC refrigerants. Take all necessary precautions to
avoitd exposure of the oil to the atmosphere.
Servicing Systems on Roofs with Synthetic Materials
POE (polyolester) compressor lubricants are known to cause long
term damage to some synthetic roofing materials. Exposure, even
if immediately cleaned up, may cause embrittlement (leading to
cracking) to occur in one year or more. When performing any
service that may risk exposure of compressor oil to the roof, take
appropriate precautions to protect roofing. Procedures which risk
oil leakage include,
but are not limited to, compressor
replacement,
repairing refrigerant leaks, replacing refrigerant
components such as filter drier, pressure switch, metering device,
coil, accumulator, or reversing valve.
Synthetic Roof Precautionary Procedure
must be replaced whenever the refrigerant system is opened.
When removing a filter drier, use a tubing cutter to cut the drier
from the system. Do not unsweat a filter drier from the system.
Heat from unsweating will release moisture and contaminants
from drier into system.
R-410A Refrigerant
Charging
Refer to unit information plate and charging chart. Some R-410A
refrigerant cylinders contain a dip tube to allow liquid refrigerant to
flow from cylinder in upright position. For cylinders equipped with
a dip tube, charge R-410A units with cylinder in upright position
and a commercial metering device in manifold hose. Charge
refrigerant into suction-line.
Step 13 m System
Information
Loss of Charge Switch
The loss of charge switch is a protective device wired into control
circuit (low voltage). It shuts off the compressor if abnormally low
pressures are present in the refrigeration circuit.
NOTE:
Because these switches are attached to refrigeration
system under pressure, it is not advisable to remove this device
for troubleshooting
unless you are reasonably certain that a
problem exists. If switch must be removed, remove and recover
all system charge so that pressure gauges read 0 psi. Never open
system without breaking vacuum with dry nitrogen.
Check Defrost Thermostat
The defrost thermostat signals heat pump that conditions are nght
for defrost or that conditions have changed to terminate defrost. It
is a thermally actuated switch clamped to outdoor coil to sense its
temperature. Normal temperature range is closed at 32 ° + 3°F (0
+ 1.7°C) and open at65 ° + 5°F (18 + 2.8°C).
NOTE: The defrost thermostat is usually located on the lowest
liquid leaving circuit of the left condenser coil.
FIG. 24 - DEFROST THERMOSTAT
FEEDERTUBE
1. Cover extended roof working area with an impermeable
polyethylene
(plastic)
drip cloth or tarp. Cover an
approximate 10xl 0 ft (3x3 m) area.
STUBTUBE
2. Cover area in front of the unit service panel with a terry
cloth shop towel to absorb lubricant spills and prevent
run-offs, and protect drop cloth from tears caused by tools
or components.
3. Place terry cloth shop towel inside unit immediately under
component(s) to be serviced and prevent lubricant run-offs
through the Iouvered openings in the unit base.
DEFROST
THERMOSTAT
TROUBLESHOOTING
4. Perform required service.
5. Remove and dispose of any oil contaminated
local codes.
material per
Refer to the Cooling and Heating Troubleshooting
for troubleshooting information.
START-UP
Liquid Line Filter Drier
The biflow filter drier is specifically
R-410A. Use only factory-authorized
516 01 2203
01
designed to operate with
components. Filter drier
Use the Start-Up
Chart (Table 9)
CHECKLIST
Checklist.
27
R-410A
•
QUICK
REFERENCE
GUIDE
R-410A refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing equipment and
replacement components are designed to operate with R-410A
•
R-410A refrigerant cylinders are rose colored.
•
Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.
•
R-410A systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold
hose when charging into suction line with compressor
operating
•
Manifold sets should be minimum 700 psig high side and 180 psig low side with 550 psig low-side
•
Use hoses with minimum700
•
Leak detectors should be designed to detect HFC refrigerant.
retard.
psig service pressure rating.
•
R-410A, as with other HFCs, is only compatible with POE oils.
•
Vacuum pumps will not remove moisture from oil.
•
Do not use liquid-line filter driers with rated working pressures less than 600 psig.
•
Do not leave R-410A suction line filter driers in line longer than 72 hours.
•
Do not install a suction-line
•
POE oils absorb moisture rapidly. Do not expose oil to atmosphere.
filter drier in liquid line.
•
POE oils may cause damage to certain plastics and roofing materials.
•
Wrap all filter driers and service valves with wet cloth when brazing.
•
•
A factory approved liquid-line
Do NOT use an R-22TXV.
filter drier is required on every unit.
•
Never open system to atmosphere while it is under a vacuum.
•
When system must be opened for service, recover refrigerant, evacuate then break vacuum with dry nitrogen and
replace filter driers. Evacuate to 500 microns prior to recharging.
•
Do not vent R-410A into the atmosphere.
•
Observe all warnings, cautions, and bold text.
•
All indoor coils must be installed with a hard shutoff R-410A TXV metering device.
28
516 01 2203 01
Table
9 - Troubleshooting
SYMPTOM
Chart
CAUSE
REMEDY
Power failure
Call power company
Replace fuse or reset circuit breaker
Fuse blown or circuit breaker tripped
Compressor
and condenser
fan will not start.
Defective contactor, transformer, or high-pressure,
of-charge or low-pressure
switch
Insufficient
loss-
Incorrect or faulty wiring
Thermostat setting too high
Faulty wiring or loose connections
Compressor
will not start but condenser
fan runs
Three-phase
scroll compressor
makes excessive noise, and there may be a low
pressure differential.
operates continuously
start relay
power dead
is rotating in the wrong direction
overcharge
or undercharge
Check wiring and repair or replace
Determine cause
Replace compressor
Determine cause and replace
Replace fuse or reset circuit breaker
Determine cause
3-phase
power leads to the unit.
Recover refrigerant, evacuate system, and recharge
to capacities shown on rating plate
Defective compressor
Insufficient line voltage
Blocked condenser
Replace and determine cause
Determine cause and correct
Defective run/start capacitor, overload or start relay
Defective thermostat
Determine cause and replace
Replace thermostat
Faulty condenser-fan
motor or capacitor
Restriction in refrigerant system
Replace
Locate restriction and remove
Dirty air filter
Unit undersized
Replace filter
Decrease load or increase unit size
Determine
for load
set too low
cause and correct
Reset thermostat
Low refrigerant charge
Mechanical damage in compressor
Locate leak, repair, and recharge
Replace compressor
Air in system
Recover refrigerant, evacuate system, and recharge
Clean coil or remove restriction
Condenser coil dirty or restricted
Dirty air filter
Excessive head pressure
circuit
Correct the direction of rotation by reversing the
Scroll compressor
Thermostat
Compressor
in compressor
Defective run/start capacitor, overload,
Refrigerant
Compressor cycles (other than normally satisfying thermostat).
cause and correct
Check wiring diagram and rewire correctly
Lower thermostat setting below room temperature
Compressor motor burned out, seized, or
internal overload open
One leg of 3-phase
Replace component
Determine
line voltage
Dirty condenser coil
Refrigerant overcharged
Replace filter
Clean coil
Recover excess refrigerant
Air in system
Condenser air restricted or air short-cycling
Low refrigerant charge
Recover refrigerant, evacuate system, and recharge
Determine cause and correct
Check for leaks, repair, and recharge.
Head pressure too low
Compressor IPR leaking
Restriction in liquid tube
Replace compressor
Remove restriction
High heat load
Check for source and eliminate
Excessive suction pressure
Compressor IPR leaking
Refrigerant overcharged
Replace compressor
Recover excess refrigerant
Dirty air filter
Low refrigerant charge
Replace filter
Check for leaks, repair and recharge
Remove source of restriction
Metering device or low side restricted
Suction pressure
too low
Insufficient
evaporator
airflow
Temperature too low in conditioned area
Outdoor ambient below 55°F (12.7°C)
Filter drier restricted
516 01 2203
01
Increase air quantity
Check filter-replace if necessary
Reset thermostat
Install low-ambient kit
Replace filter
29
START-UP
CHECKLIST
(Remove and Store in Job Files)
I. PRELIMINARY
INFORMATION
MODEL NO.:
SERIAL NO.:
DATE:
TECHNICIAN:
II. PRESTART-UP (Insert check mark in box as each item is completed)
() VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION
INSTRUCTIONS
( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS
( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE
() VERIFY THAT UNIT INSTALLATION IS LEVEL
( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE
AND SETSCREW TIGHTNESS
III. START-UP
ELECTRICAL
SUPPLY VOLTAGE
COMPRESSOR
AMPS
INDOOR (EVAPORATOR)
TEMPERATURES
FAN AMPS
OUTDOOR (CONDENSER) AIR TEMPERATURE
RETURN-AIR TEMPERATURE
COOLING SUPPLY AIR
DB
DB
DB
WB
WB
HEAT PUMP SUPPLY AIR
ELECTRIC HEAT SUPPLY AIR
PRESSURES
REFRIGERANT
REFRIGERANT
SUCTION
DISCHARGE
( ) VERIFY REFRIGERANT
PSIG, SUCTION LINE TEMP*
PSIG, LIQUID TEMPt
CHARGE USING CHARGING CHARTS
* Measured at suction inlet to compressor
1- Measured at liquid line leaving condenser.
30
516 01 2203 01