HP (Hewlett-Packard) Heat Pump H2H3 User manual

INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
Product Family: N2H3, H2H3
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, CAU‐
TION, and NOTE are used to identify levels of haz‐
ard seriousness. The signal word DANGER is only
used on product labels to signify an immediate haz‐
ard. The signal words WARNING, CAUTION, and
NOTE will be used on product labels and through‐
out this manual and other manuals that may apply
to the product.
DANGER - Immediate hazards which will result in
severe personal 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 in Manuals
The signal word WARNING is used throughout this
manual in the following manner:
!
WARNING
WARNING
The signal word CAUTION is used throughout this
manual in the following manner:
!
CAUTION
Signal Words on Product Labeling
Signal words are used in combination with colors
and/or pictures on product labels.
NOTE - Used to highlight suggestions which will
result in enhanced installation, reliability, or opera‐
tion.
TABLE OF CONTENTS
Inspect New Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
Unit Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . 4 - 9
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 10
Defrost System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . 12 - 13
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 13
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Comfort Alertt Diagnostics Codes . . . . . . . . . . . . . . 15
!
WARNING
DEATH, 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 per‐
sons could result in equipment malfunction, prop‐
erty damage, personal injury and/or death.
The information contained in this manual is in‐
tended for use by a qualified service technician fa‐
miliar with safety procedures and equipped with
the 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.
506 01 5001 00 May 2007
INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
INSPECT NEW UNIT
After uncrating unit, inspect thoroughly for hidden
damage. If damage is found, notify the transportation
company immediately and file a concealed damage
claim.
SAFETY CONSIDERATIONS
Consult a qualified installer, service agency, or the
dealer/distributor for information and assistance. The
qualified installer must use factory authorized kits and
accessories when modifying this product. Refer to the
individual instructions packaged with the kit or accessory
when installing.
The weight of the product requires careful and proper
handling procedures when lifting or moving to avoid
personal injury. Use care to avoid contact with sharp or
pointed edges.
Follow all safety codes. Wear safety glasses, protective
clothing, and work gloves. Use a heat sinking material such as a wet rag - during brazing operations. Keep a fire
extinguisher available. Consult local codes and the
National Electric Code (NEC) for special requirements.
Improper installation, adjustment, alteration, service or
maintenance can void the warranty.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in per‐
sonal injury or death.
Before installing, modifying or servicing system,
turn OFF the main (remote) electrical disconnect
device. There may be more than one disconnect
device.
LOCATION
Check local codes for regulations concerning zoning,
noise, platforms, and other issues.
Locate unit away from fresh air intakes, vents, or
bedroom windows. Noise may carry into the openings
and disturb people inside.
Locate unit in a well drained area, or support unit high
enough so that water runoff will not enter the unit.
Locate unit away from areas where heat, lint, or exhaust
fumes will be discharged onto unit (as from dryer vents).
Locate unit away from recessed or confined areas where
recirculation of discharge air may occur (refer to
CLEARANCES section of this document).
Roof-top installation is acceptable providing the roof will
support the unit and provisions are made for water
drainage and noise/vibration dampening.
NOTE: Roof mounted units exposed to wind may require
wind baffles. Consult the manufacturer for additional
information.
CLEARANCES
Nominal minimum clearances are 48 inches above unit
for discharge air and 18 inches on each side of the coil for
intake air. Clearance on any one side of the coil (normally
between unit and structure) may be reduced to 6 inches.
Nominal minimum clearances are based on a solid
parallel object such as a wall or roof overhang.
The clearance may be reduced for a single object with
small surface area, such as the end of a wall, outside
corner of a wall, fence section, post, etc. As a general
rule, the minimum clearance from the unit should equal
the width of the object. For example, a 6 inch fence post
should be a minimum of 6 inches from the unit.
Do not install unit under roof overhangs unless gutters are
present. A minimum vertical clearance of 48 inches is
required to the overhang.
2
Inside corner locations on single story structures require
evaluation. Large overhanging soffits may cause air
recirculation in a corner area even though recommended
minimum clearances are maintained. As a guide, locate
the unit far enough out so that half of the discharge grille is
out from under the soffit.
When placing two or more units side-by-side, provide a
minimum of 18 inches between units.
Provide minimum service clearance of 24 inches from
control box corner and side service panel.
Refer to Figure 1.
506 01 5001 00
INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
Figure 1
Clearances (various examples)
Wall
Wall
6”
24”
Service
24”
Service
18”
Wall
6”
18”
18”
18”
Wall
Wall
6”
6”
24”
Service
18”
24”
Service
6”
4”
wide fence
4”
18”
6”
Post
Wall
24”
Service
18”
506 01 5001 00
24”
Service
18”
24”
Service
18”
18”
3
INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
UNIT SUPPORT
NOTE: Unit must be level | 2 degrees (a inch rise or fall
per foot of run) or compressor may not function properly.
A. GROUND LEVEL INSTALLATION
The unit must be level and supported above grade by
beams, platform, or a pad. Platform or pad can be of open
or solid construction but should be of permanent
materials such as concrete, bricks, blocks, steel, or
pressure- treated timbers approved for ground contact.
Soil conditions must be considered so that the platform or
pad does not shift or settle and leave the unit partially
supported. Minimum pad dimensions are shown in Figure
2.
If beams or an open platform are used for support, it is
recommended that the soil be treated or area be graveled
to reduce the growth of grasses and weeds.
To minimize vibration or noise transmission, it is
recommended that supports not be in contact with the
building structure. However, slabs on grade constructions
with an extended pad are normally acceptable.
!
C. FASTENING UNIT DOWN
If conditions or local codes require the unit be attached in
place, remove the knockouts in the base pan and install
tie down bolts through the holes (refer to Figure 2).
Contact local distributor for hurricane hold-down details
and the P.E. (Professional Engineer) certification, when
required.
CAUTION
!
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in proper‐
ty damage.
Inadequate unit support may cause excessive
vibration, noise, and/or stress on the refrigerant
lines, leading to refrigerant line failure.
Figure 2
CAUTION
Tie Down Knockouts
a” dia. Tie Down Knockouts
In Base Pan (2 places)
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in proper‐
ty damage.
Top surface of platform must be above estimated
snowfall level to prevent snow blocking coil and to
allow water melt to drain from unit.
B. ROOF TOP INSTALLATION
This type of installation is not recommended on wood
frame structures where low noise levels are required.
Supporting structure or platform for the unit must be level.
If installation is on a flat roof, locate unit minimum 6 inches
above roof level.
Place the unit over one or more load bearing walls. If there
are several units, mount them on platforms that are
self-supporting and span several load bearing walls.
These suggestions are to minimize noise and vibration
transmission through the structure. If the structure is a
home or apartment, avoid locating the unit over
bedrooms or study.
NOTE: When unit is to be installed on a bonded
guaranteed roof, a release must be obtained from the
building owner to free the installer from all liabilities.
VIEW
FROM
TOP
Base
Pan
Depth
C
B
A
Base Pan Width
Base Pan
Width x Depth
@%w” ~ @^c”
#!x” ~ #@v”
#%” ~ #^b”
Tie Down
Knockouts
A
B
C
(8” $v” @!4”
(8” ^b” @$n”
(8” ^b” @*v”
Minimum
Mounting Pad
Dimensions
@^ X~ @^2”
#!2 ~ #@2”
#%” ~ #^2”
REFRIGERATION SYSTEM
A. COMPONENT MATCHES
Check to see that the proper system components are in
place, especially the indoor coil.
R-22 outdoor units can only be used with R-22 specific
indoor coils. If there is a refrigerant mis-match, consult
the indoor coil manufacturer to determine if a refrigerant
conversion kit is available for the indoor coil.
4
This outdoor unit is designed for use only with indoor coils
that utilize a hard shut-off TXV refrigerant metering
device. If any other type of metering device is installed on
the indoor coil, consult the indoor coil manufacturer to
determine if a hard shut-off TXV conversion kit is
available.
506 01 5001 00
INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
CAUTION
!
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Indoor coil and outdoor unit must be listed as a
certified combination (match) in the ARI Unitary
Directory of Certified Products.
Indoor coil must have R-22 specific, hard shut-off
TXV refrigerant metering device.
When installing a hard shut-off TXV on an indoor coil,
follow the instructions provided with the new TXV.
A typical hard shut-off TXV installation is shown in Figure
3.
Figure 3
Typical TXV Installation
INDOOR
COIL
B. REFRIGERANT LINE SETS
The refrigerant line set must be properly sized to assure
maximum efficiency and proper oil circulation. Select line
set tube diameters as specified in Figure 4.
NOTE: If the line set actual length is to exceed 80 feet, or
if there is more than 20 feet vertical separation between
outdoor and indoor units, refer to the Long Line
Application Guidline document for additional instructions.
NOTE: Line set actual length must not exceed 200 feet.
NOTE: A crankcase heater must be used when the
refrigerant line length exceeds 80 feet.
If it is necessary to add refrigerant line in the field, use
dehydrated or dry, sealed, deoxidized, copper
refrigeration tubing. Do not use copper water pipe.
Do not remove rubber plugs or caps from copper tubing
until connections are ready to be made.
Be extra careful when bending refrigeration tubing.
Tubing can “kink” easily, and if this occurs, the entire
length of tubing must be replaced.
!
EQUALIZER
TUBE
WARNING
PERSONAL INJURY HAZARD
SUCTION
TUBE
SENSING
BULB
LIQUID
TUBE
CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in improp‐
er product operation.
SENSING BULB
(EITHER SIDE)
STRAP
SUCTION
ÉÉ ÉÉ
ÉÉ ÉÉ
TUBE
Figure 4
Relieve pressure and recover all refrigerant before
servicing existing equipment, and before final unit
disposal. Use all service ports and open all flow-‐
control devices, including solenoid valves.
!
HARD
SHUT-OFF
TXV
8 O'CLOCK
Failure to follow this warning could result in per‐
sonal injury and/or death.
4 O'CLOCK
Do not leave system open to atmosphere any lon‐
ger than absolutely required for installation. Inter‐
nal system components - especially refrigerant
oils - are extremely susceptible to moisture con‐
tamination. Keep ends of tubing sealed during
installation until the last possible moment.
R-22 Line Set Tube Diameter (Liquid Tube Always a"” dia.)
Service Valve Fittings
Line Set < 80 feet long
Line Set 80 - 200 feet long
Liquid
Suction
Suction Line Diameter
Suction Line Diameter
Model Size
36 (3 ton)
a”
w”
w”
d”
42 (32 ton), 48 (4 ton)
a”
d”
d”
!8”
60 (5 ton)
a”
d”
!8”
!8”
NOTE: If the line set actual length is to exceed 80 feet, or if there is more than 20 feet vertical separation
between outdoor and indoor units, refer to the Long Line Application Guideline document for additional instruc‐
tions.
506 01 5001 00
5
INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
C. ROUTING AND SUSPENDING REFRIGERANT
LINES
Run refrigerant lines as straight and direct as possible,
avoiding unnecessary bends and turns. Always insulate
the entire suction line. Both lines should be insulated
when routed through an attic or when routed through an
underground raceway.
When routing refrigerant lines through a foundation or
wall, do not allow refrigerant lines to come in direct
contact with the building structure. Make openings large
enough so that lines can be wrapped with extra insulation.
Fill all gaps with RTV caulk. This will prevent noise
transmission between the tubing and the foundation or
wall.
Along floor or ceiling joists, suspend refrigerant lines so
that they do not contact the building structure, water
pipes, or ductwork. Use insulated or suspension type
hangers. Metal straps must be at least 1” wide to avoid
cutting into the tube insulation. Keep the liquid and
suction lines separate. Refer to Figure 5.
Routing and Suspending Refrigerant Lines
Figure 5
OUTDOOR WALL
JOIST
INDOOR WALL
CAULK
LIQUID TUBE
HANGER STRAP
(AROUND SUCTION
TUBE ONLY)
INSULATION
SUCTION TUBE
SUCTION TUBE
INSULATION
1” MIN
LIQUID TUBE
THROUGH THE WALL
!
CAUTION
SUSPENSION
Figure 6
Oil Traps for Outdoor Unit Higher
than Indoor Coil
UNIT OPERATION HAZARD
Failure to follow this caution may result in improp‐
er product operation.
Do not bury more than 36” of line set underground.
Refrigerant may migrate to cooler buried section
during extended periods of unit shut-down, caus‐
ing refrigerant slugging and possible compressor
damage at start-up.
If ANY section of the line set is buried under‐
ground, provide a minimum 6” vertical rise at the
service valve.
D. OUTDOOR UNIT HIGHER THAN INDOOR UNIT
Proper oil return to the compressor should be maintained
with suction gas velocity. If velocities drop below 1500
fpm (feet per minute), oil return will be decreased. To
maintain suction gas velocity, do not upsize vertical
suction risers. Use the “<80 feet” suction line sizes shown
Figure 4.
Install oil traps every 20 feet of vertical suction line riser
(refer to Figure 6).
NOTE: If there is more than 20 feet vertical separation
between outdoor and indoor units, refer to the Long Line
Application Guidline document for additional instructions.
6
10” Max.
3” Min.
20 ft.
20 ft.
E. LIQUID LINE FILTER-DRIER
Outdoor units are shipped with an appropriate filter-drier
for installation in the liquid line. Leave the plugs in the tube
ends until the filter-drier is installed. The optimal location
for the filter-drier is close to the indoor coil. Heat pump
filter-driers are “bi-flow” type. Either end can be pointed
towards indoor coil. Refer to Figure 7.
506 01 5001 00
INSTALLATION INSTRUCTIONS
Figure 7
3-phase R-22 Split System Heat Pump
Liquid Line Filter-Drier
Installed at Indoor Coil
Service valve bodies are brass and suction tube stub is
copper.
Liquid Service Valve with Piston
and Sweat/Flare Adapter Tube
Figure 8
PISTON BODY
LIQUID
SERVICE
VALVE
PISTON
PISTON RETAINER
BRASS NUT
SWEAT/FLARE ADAPTER TUBE
G. BRAZING CONNECTIONS
!
WARNING
FIRE HAZARD
Failure to follow this warning could result in per‐
sonal injury, death, and/or property damage.
Filter-Drier
38-1 1-84
F. SERVICE VALVES
Service valves are closed and plugged from the factory.
Outdoor units are shipped with a refrigerant charge
sealed in the unit. Leave the service valves closed until all
other refrigeration system work is complete or the charge
will be lost. Leave the plugs in place until line set tubing is
ready to be inserted.
Heat pumps require a piston metering device in the liquid
service valve for proper heating operation. Piston and
retainer are shipped in the piston body of the liquid service
valve, temporarily held in place with a plastic cap. Do not
remove the plastic cap until line set tubing is ready to be
installed.
Refer to Figure 8 and follow these steps for piston
installation:
1. Remove plastic cap holding piston and retainer in
piston body of liquid service valve.
2. Check that piston size (stamped on side of piston)
matches with number listed on unit rating plate.
Return piston to piston body of liquid service valve
(either direction).
Return retainer to piston body.
NOTE: Small end of retainer fits inside piston body,
with O-ring sealing against inside of piston body
3. Find plastic bag taped to unit containing copper
adapter tube with brass nut.
4. Install adapter tube against retainer and thread
brass nut onto liquid service valve. Tighten nut
finger tight, then wrench additional ½ turn only.
506 01 5001 00
Refrigerant and oil mixture could ignite and burn
as it escapes and contacts brazing torch. Make
sure the refrigerant charge is properly removed
from both the high and low sides of the system be‐
fore brazing any component or lines.
Clean line set tube ends with emery cloth or steel brush.
Remove any grit or debris.
Insert line set tube ends into service valve tube stubs.
Apply heat absorbing paste or heat sink product between
service valve and joint. Wrap service valves with a heat
sinking material such as a wet cloth.
Braze joints using a Sil-Fos or Phos-copper alloy.
!
CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Braze with Sil-Fos or Phos-copper alloy on cop‐
per-to-copper joints and wrap a wet cloth around
rear of fitting to prevent damage to TXV.
7
INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
H. EVACUATING LINE SET AND INDOOR COIL
The unit is shipped with a factory refrigerant charge. The
liquid line and suction line service valves have been
closed after final testing at the factory. Do not disturb
these valves until the line set and indoor coil have been
evacuated and leak checked, or the charge in the unit
may be lost.
NOTE: Do not use any portion of the factory charge for
purging or leak testing. The factory charge is for filling the
system only after a complete evacuation and leak check
has been performed.
CAUTION
!
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Never use the outdoor unit compressor as a vacu‐
um pump. Doing so may damage the compressor.
Line set and indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns. If
deep vacuum equipment is not available, the alternate
triple evacuation method may be used by following the
specified procedure.
If vacuum must be interrupted during the evacuation
procedure, always break vacuum with dry nitrogen.
Deep Vacuum Method
The deep vacuum method requires a vacuum pump
capable of pulling a vacuum to 500 microns and a vacuum
gauge capable of accurately measuring this vacuum
level. The deep vacuum method is the most positive way
of assuring a system is free of air and water.
Watch the vacuum gauge as the system is pulling down.
The response of the gauge is an indicator of the condition
of the system (refer to Figure 9).
With no leaks in the system, allow the vacuum pump to
run for 30 minutes minimum at the deep vacuum level.
Deep Vacuum Gauge Response
and System Conditions
Figure 9
Triple Evacuation Method
The triple evacuation method should only be used when
system does not contain any water in liquid form and
vacuum pump is only capable of pulling down to 28 inches
of mercury. Refer to Fig. 10 and proceed is as follows:
1. Pull system down to 28 inches of mercury and
allow pump to continue operating for an additional
15 minutes.
2. Close manifold valves or valve at vacuum pump
and shut off vacuum pump.
3. Connect a nitrogen cylinder and regulator to
system and fill with nitrogen until system pressure
is 2 psig.
4. Close nitrogen valve and allow system to stand for
1 hour. During this time, dry nitrogen will diffuse
throughout the system absorbing moisture.
5. Repeat this procedure as indicated in Figure 10.
6. After the final evacuate sequence, confirm there
are no leaks in the system. If a leak is found, repeat
the entire process after repair is made.
Figure 10
Triple Evacuation Sequence
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
CHARGE SYSTEM
5000
4500
4000
LEAK IN
SYSTEM
MICRONS
3500
3000
2500
2000
VACUUM TIGHT
TOO WET
1500
1000
TIGHT
DRY SYSTEM
500
0
1
2
3
4
MINUTES
8
5
6
7
I. OPENING SERVICE VALVES
Outdoor units are shipped with a refrigerant charge
sealed in the unit. Opening the service valves releases
this charge into the system.
NOTE: Open the Suction service valve first. If the Liquid
service valve is opened first, oil from the compressor may
be drawn into the indoor coil TXV, restricting refrigerant
flow and affecting operation of the system.
Remove Suction service valve cap and insert a hex
wrench into the valve stem. Hold the valve body steady
with an end-wrench and back out the stem by turning the
hex wrench counterclockwise. Turn the stem until it just
contacts the rolled lip of the valve body.
After the refrigerant charge has bled into the system,
open the Liquid service valve.
506 01 5001 00
INSTALLATION INSTRUCTIONS
NOTE: These are not back-seating valves. It is not
necessary to force the stem tightly against the rolled lip.
The service valve cap is a primary seal for the valve and
must be properly tightened to prevent leaks. Make sure
cap is clean and apply refrigerant oil to threads and
sealing surface on inside of cap.
3-phase R-22 Split System Heat Pump
Tighten cap finger tight and then tighten additional 6 of a
turn (1 wrench flat) to properly seat the sealing surfaces.
J. GAUGE PORTS
Check for leaks at the schrader ports and tighten valve
cores if necessary. Install plastic caps finger tight.
ELECTRICAL WIRING
!
WARNING
Figure 11
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in per‐
sonal injury or death.
Before installing, modifying or servicing system,
turn OFF the main (remote) electrical disconnect
device. There may be more than one disconnect
device.
Refer to unit rating plate for the required supply voltage.
Depending on the model, required supply voltage will be:
208/230 V, 3-phase, 60 Hz.
or
460 V, 3-phase, 60 Hz.
Outdoor units are approved for use with copper
conductors only. Do not use aluminum wire.
Refer to unit rating plate for minimum circuit ampacity and
circuit protection requirements.
Grounding
Permanently ground unit in accordance with the National
Electrical Code and local codes or ordinances. Use a
copper conductor of the correct size from the grounding
lug in control box to a grounded connection in the service
panel or a properly driven and electrically grounded
ground rod.
Supply Voltage Wiring Connections
Make all outdoor electrical supply (Line Voltage)
connections with raintight conduit and fittings. Most
codes require a disconnect switch outdoors within sight of
the unit. Consult local codes for special requirements.
Route electrical supply (Line Voltage) wiring through
knockout hole in bottom of Control Box.
Connect two power wires to Contactor and one power
wire to Blue lead wire (use wire nut). Connect ground wire
to Ground Lug. Refer to Wiring Diagram on unit and
Figure 11.
506 01 5001 00
208/230 V and 460 V
Electrical Supply
(Line Voltage) Connections
DISCONNECT
PER NEC AND/OR
LOCAL CODES
L1
FIELD POWER
WIRING
CONTACTOR
11
L3
L2
13
BLUE LEAD WIRE
FIELD GROUND
WIRING
GROUND
LUG
Phase Monitor Relay Board
The Phase Monitor Board detects the sequence of the
three phase electrical system, and a relay breaks the Y
(call for cooling) control signal if the phasing is incorrect.
Additionally, the board will detect the loss of voltage on
any of the three phase inputs and break the Y signal in the
same way.
An LED on the board displays the following status:
Red LED ON Normal function, relay contact
closed.
Red LED Blinking - Abnormal function, relay contact
open.
Red LED OFF No 24 VAC control power present at
board.
NOTE: Units with Comfort Alertt Diagnostics device
have phase monitor feature built in.
Figure 12
Phase Monitor Relay Board
9
INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
Thermostat Wiring Connections
Route thermostat wiring through rubber grommet in
bottom of Control Box. Low voltage lead wires are
provided in the control box for connection to thermostat
wires (use wire nuts). Refer to Wiring Diagram on unit and
Figure 13 for low voltage wiring examples.
NOTE: Use No. 18 AWG (American Wire Gage)
color-coded, insulated (35 °C minimum) wire. If
thermostat is located more than 100 feet (30.5 m) from
unit as measured along the control voltage wires, use No.
16 AWG color-coded wires to avoid excessive voltage
drop.
Typical Thermostat (Control Circuit) Connections
Figure 13
NOTE: WHEN USING OUTDOOR THERMOSTATS, W2 MUST BE ENERGIZED WHEN REQUESTING SUPPLEMENTAL HEAT.
SYSTEMS WITH ONE OUTDOOR THERMOSTAT
THERMOSTAT
SUBBASE
INDOOR
SPLICE
CONNECTION
OUTDOOR
SPLICE
CONNECTION
SYSTEMS WITH TWO OUTDOOR THERMOSTATS
DEFROST
BOARD
THERMOSTAT
SUBBASE
W3
INDOOR
SPLICE
CONNECTION
OUTDOOR
SPLICE
CONNECTION
DEFROST
BOARD
ODT
W3
C
C
SHR
C
C
C
C
W2
W2E
W2
W2
W2
W2
ODT
L
L
G
G
G
SHR
G
Y
Y
Y
Y
ODT
E
E
E
EHR
O
O
O
O
R
R
R
R
R
R
REMOVE WIRES FROM CRIMP NUT IN INDOOR FAN COIL WHEN INSTALLING OUTDOOR THERMOSTATS.
SYSTEMS WITHOUT OUTDOOR THERMOSTATS
THERMOSTAT
SUBBASE
INDOOR
SPLICE
CONNECTION
OUTDOOR
SPLICE
CONNECTION
DEFROST
BOARD
LEGEND
C
C
24-V FACTORY WIRING
W2
W2
24-V FIELD WIRING
C
W2
FIELD SPLICE CONNECTION
L
OUTDOOR THERMOSTAT
G
G
EHR
EMERGENCY HEAT RELAY
SHR
SUPPLEMENTAL HEAT RELAY
Y
Y
E
O
O
R
R
R
10
506 01 5001 00
INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
DEFROST SYSTEM
Figure 14
Defrost Thermostat
Defrost Control Board
Figure 15
FEEDER TUBE
TUBE STUB
H9C1
C
OF1
®
US
O1
R14
R13
The defrost thermostat is factory installed on a short tube
stub extending from the coil end plate. Refer to Figure 14
and confirm that the thermostat is securely fastened in
place on the tube stub.
7. Unit will remain in defrost for remainder of
defrost-cycle time or until defrost thermostat
reopens at approximately 65 °F coil temperature of
liquid line.
8. Turn off power to outdoor unit and reconnect
fan-motor lead to OF2 on control board (refer to
Figure 15).
R6
A. DEFROST THERMOSTAT
R21
K1
R4
C13
R20
1
P2
T1 C C O
Y
HK32EA001
1
R11
R5 U3
JW3
R1
R2
R3
C7
D3
D6
C16 R28
C17
P3
DFT
J2
1
P1
1
30 60 90
W1
J1
1
SPEEDUP
To initiate a forced defrost cycle, the defrost thermostat
must be closed. This can be accomplished as follows:
1. Turn off power to outdoor unit.
2. Disconnect outdoor fan-motor lead from OF2 on
control board (refer to Figure 15). Tape lead to
prevent grounding.
3. Restart unit in heating mode, allowing frost to
accumulate on outdoor coil.
4. After a few minutes in heating mode, liquid line
temperature should drop below closing point of
defrost thermostat (approximately 32 °F).
5. Short between speed-up terminals with a
flat-bladed screwdriver (refer to Figure 15). This
reduces the timing sequence to 7, 14, or 21
seconds (30, 60, or 90 minute defrost selection,
respectively).
6. When you hear reversing valve change position,
remove screwdriver immediately; otherwise,
control will terminate normal 10-minute defrost
cycle in approximately 2 seconds.
R8
R7
1 U1
Defrost mode is identical to cooling mode except that
outdoor-fan motor stops and second-stage heat is
turned on to continue warming conditioned space.
Initially, the defrost cycle timer starts when the contactor
is energized and a 24 VAC signal is present on the T1
terminal. Then the defrost cycle begins when the defrost
thermostat is closed and the cycle timer times out (30, 60,
90 or minutes).
C4
C10
JW1
JW2
D4
C1
R9
A29
C9
D2
The defrost board is a time/temperature control which
includes a field-selectable time period between defrost
cycles of 30, 60, or 90 minutes (quick-connects located
at board edge, factory set at 90 minutes).
OF2
R26
B. DEFROST CONTROL BOARD
C19
D1
DEFROST
THERMOSTAT
CEBD430524-01A 5501A
D10
C2
D13
COIL
O
R
W2
Y
C
NOTE: Length of defrost cycle is dependent upon length
of time it takes to remove screwdriver from test pins after
reversing valve has shifted.
506 01 5001 00
11
INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
START-UP PROCEDURE
1. Set indoor thermostat selector switch to OFF.
2. Turn ON all electrical disconnect devices.
3. If unit has a crankcase heater, energize the heater
and wait 24 hours before proceeding.
4. Set indoor thermostat at desired temperature. Be
sure setpoint is below indoor ambient temperature
to call for cooling, or above indoor ambient to call
for heating.
5. Set indoor thermostat selector switch to COOL or
HEAT. Operate unit for minimum 10 minutes, then
check the system refrigerant charge.
Check For Proper Phasing
Observe the LED on the Phase Monitor Relay Board. If
the LED is blinking, turn off power to the unit and swap any
two of the supply voltage wires. Turn power back on and
repeat the start-up procedure.
REFRIGERANT CHARGE
A. COOLING MODE
Outdoor units are shipped with a refrigerant charge to
match a specific indoor coil and 15 feet of refrigerant line.
If shorter or longer refrigerant lines or a different indoor
coil are used, the charge will have to be adjusted.
For different line lengths, add or remove charge based on
0.6 ounces charge per foot of difference. For example, a
25 foot line set is 10 feet longer than the specified 15 feet.
Add 0.6 ounces charge for each of the extra 10 feet:
10 x 0.6 = 6.0 ounces additional charge
This outdoor unit is designed for use only with indoor coils
that utilize a hard shut-off TXV refrigerant metering
device. With a hard shut-off indoor TXV, use the
subcooling method to make final charge adjustments:
1. Operate unit a minimum of 10 minutes before
checking charge.
NOTE: If outdoor unit has a 2-speed fan motor,
motor will operate in low speed when outdoor
ambient temperature is below 82 °F. Pull one of the
yellow low voltage wires off the fan control and the
unit will default to high speed fan for servicing.
Reconnect wire after servicing.
2. Measure liquid service valve pressure by attaching
an accurate gauge to service port.
3. Measure liquid line temperature by attaching an
accurate thermistor type sensor or electronic
thermometer to liquid line near outdoor coil.
4. Refer to unit rating plate for required subcooling
temperature.
12
5. Refer to Figure 16. Find the required liquid line
temperature where the rating plate subcooling
temperature intersects measured liquid service
valve pressure.
6. If the measured liquid line temperature is higher
than the chart number, add refrigerant to lower the
measured temperature.
NOTE: When adding refrigerant, charge in liquid
form, using a flow restricting device, into the
suction port.
If the measured liquid line temperature is lower
than the chart number, reclaim refrigerant to raise
the measured temperature.
Tolerance is | 3 °F.
B. HEATING MODE
To check system operation during heating cycle, refer to
the Tech Label on outdoor unit. This chart indicates
whether a correct relationship exists between system
operating pressure and air temperature entering indoor
and outdoor units. If pressure and temperature do not
match on chart, system refrigerant charge may not be
correct. Do not use chart to adjust refrigerant charge.
NOTE: When charging is necessary during heating
season, charge must be weighed in accordance with unit
rating plate ±0.6 ounces per foot of a inch liquid line
above or below 15 feet respectively.
506 01 5001 00
INSTALLATION INSTRUCTIONS
Figure 16
Measured Liquid
Pressure (psig)
134
141
148
156
163
171
179
187
196
205
214
223
3-phase R-22 Split System Heat Pump
R-22 Required Liquid Line
Temperature (°F) - Cooling Mode
Rating Plate (required)
Rating Plate (required)
Subcooling Temperature (°F)
Subcooling Temperature (°F)
Measured Liquid
5
71
74
77
80
83
86
89
92
95
98
101
104
10
66
69
72
75
78
81
84
87
90
93
96
99
15
61
64
67
70
73
76
79
82
85
88
91
94
20
56
59
62
65
68
71
74
77
80
83
86
89
Pressure (psig)
233
243
253
264
274
285
297
309
321
331
346
359
5
107
110
113
116
119
122
125
128
131
134
137
140
10
102
105
108
111
114
117
120
123
126
129
132
135
15
97
100
103
106
109
112
115
118
121
124
127
130
20
92
95
98
101
104
107
110
113
116
119
122
125
SEQUENCE OF OPERATION
A. COOLING MODE
B. HEATING MODE
On a call for cooling, the thermostat makes circuits R-O,
R-Y , and R-G. Circuit R-O energizes reversing valve,
switching it to cooling position. Circuit R-Y energizes
contactor, starting outdoor fan motor and compressor.
Circuit R-G energizes indoor unit blower relay, starting
indoor blower motor.
On a call for heating, the thermostat makes circuits R-Y
and R-G (circuit R-O is NOT made, and the reversing
valve stays in the de-energized, heating position). Circuit
R-Y energizes contactor, starting outdoor fan motor and
compressor. Circuit R-G energizes indoor blower relay,
starting blower motor. If the room temperature continues
to fall, circuit R-W2 is made through the second-stage
room thermostat bulb. Circuit R-W2 energizes a
sequencer, bringing on the first bank supplemental
electric heat and providing electrical potential to the
second heater sequencer (if used). If outdoor
temperature falls below the setting of the outdoor
thermostat (field-installed option), contacts close to
complete the circuit and bring on the second bank of
supplemental electric heat.
When thermostat is satisfied, its contacts open,
de-energizing contactor and blower relay. Compressor
and motors stop.
NOTE: If indoor unit is equipped with a time-delay relay
circuit, the blower runs an additional length of time to
increase system efficiency. (Applies to both cooling and
heating modes.)
NOTE: Low ambient cooling feature allows unit to
operate safely in cooling mode down to 0° F outdoor
ambient.
506 01 5001 00
When the thermostat is satisfied, its contacts open,
de-energizing contactor, blower relay, and sequencer.
Compressor, motors, and heaters stop.
13
INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
TROUBLESHOOTING
Some models are factory equipped with the Comfort
Alertt Diagnostics device in the control box (refer to
Figure 17). Comfort Alert provides around-the-clock
monitoring for common electrical problems, compressor
defects, and broad system faults. If trouble is detected, an
alert code is displayed with a flashing LED indicator.
NOTE: Comfort Alert is required for unit operation.
Comfort Alert provides active safety protection and
compressor may be shut down. Alert codes are listed in
Figures 18 and 19.
Comfort Alert is factory wired and requires no
modification. Low voltage lead wires are provided in the
control box for connection to thermostat wires (use wire
nuts).
The Comfort Alert device operates by monitoring the
compressor power leads and the thermostat demand
signal (Y terminal). It draws constant 24 VAC power at the
R and C terminals.
Figure 17
Comfort Alertt Diagnostics
(some models)
POWER LED
Y2
Y
DATA
PORT
L
Second Stage
Compressor Signal
First Stage
Compressor Signal
24 VAC for Thermostat
Indicator
R
24 Volt Power
C
24 Volt Common
P
DC
SOL
24 Volt Compressor
Protection Function
DC Compressor
Solenoid
ALERT LED
TRIP LED
Compressor Wires
Pass Through Holes (3)
MAINTENANCE
Condensate Drain
During the cooling season, check monthly for free flow of
drainage and clean if necessary.
Cleanliness
These tips will help keep the air conditioner looking better
and working more efficiently:
1. Free flow of air is essential. Keep fences, shrubs,
trash cans, and other obstructions at least 18
inches from all coil inlets.
14
2. Keep the coil free of grass clippings, leaves,
weeds, and other debris.
NOTE: Coil may occasionally require cleaning with
a liquid solution. The coil must be cold when
cleaning. Use an alkaline based cleaner only.
Cleaning a hot coil or using an acid based cleaner
will remove the paint from the fins and may clog the
coil.
3. Never use a weather cover over the outdoor unit
unless it is a ventilated type or made of breathable
fabric that will allow moisture to evaporate rapidly.
A cover that holds moisture in the unit will cause
more rust build-up and damage than normal
exposure to weather.
506 01 5001 00
INSTALLATION INSTRUCTIONS
3-phase R-22 Split System Heat Pump
Figure 18
Comfort Alertt Diagnostics (some models)
Status LED
Status LED Description
Status LED Troubleshooting Information
Green “POWER” Module has power
Supply voltage is present at module terminals
Red “TRIP” LED Thermostat demand signal 1. Compressor protector is open
On Solid
Y1 is present, but the
2. Outdoor unit power disconnect is open
compressor is not running
3. Compressor circuit breaker or fuse(s) is open
4. Broken wire or connector is not making contact
5. Compressor power wires not routed through Comfort Alert
6. Compressor contactor has failed open
Red “TRIP”
The anti-short cycle timer (3 minutes), in module is preventing compressor restart.
LED Flashing
Module locks out compressor when compressor damaging ALERT codes appear. Lockout ALERT codes are
noted in the Status LED Description; during a compressor lockout, 24VAC power must be removed from module
to manually reset.
Yellow “ALERT” A short circuit or over
1. Compressor contact coil shorted
LED On Solid
current condition exists on 2. Electrical load too high for PROT circuit (maximum) 1 amp
PROT terminal
3. 24 VAC wired directly to PROT terminal
Yellow “ALERT” System Pressure Trip
1. High head pressure
Flash Code 2
Discharge or suction
2. Condenser coil poor air circulation (dirty, blocked, damaged)
pressure out of limits or
compressor overloaded (if 3. Condenser fan is not running
no high pressure switch in 4. If low pressure switch present in system, check Flash Code 3
system) LOCKOUT
information
Yellow “ALERT” Short Cycling
1. If low pressure switch is open:
Flash Code 3
Compressor is running only
a. Low refrigerant charge
briefly LOCKOUT
b. Evaporator bower is not running
c. Evaporator coil is frozen
d. Faulty metering device
e. Condenser coil is dirty
f. Liquid line restriction
2. If high pressure switch present go to Flash Code 2 information
3. Intermittent thermostat demand signal
4. System or control board defective
Yellow “ALERT” Locked Rotor
1. Low line voltage to compressor
Flash Code 4
LOCKOUT
2. Excessive liquid refrigerant in compressor
3. Compressor bearings are seized
Yellow “ALERT” Open Circuit
1. Outdoor unit power disconnect is open
Flash Code 5
2. Compressor circuit breaker or fuse(s) is open
3. Compressor contactor has failed open
4. High pressure switch is open and requires manual reset
5. Broken supply wires or connector is not making contact
6. Unusually long compressor protector reset time due to
extreme ambient temperature
7. Compressor windings are damaged
Yellow “ALERT” Missing Phase
1. Compressor fuse is open on one phase
Flash Code 6
LOCKOUT
2. Broken wire or connector on one phase
3. Compressor motor winding is damaged
4. Utility supply has dropped one phase
Yellow “ALERT” Reverse Phase
1. Compressor running backward do to supply phase reversal
Flash Code 7
LOCKOUT
Yellow “ALERT” Welded Contactor
1. Compressor contactor has failed closed
Flash Code 8
Compressor always runs
2. Thermostat demand signal not connected to module
Yellow “ALERT” Low Voltage
1. Control circuit transformer is overloaded
Flash Code 9
Control circuit < 18VAC
2. Low line voltage to compressor
S Flash Code number corresponds to a number of LED flashes, followed by a pause and then repeated.
S TRIP and ALERT LEDs flashing at same time means control circuit voltage is too low for operation.
S Reset ALERT Flash code by removing 24VAC power from module.
S Last ALERT Flash code is displayed for 1 minute after module is powered on.
S ALERT codes can be reset manually or automatically. ALERT codes that result in a lockout or compressor
lockout can only be reset manually.
- For manual reset, cycle power to Comfort Alert off and on.
- For automatic reset, Comfort Alert will continue to monitor compressor and system; if condition returns to
normal, the ALERT code is automatically turned off.
506 01 5001 00
15
INSTALLATION INSTRUCTIONS
Figure 19
Miswired Module Indication
Green LED is not on, module
does not power up
Green LED intermittent, mod‐
ule powers up only when com‐
pressor runs
TRIP LED is on but system
and compressor check OK
TRIP LED and ALERT LED
flashing together
ALERT Flash Code 3
(Compressor short cycling)
displayed incorrectly
ALERT Flash Code 5 or 6
(Open Circuit, Missing Phase)
displayed incorrectly
ALERT Flash Code 8
(Welded Contactor) displayed
incorrectly
16
3-phase R-22 Split System Heat Pump
Comfort Alertt Diagnostics (some models)
Troubleshooting Information
Determine if both R and C module terminals are connected. Verify voltage is
present at module's R and C terminals.
Determine if R and Y terminals are wired in reverse. Verify module's R and C
terminals have a constant source.
Verify Y terminal is wired properly per OEM wiring diagram. Verify voltage at
contactor coil falls below 0.5VAC when off. Verify 24VAC is present across Y and
C when thermostat demand signal is present. If not, R and C are reverse wired.
Verify R and C terminals are supplied with 19-28VAC.
Verify Y terminal is connected to 24VAC at contactor coil. Verify voltage at
contactor coil falls below 0.5VAC when off.
Check that compressor T1 and T3 wires are through module's current sensing
holes. Verify Y terminal is connected to 24VAC at contactor coil. Verify voltage at
contactor coil falls below 0.5VAC when off.
Determine if module's Y terminal is connected. Verify Y terminal is connected to
24VAC at contactor coil. Verify 24VAC is present across Y and C when
thermostat demand signal is present. If not, R and C are reversed wired. Verify
voltage at contactor coil falls below 0.5VAC when off. Review.
International Comfort Products, LLC
Lewisburg, TN 37091
506 01 5001 00