Tappan FSH1BF, PSH1BF Installation guide

Tappan FSH1BF, PSH1BF Installation guide
OUTDOOR SPLIT SYSTEM HEAT PUMP
16 SEER
INSTALLATION INSTRUCTIONS
TWO-STAGE, R-410A MODELS
IMPORTANT SAFETY INFORMATION................ 2
HEAT PUMP INSTALLATION............................... 3
General Information............................................. 3
Before You Install the Heat Pump........................ 3
Locating the Heat Pump...................................... 3
Packaging Removal............................................. 3
Ground Level....................................................... 3
Rooftop................................................................ 3
Connecting Refrigerant Tubing Between the
Indoor & Outdoor Unit.......................................... 4
ELECTRICAL WIRING.......................................... 4
Pre-Electrical Checklist........................................ 4
Line Voltage......................................................... 4
Grounding............................................................ 5
Thermostat / Low Voltage Connections............... 5
CoreSenseTM Diagnostics Module....................... 5
Compressor Protection...................................... 5
Resetting Alert Codes........................................ 6
Outdoor Fan Motor............................................... 6
Optional Equipment............................................. 6
Transformer Upgrade Kit.................................... 6
START UP & ADJUSTMENTS............................. 7
Pre-Start Check List............................................. 7
Start-Up Procedures............................................ 7
Operating Temperatures.................................... 7
Air Circulation - Indoor Blower........................... 7
System Cooling.................................................. 7
System Heating.................................................. 7
Short Cycle Protection......................................... 7
Defrost Control Board Test Pins.......................... 7
HEAT PUMP MAINTENANCE.............................. 8
Panel Removal..................................................... 8
Panel Installation.................................................. 8
REFRIGERANT CHARGING................................ 9
Charging the Unit in AC Mode............................. 9
Charging the Unit in Heating Mode...................... 9
Charging Charts & Application Notes.................. 10
Figure 6. Charging Chart for 2 Ton Units............ 10
Figure 7. Charging Chart for 3 Ton Units............ 11
Figure 8. Charging Chart for 4 Ton Units............ 11
Figure 9. Charging Chart for 5 Ton Units............ 12
WIRING DIAGRAMS............................................. 13
Figure 10. W.D. for 2 Ton Models With
CoreSenseTM..................................... 13
Figure 11. W.D. for 3, 4, & 5 Ton Models
With CoreSenseTM............................. 14
CORESENSETM TROUBLESHOOTING................ 15
Table 5. CoresenseTM Diagnostics &
LED Troubleshooting............................ 15
INSTALLATION CHECKLIST............................... 20
REPLACEMENT PARTS....................................... 20
IMPORTANT
ATTENTION INSTALLERS:
It is your responsibility to know this product better than your customer. This includes being able to install
the product according to strict safety guidelines and instructing the customer on how to operate and
maintain the equipment for the life of the product. Safety should always be the deciding factor when
installing this product and using common sense plays an important role as well. Pay attention to all safety
warnings and any other special notes highlighted in the manual. Improper installation of the furnace or
failure to follow safety warnings could result in serious injury, death, or property damage.
These instructions are primarily intended to assist qualified individuals experienced in the proper
installation of this appliance. Some local codes require licensed installation/service personnel for this
type of equipment. Please read all instructions carefully before starting the installation. Return these
instructions to the customer’s package for future reference.
DO NOT DESTROY. PLEASE READ CAREFULLY & KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.
IMPORTANT SAFETY INFORMATION
INSTALLER: Please read all instructions before servicing
this equipment. Pay attention to all safety warnings and
any other special notes highlighted in the manual. Safety
markings are used frequently throughout this manual to
designate a degree or level of seriousness and should
not be ignored.
WARNING indicates a potentially hazardous situation that
if not avoided, could result in personal injury or death.
CAUTION indicates a potentially hazardous situation that
if not avoided, may result in minor or moderate injury or
property damage.
WARNING:
ELECTRICAL SHOCK OR FIRE HAZARD
To avoid risk of electrical shock, personal injury,
or death, disconnect all electrical power to the unit
before performing any maintenance or service. The
unit may have more than one electrical supply.
Label all wires prior to disconnection when servicing
the unit. Wiring errors can cause improper and
dangerous operation
WARNING:
This split system heat pump is shipped charged
with R410A refrigerant and ready for installation.
If repairs make it necessary for evacuation and
charging, it should only be attempted by qualified
trained personnel thoroughly familiar with this
equipment. Under no circumstances should
the owner attempt to install and/or service this
equipment. Failure to comply with this warning
could result in property damage, personal injury,
or death.
CAUTION:
This unit uses R-410A refrigerant. DO NOT use
any other refrigerant in this unit. Use of another
refrigerant will damage the unit.
2
WARNING:
Unless noted otherwise in these instructions,
only factory authorized parts or accessory
kits may be used with this product. Improper
installation, service, adjustment, or maintenance
may cause explosion, fire, electrical shock or
other hazardous conditions which may result in
personal injury or property damage.
• Installation of equipment may require brazing
operations. Installer must comply with safety codes
and wear appropriate safety equipment (safety glasses,
work gloves, fire extinguisher, etc.) when performing
brazing operations.
• Follow all precautions in the literature, on tags, and
on labels provided with the equipment. Read and
thoroughly understand the instructions provided with
the equipment prior to performing the installation and
operational checkout of the equipment.
• Use caution when handling this appliance or removing
components. Personal injury can occur from sharp
metal edges present in all sheet metal constructed
equipment.
WARNING:
The information listed below and the next page
must be followed during the installation, service,
and operation of this furnace. Failure to follow
safety recommendations could result in possible
damage to the equipment, serious personal
injury or death.
• The installer must comply with all local codes and
regulations which govern the installation of this type
of equipment. Local codes and regulations take
precedence over any recommendations contained in
these instructions. Consult local building codes and
the National Electrical Code (ANSI CI) for special
installation requirements.
• All electrical wiring must be completed in accordance
with local, state and national codes and regulations
and with the National Electric Code (ANSI/NFPA 70)
or in Canada the Canadian Electric Code Part 1 CSA
C.22.1.
• This equipment contains liquid and gaseous refrigerant
under high pressure. DO NOT USE ANY PORTION OF
THE CHARGE FOR PURGING OR LEAK TESTING.
Installation or servicing should only be performed by
qualified trained personnel thoroughly familiar with this
type equipment.
• Fully annealed, refrigerant grade copper tubing should
be used when installing the system. Refrigerant suction
line tubing should be fully insulated.
• This unit is designed for outdoor installations only and
should be positioned as described on page 3.
HEAT PUMP INSTALLATION
General Information
Split system heat pumps are designed only for outdoor
rooftop or ground level installations. This unit has been
tested for capacity and efficiency in accordance with
AHRI Standards and will provide many years of safe
and dependable comfort, provided it is properly installed
and maintained. Abuse, improper use, and/or improper
maintenance can shorten the life of the appliance and
create unsafe hazards.
To achieve optimum performance and minimize equipment
failure, it is recommended that periodic maintenance be
performed on this unit. The ability to properly perform
maintenance on this equipment requires certain
mechanical skills and tools.
Before You Install the Heat Pump
√ The cooling load of the area to be conditioned must be
calculated and a system of the proper capacity selected.
It is recommended that the area to be conditioned be
completely insulated and vapor sealed.
√ Check the electrical supply and verify the power supply
is adequate for unit operation. The system must be wired
and provided with circuit protection in accordance with
local building codes. If there is any question concerning
the power supply, contact the local power company.
√ The indoor section (air handler, furnace, etc) should be
installed before routing the refrigerant tubing. Refer to
the indoor unit's installation instructions for installation
details.
√ All units are securely packed at the time of shipment and
upon arrival should be carefully inspected for damage
prior to installing the equipment at the job site. Verify
coil fins are straight. If necessary, comb fins to remove
flattened or bent fins. Claims for damage (apparent or
concealed) should be filed immediately with the carrier.
√ Please consult your dealer for maintenance information
and availability of maintenance contracts. Please read
all instructions before installing the unit.
Locating the Heat Pump
• Survey the job site to determine the best location for
mounting the outdoor unit.
• Overhead obstructions (Figure 1), poorly ventilated
areas, and areas subject to accumulation of debris
should be avoided.
• Sufficient clearance for unobstructed airflow through the
outdoor coil must be maintained in order to achieve rated
performance. See Figure 1 for minimum clearances to
obstructions.
• Consideration should be given to availability of electric
power, service access, noise, and shade.
Packaging Removal
To prevent damage to the tubing onnections, carefully
remove the carton and user’s manual from the equipment.
Discard the shipping carton.
Ground Level
Ground level installations must be located according to
local building codes or ordinances and these requirements:
• Clearances must be in accordance with those shown
in Figure 1.
• A suitable mounting pad must be provided and be
separate from the building foundation. The pad must
be level and strong enough to support the unit’s weight.
The slab height must be a minimum of 2” (5 cm) above
grade and with adequate drainage. See Figure 1.
Rooftop
• The method of mounting should be designed so that it
does not overload roof structures or transmit noise to
the interior of the structure. The roof must be structurally
capable of handling the weight of the unit.
• Full perimeter support is required under the unit.
Support must be made of weather resistant materials
and installed prior to unit installation.
• The support must be built to raise the unit 6" above
the roof.
6” from Building
or Structure
24" for
Service Access
12" or 18”
See Note
DO NOT
OBSTRUCT
TOP OF UNIT
12" or 18”
See Note
NOTE: Units require full perimeter clearances.
Installer must maintain 18” between two units
or 12” between single unit and structure.
48”
2” Mounting Pad
Figure 1. Clearance Requirements
3
Connecting Refrigerant Tubing Between
the Indoor & Outdoor Unit
CAUTION:
When servicing, cover or seal openings to
minimize the exposure of the refrigerant system
to air to prevent accumulation of moisture and
other contaminants.
After outdoor and indoor unit placement has been
determined, route refrigerant tubing between the
equipment in accordance with sound installation practices.
• When connecting refrigerant linesets together, it is
recommended that dry nitrogen be flowing through the
joints during brazing. This will prevent internal oxidation
and scaling from occurring.
• Refrigerant tubing should be routed in a manner that
minimizes the length of tubing and the number of bends
in the tubing.
• Refrigerant tubing should be supported in a manner
that the tubing will not vibrate or abrade during system
operation.
• Tubing should be kept clean of foreign debris during
installation.
• Every effort should be made by the installer to ensure
that the field installed refrigerant containing components
of the system have been installed in accordance with
these instructions and sound installation practices to
insure reliable system operation and longevity.
• The maximum recommended interconnecting
refrigerant line length is 75 feet, and the vertical
elevation difference between the indoor and outdoor
sections should not exceed 20 feet.
• If precise forming of refrigerant lines is required, a
copper tubing bender is recommended. Avoid sharp
bends and contact of the refrigerant lines with metal
surfaces.
• A filter dryer is provided with the unit and must be
installed in the liquid line of the system. If the installation
replaces a system with a filter dryer already present
in the liquid line, the filter dryer must be replaced with
COPPER WIRE SIZE — AWG
(1% VOLTAGE DROP)
SUPPLY WIRE LENGTH-FEET
200
150
100
50
6
4
4
4
3
3
2
2
2
1
8
6
6
4
4
4
3
3
3
2
10
8
8
6
6
6
4
4
4
3
14
12
10
10
8
8
6
6
6
4
SUPPLY CIRCUIT
AMPACITY
15
20
25
30
35
40
45
50
55
60
Wire Size based on N.E.C. for 60° type copper conductors.
Table 1. Copper Wire Size
4
the one supplied with the unit. The filter dryer must be
installed in strict accordance with the manufacturer’s
installation instructions.
• Optional equipment such as liquid line solenoid valves,
low ambient, etc., should be installed in strict accordance
with the manufacturer’s installation instructions.
ELECTRICAL WIRING
WARNING:
To avoid risk of electrical shock, personal
injury, or death, disconnect all electrical power
to the unit before performing any maintenance
or service. The unit may have more than one
electrical supply.
Label all wires prior to disconnection when
servicing the unit. Wiring errors can cause
improper and dangerous operation
• All electrical connections must be in compliance with
all applicable local codes and ordinances, and with the
current revision of the National Electric Code (ANSI/
NFPA 70).
• For Canadian installations the electrical connections
and grounding shall comply with the current Canadian
Electrical Code (CSA C22.1 and/or local codes).
Pre-Electrical Checklist
√ Verify that the voltage, frequency, and phase of the
supply source match the specifications on the unit
rating plate.
√ Verify that the service provided by the utility is sufficient
to handle the additional load imposed by this equipment.
Refer to the unit wiring label for proper high and low
voltage wiring.
√ Verify factory wiring is in accordance with the units
wiring diagram. See Figure 10, (page 13), & Figure
11, (page 14). Inspect for loose connections.
Line Voltage
• A wiring diagram is located on the inside cover of the
electrical box of the outdoor unit. The installer should
become familiar with the wiring diagram before making
any electrical connections to the outdoor unit.
• An electrical disconnect must be located within
sight of and readily accessible to the unit. This
switch shall be capable of electrically de-energizing
the outdoor unit.
• Line voltage to the unit should be supplied from a
dedicated branch circuit containing the correct fuse
or circuit breaker for the unit. Incoming field wiring
and minimum size of electrical conductors and circuit
protection must be in compliance with information listed
on the outdoor unit data label. Any other wiring methods
must be acceptable to authority having jurisdiction.
• The outdoor unit requires both power and control circuit
electrical connections. Refer to the wiring diagrams for
identification and location of outdoor unit field wiring
•
•
•
•
•
OD T-stat
(Optional)
W2 IN
W2
G
R
R
W2 out
W
C
C
O
O
Y1 IN
Y1
Y2 IN
Y/Y2
Outdoor
Heat
Pump
Air Handler
Green
Red
White
Black
G
R
E
C
O
Thermostat
•
interfaces. Make all electrical connections in accordance
with all applicable codes and ordinances.
Overcurrent protection must be provided at the branch
circuit distribution panel and sized as shown on the unit
rating label and according to applicable local codes.
See the unit rating plate for minimum circuit ampacity
and maximum overcurrent protection limits.
Provide power supply for the unit in accordance with the
unit wiring diagram, and the unit rating plate. Connect
the line-voltage leads to the terminals on the contactor
inside the control compartment.
Use only copper wire for the line voltage power supply
to this unit as listed in Table 1, (page 4). Use proper
code agency listed conduit and a conduit connector
for connecting the supply wires to the unit. Use of rain
tight conduit is recommended.
208/230 Volt units are shipped from the factory wired
for 230 volt operation. For 208V operation, remove the
lead from the transformer terminal marked 240V and
connect it to the terminal marked 208V.
Optional equipment requiring connection to the power
or control circuits must be wired in strict accordance
of the NEC (ANSI/NFPA 70), applicable local codes,
and the instructions provided with the equipment.
For 2 ton units only: Jumper together Y/Y2 and Y1 on
the indoor unit's control board so that the indoor unit
operates in second satge when operating in cooling
mode.
Y1
Y2
Figure 2. Typical 2 - Stage Heat Pump w/ Optional
Outdoor Thermostat and Variable Speed Air Handler
THERMOSTAT
WIRE GAUGE
MAXIMUM RECOMMENDED
THERMOSTAT WIRE LENGTH (FT)
24
25
22
45
20
70
18
110
Table 2. Thermostat Wire Gauge
Grounding
WARNING:
The unit cabinet must have an uninterrupted or
unbroken electrical ground to minimize personal
injury if an electrical fault should occur. Do not
use gas piping as an electrical ground!
This unit must be electrically grounded in accordance
with local codes or, in the absence of local codes, with
the National Electrical Code (ANSI/NFPA 70) or the CSA
C22.1 Electrical Code. Use the grounding lug provided in
the control box for grounding the unit.
Thermostat / Low Voltage Connections
• Thermostat connections should be made in accordance
with the instructions supplied with the thermostat and
the indoor equipment. A typical installation with a heat
pump thermostat and air handler is shown in Figure 2.
• The outdoor unit is designed to operate from a 24 VAC
Class II control circuit. The control circuit wiring must
comply with the current provisions of the NEC (ANSI/
NFPA 70) and with applicable local codes having
jurisdiction.
• The low voltage wires must be properly connected to the
unit's defrost control board. Recommended wire gauge
and wire lengths for typical thermostat connections are
listed in Table 2.
• The thermostat should be mounted about 5 feet
above the floor on an inside wall. DO NOT install the
thermostat on an outside wall or any other location
where its operation may be adversely affected by radiant
heat from fireplaces, sunlight, or lighting fixtures, and
convective heat from warm air registers or electrical
appliances. Refer to the thermostat manufacturer’s
instruction sheet for detailed mounting and installation
information.
CoreSenseTM Diagnostics Module
(Select Models Only)
The CoreSenseTM Diagnostics Module (Figure 3, (page
6)) is a breakthrough innovation for troubleshooting
heat pump and air conditioning system failures.The module
installs easily in the electrical box of the outdoor unit
near the compressor contactor.By using the compressor
as a sensor, CoreSense Diagnostics helps the service
technician more accurately troubleshoot system and
compressor fault conditions.
A flashing LED indicator communicates the ALERT code
and a diagnostic key is also imprinted on the side of the
module to quickly direct the technician to the root cause
of a problem. Alert identification codes are also listed in
Table 5, (page 15).
Compressor Protection
The CoreSenseTM Diagnostics module utilizes proprietary
algorithms to protect the compressor and system from
repeated trips of system pressure controls and the
compressor internal overload. The protection terminal
of the module should be wired in series with the system
5
Outdoor Fan Motor
Power LED
Y2 (Thermostat 2nd Stage Demand)
Y (Thermostat Demand)
Data Port
L (Alert)
R (24VAC)
C (Common)
Prot (Contactor Cutout)
DC SOL (2nd Stage Solenoid Power)
Alert LED (Yellow)
Trip / Lock LED (Red)
Figure 3. CoreSenseTM Diagnostics Module
low pressure and high pressure cutouts, as well as the
compressor contactor. When the module detects a series
of trips as described below, it will activate a lockout feature
that opens the normally closed protection contacts in
the module, thereby cutting power to the contactor and
shutting off the compressor.
Resetting Alert Codes
When the CoreSenseTM Diagnostics module has detected a
series of adverse conditions that have caused it to lockout
the compressor, and after the issue has been resolved,
it is necessary to manually reset the module in order to
clear the present alert code.
The primary way of clearing the code and resetting the
alert is to press the reset button located on the module.
NOTE: Pressing the reset will require a pin or a mini
electronics screwdriver. This button must be pressed and
held for a minimum of one second for the module to be
reset. Pressing the reset button clears the immediate lock
code and the seven day operating history. It will not clear
the permanent module history. In the case of the threewire module, the codes can be reset or cleared by cycling
power to the module. This can be done by disengaging
the Common (C) terminal. This will not clear the seven
day operating history.
6
If the unit utilizes a 2-speed condenser fan motor, this
motor will operate on low speed when in low cooling,
and on high speed when in high cooling. A relay within
the control area switches the fan motor from low to high
speed using the call for high cooling as the trigger. Other
models that utilize BLDC fixed torque variable speed fan
motors will not require a relay.
Optional Equipment
Optional equipment requiring connection to the power
or control circuits must be wired in strict accordance
with current provisions of the NEC (ANSI/NFPA 70),
with applicable local codes having jurisdiction, and the
installation instructions provided with the equipment.
Optional Equipment (low ambient control, hard start
kits, etc.) should be installed in strict accordance with
the manufacturer’s installation instructions. A functional
checkout should be performed in accordance with the
checkout procedures supplied with the equipment.
Transformer Upgrade Kit
If this 2-stage heat pump is installed in conjunction with
a gas furnace and fossil fuel kit, the furnace transformer
MUST be upgraded to one with a 60 VA rating or using
the transformer upgrade kit (904077). To upgrade the
transformer:
• Remove the existing transformer and install the new
60 VA transformer.
• Remove the 3 amp fuse on the furnace control board
and install the 5 amp fuse provided.
NOTE: The new transformer may be larger than the
existing transformer that is mounted in the furnace. If this
happens, mount the 60 VA transformer using one of the
mounting holes in the furnace panel. On the other side
either drill a 0.149 hole in the panel and use the existing
fastener, or use a self-drilling fastener to secure the other
side of the transformer.
START UP & ADJUSTMENTS
System Cooling
Pre-Start Check List
√ Verify the unit is level and has sufficient clearances for
unobstructed airflow.
√ Verify the outdoor coil and top of the unit are free from
obstructions and debris, and all equipment access/
control panels are in place.
√ Verify that the line voltage power leads are securely
connected and the unit is properly grounded.
√ Verify that the low voltage wires are securely connected
to the correct leads on the low voltage terminal strip.
√ Verify that the power supply branch circuit overcurrent
protection is sized properly.
√ Verify that the thermostat is wired correctly.
Start-Up Procedures
WARNING:
System Heating
This unit is equipped with a crankcase heater.
Allow 24 hours prior to continuing the start up
procedures to allow for heating of the refrigerant
compressor crankcase. Failure to comply may
result in damage and could cause premature
failure of the system. This warning should be
followed at initial start up and any time the power
has been removed for 12 hours or longer.
Operating Temperatures
This equipment has been designed to operate within the
temperatures specified inTable 3. Running the equipment
in heating at higher than 70° F may require the use of a
Heat Pump Mild Weather Control Kit or changing over to
emergency or auxiliary heating.
Air Circulation - Indoor Blower
1. Set the thermostat system mode on OFF and the fan
mode to ON.
2. Verify the blower runs continuously. Check the air delivery
at the supply registers and adjust register openings for
balanced air distribution. If insufficient air is detected,
examine ductwork for leaks or obstructions.
3. Set the thermostat fan mode to AUTO and verify the
blower stops running.
COOLING
1. Set the thermostat’s system mode to COOL and the
fan mode to AUTO. Gradually lower the thermostat
temperature setpoint below room temperature and
verify the outdoor unit and indoor blower energize.
2. Verify blower wheel is spinning in direction indicated by
arrow. Feel the air being circulated by the indoor blower
and verify that it is cooler than ambient temperature.
Listen for any unusual noises. If unusual sounds occur,
determine the source of the noise and correct as
necessary.
3. Verify HI and LO refrigerant pressures.
4. Allow the system to operate for several minutes and then
set the temperature selector above room temperature.
Verify the fan and compressor cycle off with the
thermostat. NOTE: The blower should also stop unless
fan switch is set to the ON position.
HEATING
MIN (°F)
MAX (°F)
MIN (°F)
MAX (°F)
60
115
-10
70
Table 3. Heat Pump Operating Temperatures
1. Set the thermostat's system mode to HEAT and the
temperature mode to below room temperature.
2. Verify the outdoor unit and indoor fan stop running. After
5 minutes, increase the temperature on the thermostat
to it's maximum setting.
3. Verify the outdoor unit and indoor blower energize. Feel
the air being circulated by the indoor blower and verify
that it is warmer than ambient temperature. Listen for
any unusual noises. If unusual sounds occur, determine
the source of the noise and correct as necessary.
NOTE: Other sources for heating (electric furnace, fossil
fuel furnace, air handler with electric heat options, etc.)
that interface with the heat pump should be functionally
checked to verify system operation and compatibility
with the heat pump. Refer to the installation instructions
for this equipment and perform a functional checkout in
accordance with the manufacturer’s instructions.
Short Cycle Protection
1. With the system operating in COOLING mode, record
the setpoint temperature setting of the thermostat.
2. Gradually raise the setpoint temperature until the outdoor
unit and indoor blower de-energize.
3. Immediately lower the setpoint temperature of the
thermostat to its original setting and verify that the
indoor blower is energized and that the outdoor unit
remains de-energized.
4. After approximately 5 minutes, verify that the outdoor
unit energizes and the temperature of the air supplied
to the facility is cooler than ambient temperature.
Defrost Control Board Test Pins
• Placing a jumper between the test pins for less than 1
second will bypass the Anti-Short Cycle Timer.
• Placing a jumper between the test pins for more than 1
second will force the unit into a defrost cycle. As soon
as the jumper is removed, the defrost cycle will end
as determined by the typical criteria.
• Verify the Status Indicator (on the control board) against
the codes listed in Table 4, (page 8) to determine
proper diagnostic description.
7
STATUS
INDICATOR
STATUS
TYPE
C1
C2
H1
H2
SC
OF
_.
01
02
03
04
05
Operating Status
Operating Status
Cooling, 1st Stage
Cooling, 2nd Stage
Operating Status
Heating, 1st Stage
Operating Status
Heating, 2nd Stage
Operating Status
Anti Short Cycle Timer
Operating Status
Defrost
Operating Status
Power on, no call for operation
OF
(FLASHING)
DIAGNOSTIC
DESCRIPTION
Fault
Pressure switch, low
Fault
Pressure switch, high
Fault
Temperature Sensor, Ambient
Fault
Temperature Sensor, Coil
Fault
Board
Input Error
Forced defrost - test short
applied longer than 11 minutes
Panel Removal
1. Remove screws securing the panel.
2. Slide the panel up towards the top pan in order to clear
the bottom flange from the base pan. See Figure 4.
3. Swing the bottom of the panel out and pull the panel
down to remove it from the unit.
Panel Installation
1. Insert the top corners of side panel flanges into the
corner post channels as shown in Detail A in Figure 5.
2. Slide the panel up into the top pan. (You may need to
push on the center of the panel at the top in order to
clear the top pan edge).
3. Swing the panel in and push down until the panel is
resting on the top edge of the base pan wall as shown
in Detail B.
4. Insert screws into the panel to secure it to the unit.
Table 4. Defrost Control Board Status Indicators
HEAT PUMP MAINTENANCE
WARNING:
To prevent electrical shock, personal injury, or
death, disconnect all electrical power to the unit
before performing any maintenance or service.
The unit may have more than one electrical supply.
Proper maintenance is important to achieve optimum
performance from the heat pump. The ability to properly
perform maintenance on this equipment requires certain
mechanical skills and tools. If you do not possess these
skills, contact your dealer for maintenance. Consult your
local dealer about the availability of maintenance contracts.
Routine maintenance should include the following:
• Inspect the electrical connections for tightness at the
beginning of each heating and cooling season. Service
as necessary.
• Inspect and clean or replace air filters at the beginning
of each heating and cooling season, or more frequently
if required.
Figure 4. Panel Removal
DETAIL A
CAUTION:
The unit should never be operated without a
filter in the return air system. Replace disposable
filters with the same type and size.
• Inspect the outdoor coil at the beginning of each cooling
season. Remove any debris. Clean the outdoor coil
and louvers as necessary using a mild detergent and
water. Rinse thoroughly with water.
• Do not add additional oil to motors unequipped with oil
tubes. The compressor is hermetically sealed at the
factory and does not require lubrication.
DETAIL B
Figure 5. Panel Installation
8
REFRIGERANT CHARGING
WARNING:
This split system heat pump is shipped charged
with R410A refrigerant and ready for installation.
If repairs make it necessary for evacuation and
charging, it should only be attempted by qualified
trained personnel thoroughly familiar with this
equipment. Under no circumstances should
the owner attempt to install and/or service this
equipment. Failure to comply with this warning
could result in property damage, personal injury,
or death.
After refrigerant line connections are completed, it is
required that you leak check and evacuate the indoor
section and all line connections (using proper methods)
before finalizing the full system refrigerant charge.
• To achieve rated capacity and efficiency, the compressor
must be exposed to refrigerant for at least 24 hours
prior to running and then the compressor must be run
for a minimum of 12 hours.
• The refrigerant charge can be checked and adjusted
through the service ports provided external to the
outdoor unit. Use only gage line sets which have a
“Schrader” depression device present to actuate the
valve. A common suction port for heating mode charging
is included and located on the compressor access panel
above the outdoor unit service valves.
• A high-pressure switch is factory installed and located
internally on the compressor discharge line of the
outdoor unit. If the discharge pressure rises above 650
psig, the switch will open and de-energize the outdoor
unit. The switch will close again after the discharge
pressure decreases to 460 psig. NOTE: When the
switch opens and then closes, there will be a 3 minute
short cycling delay before the outdoor unit will energize.
Under normal conditions the switch is closed
• A low-pressure switch is factory installed (certain
models) and located internally on the suction line of
the outdoor unit. The switch is designed to protect the
compressor from a loss of charge by interrupting the
thermostat inputs to the unit.
• If the suction pressure falls below 5 psig, the switch will
open and de-energize the outdoor unit. The switch will
close again when the suction pressure increases above
20 psig. When the switch opens and then closes, there
is a 3 minute short cycling delay before the outdoor
unit will energize. Under normal conditions the switch
is closed.
To properly charge these units:
1. Read all Installation Instructions first.
2. Complete any brazing operations. (e.g. Split system
line-sets)
3. Leak check and evacuate the whole system using proper
methods.
4. Purge the nitrogen holding charge.
5. Evacuate the unit to 350-500 microns.
6. Allow the unit to remain under vacuum for at least 30
min.
7. Weigh-In the proper amount of new (or reclaimed)
R-410A refrigerant. Refer to the units Quick Reference
Data Sheet to determine the correct amount of charge.
Charging the Unit in AC Mode
(At outdoor temperatures above 65° F)
1. With the system operating at steady-state, measure the
liquid refrigerant pressure (in psig) at the outdoor unit
service valve.
2. Measure the liquid refrigerant temperature (in
Fahrenheit) at the service valve.
3. Determine the required liquid refrigerant pressure. See
Figure 6, (page 10), Figure 7, (page 11), Figure 8,
(page 11) & Figure 9, (page 12).
• If the pressure measured in Step 1 is greater than
the required liquid refrigerant pressure determined in
Step 3, then there is too much charge in the system.
Remove refrigerant and repeat Steps 1 through 3
until the system is correctly charged.
• If the pressure measured in Step 1 is less than the
required liquid refrigerant pressure determined in
Step 3, there is too little charge in the system. Add
refrigerant and repeat Steps 1 through 3 until the
system is correctly charged.
Charging the Unit in Heating Mode
1. Evacuate the unit to 350-500 microns.
2. Weigh in the proper charge as indicated on the unit
label. NOTE: Initial charge nust be verified in cooling
season.
3. Verify the unit is operating properly according to the
system heating section on page 7.
9
Charging Charts & Application Notes
• This equipment’s cooling system contains
refrigerant under high pressure. Always use safe
and environmentally sound methods when handling
refrigerant handling or servicing the unit. Review
the factory literature and safety warnings prior to
servicing.
• Cooling mode charging charts are applicable only
to matched assemblies of this equipment and listed
airflows for the indoor coil. Outdoor units with nonAHRI lsited indoor coils are not recommended and
deviations from rated airflows or non-listed combinations
may require modification to the expansion device and
refrigerant charging procedures for proper and efficient
system operation. Refer to Figure 6, (page 10), Figure
7, (page 11), Figure 8, (page 11) & Figure 9, (page
12) for correct system charging.
• When repairing system leaks, always use a nitrogen
(inert) gas to protect the refrigerant system and pressure
check the repair before re-charging. Always replace
the filter-dryers when performing any repair to the
refrigeration system with one capable of acid removal.
After completing the repairs, evacuate the system to
350 - 500 microns and weigh in the refrigerant to the
amount specified on the unit rating label.
• Charging charts are valid for a variety of indoor, return
air conditions and are most influenced by the outdoor
ambient temperature, outdoor fan operation and the
unit operating voltage. Before using these charts, make
sure the unit is in a stable operating mode.
• As shown in Figure 6, Figure 7, Figure 8 & Figure 9 the
ideal system sub-cooling can vary over the range of
operation. Reference the charts to determine the ideal
amount of sub-cooling for a given liquid pressure. Units
charged to other values will not perform at the rated unit
efficiency (EER) or rated Coefficient of Performance
(COP) in heating mode.
• To inspect a systems operation using quality
instruments, match the measured liquid temperature
to the units chart. The measured liquid pressure
reading should be within 3% of the charts value for
most installations.
• For systems that are operating with more than a 5%
deviation, inspect the unit for the proper voltage and
phase balance and the refrigeration system for leaks.
• Units that are operating at less then 95% of the nominal
voltage or with a 2% phase imbalance may see a more
significant deviation than the amount stated above.
• DO NOT use the charts in systems that have a fan cycling
under low-ambient control. Refer to the low-ambient
kit instructions for more information. (If applicable)
*SH1BF4M2SX24K Charging Chart-Cooling
600
580
Remove refrigerant when above curve
560
540
520
Liquid Pressure (psig)
500
480
460
440
420
400
380
360
340
320
300
280
260
Add refrigerant when below curve
240
220
200
75
80
85
90
95
100
105
110
115
Liquid Temperature (F)
Figure 6. Charging Chart for 2 Ton Units
10
120
125
130
135
*SH1BF4M2SX36K Charging Chart-Cooling
600
580
Remove refrigerant when above curve
560
540
520
Liquid Pressure (psig)
500
480
460
440
420
400
380
360
340
320
300
280
260
Add refrigerant when below curve
240
220
200
75
80
85
90
95
100
105
110
115
120
125
130
135
Liquid Temperature (F)
Figure 7. Charging Chart for 3 Ton Units
*SH1BF4M2SX48K Charging Chart-Cooling
600
580
Remove refrigerant when above curve
560
540
520
Liquid Pressure (psig)
500
480
460
440
420
400
380
360
340
320
300
280
260
Add refrigerant when below curve
240
220
200
75
80
85
90
95
100
105
110
115
120
125
130
135
Liquid Temperature (F)
Figure 8. Charging Chart for 4 Ton Units
11
*SH1BF4M2SX60K Charging Chart-Cooling
600
580
Remove refrigerant when above curve
560
540
520
Liquid Pressure (psig)
500
480
460
440
420
400
380
360
340
320
300
280
260
Add refrigerant when below curve
240
220
200
75
80
85
90
95
100
105
110
115
Liquid Temperature (F)
Figure 9. Charging Chart for 5 Ton Units
12
120
125
130
135
P
CC
C
FIELD WIRING
LOW VOLTAGE
HIGH VOLTAGE
LEGEND:
SOL
DC
CSC
L1
T1
R
F
C
H
L
Y1
Y2
COIL
SENSOR
CAPACITOR
OUTDOOR
FAN MOTOR
COMPRESSOR
C
C
T2
CCH
L2
Y1 IN
R
C W2 IN
TO THERMOSTAT
O
HP2 HP1 LP2 LP1 W2 OUT
COIL#1
TEMP
HOT1
HOT2
(24V COM)
Y1 OUT
Y2 OUT LPS
Y2 IN
L
RV2 RV1
OUTDOOR
FAN1 FAN2 CCH2 CCH1
TEMP
DEFROST CONTROL
BOARD
AMB
SENSOR
HGBP
R
S
HPS
S
R
ODT
RVS
HGBP
L1
T1
Y1 IN
R
C W2 IN
TO THERMOSTAT
O
HP2 HP1 LP2 LP1 W2 OUT
COIL#1
TEMP
HOT1
HOT2
(24V COM)
Y1 OUT
Y2 OUT LPS
Y2 IN
L
RV2 RV1
RIGHT
LEFT
YELLOW
ODT
(OPTIONAL OUTDOOR
THERMOSTAT)
L2
T2
RVS
GROUNDING
SCREW
GRND L1 L2
CONTACTOR
OUTDOOR
FAN1 FAN2 CCH2 CCH1
TEMP
DEFROST CONTROL
BOARD
AMB SENSOR
(OPTIONAL OUTDOOR
THERMOSTAT)
HPS
COIL
SENSOR
BLACK
BLACK
BLACK
BLACK
CAPACITOR
BLACK
208/230V
1. Couper le courant avant
de faire letretien.
2. Employez uniquement des
conducteurs en cuivre.
3. Ne convient pas aux installations
de plus de 150 volt a la terre.
F
C
H
BLUE
P
C
R
L
Y1
Y2
BLACK
YELLOW
C
BLACK
R
S
RED
12/17
711456B
(Replaces 711456A)
AMB - Ambient Sensor
CC - Contactor Coil
CCH - Crankcase Heater
CSC - Compressor Solenoid Coil
LPS - Low Pressure Switch
HPS - High Pressure Switch
HGBP- Hot Gas By Pass Valve
RVS - Reversing Valve Solenoid
* OUTDOOR THERMOSTAT (OPTIONAL)
C
COMPRESSOR
BLACK
CORESENSE
MODULE
R
S
BLACK
RED
BLACK
Single Phase / 60 Hz.
OUTDOOR
FAN MOTOR
ORANGE
DC SOL
208/230V
BLACK
RED
NOTES:
1. Disconnect all power before servicing.
2. For supply connections use copper conductors only.
3. Not suitable on systems that exceed 150 volts to ground.
4. For replacement wires use conductors suitable for 105 °C
5. For ampacities and overcurrent protection, see unit rating plate.
6. Connect to 24 vac/40va/class 2 circuit. See furnace/airhandler installation
instructions for control circuit and optional relay/transformer kits.
BLACK
Two Stage Split System Heat Pump (Outdoor Section) With Coresense and PSC Fan Motor
BLACK
CCH
WIRING DIAGRAM
WIRING DIAGRAMS
Figure 10. W.D. for 2 Ton Models With CoreSenseTM
13
P
FIELD WIRING
LOW VOLTAGE
HIGH VOLTAGE
LEGEND:
CORESENSE
MODULE
SOL
DC
CSC
T1
L1
C
C
R
H
L
Y1
S
R
Y2
L2
C
Y1
C
Y2
CC
HPS
HGBP
T2
CCH
L2
Y1 IN
R
C W2 IN
TO THERMOSTAT
O
HP2 HP1 LP2 LP1 W2 OUT
COIL#1
TEMP
HOT1
HOT2
(24V COM)
Y1 OUT
Y2 OUT LPS
Y2 IN
L
RV2 RV1
OUTDOOR
FAN1 FAN2 CCH2 CCH1
TEMP
DEFROST CONTROL
BOARD
AMB
SENSOR
COMPRESSOR
COIL
SENSOR
CAPACITOR
OUTDOOR
FAN MOTOR
ECM
L1
208/230V
ODT
RVS
WHITE
L1
HPS
L2
L1
Y1 IN
R
C W2 IN
TO THERMOSTAT
O
HP2 HP1 LP2 LP1 W2 OUT
COIL#1
TEMP
HOT1
HOT2
(24V COM)
Y1 OUT
Y2 OUT LPS
Y2 IN
L
RV2 RV1
OUTDOOR
FAN1 FAN2 CCH2 CCH1
TEMP
DEFROST CONTROL
BOARD
HGBP
BLACK
T2
T1
YELLOW
GRND L1 L2
CONTACTOR
GROUNDING
SCREW
AMB SENSOR
BLUE
BROWN
OUTDOOR
FAN MOTOR
BLACK
(OPTIONAL OUTDOOR
THERMOSTAT)
COIL SENSOR
L2
ECM
Y1
Y2
C
BLACK
YELLOW
1. Couper le courant avant
de faire letretien.
2. Employez uniquement des
conducteurs en cuivre.
3. Ne convient pas aux installations
de plus de 150 volt a la terre.
BLACK
H
ODT
RVS
RED
BLACK
BLACK
RIGHT
LEFT
BLUE
C
208/230V
BLACK
Two Stage Split System Heat Pump (Outdoor Section) With Coresense and ECM Fan Motor
RED
BLACK
DC SOL
P
C
R
L
Y1
Y2
CORESENSE
MODULE
BLACK
R
S
C
12/17
1010407B
(Replaces 1010407A)
AMV- Ambient Sensor
CC- Contactor Coil
CCH- Crankcase Heater
CSC- Compressor
Solenoid Coil
LPS- Low Pressure Switch
HPS- High Pressure Switch
HGBP- Hot Gas By Pass
Valve
RVS- Reversing Valve
Solenoid
*OUTDOOR THERMOSTAT
(OPTIONAL)
BLACK
Single Phase / 60 Hz.
COMPRESSOR
YELLOW
(OPTIONAL
OUTDOOR
THERMOSTAT)
RED
NOTES:
1. Disconnect all power before servicing.
2. For supply connections use copper conductors only.
3. Not suitable on systems that exceed 150 volts to ground.
4. For replacement wires use conductors suitable for 105 °C
5. For ampacities and overcurrent protection, see unit rating plate.
6. Connect to 24 vac/40va/class 2 circuit. See furnace/airhandler installation
instructions for control circuit and optional relay/transformer kits.
CCH
WIRING DIAGRAM
BLACK
14
BLACK
Figure 11. W.D. for 3, 4, & 5 Ton Models With CoreSenseTM
CORESENSETM TROUBLESHOOTING
STATUS LED
Solid Green
“RUN”
Solid Red
“TRIP”
STATUS LED DESCRIPTION
STATUS LED TROUBLESHOOTING INFORMATION
Module has power and
operating normally
Supply voltage is present at module terminals
Thermostat demand signal Y is
present, but the compressor is not
running
1. Compressor protector is open
• Check for high head pressure
• Check compressor supply voltage
2. Outdoor unit power disconnect is open
3. Compressor circuit breaker or fuse(s) is open
4. Broken wire or connector is not making contact
5. High pressure switch open if present in system
6. Compressor contactor has failed open
ALERT Flash Codes
Yellow “ALERT”
Flash Code 1
Long Run Time
Low Refrigerant Charge
Compressor is running extremely
long run cycles
Yellow “ALERT”
Flash Code 2
Compressor (Pressure) Trip
High Refrigerant Charge Discharge
pressure out of limits or compressor
overloaded
Yellow “ALERT”
Flash Code 3
Pressure Switch Cycling
Compressor is running only briefly
due to pressure switch cycling
Yellow “ALERT”
Flash Code 4
Locked Rotor
Yellow “ALERT”
Flash Code 5
Compressor (Moderate Run)
Trip
1. Low refrigerant charge
2. Evaporator blower is not running
• Check blower relay coil and contacts
• Check blower motor capacitor
• Check blower motor for failure or blockage
• Check evaporator blower wiring and connectors
• Check indoor blower control board
• Check thermostat wiring for open circuit
3. Evaporator coil is frozen
• Check for low suction pressure
• Check for excessively low thermostat setting
• Check evaporator airfl ow (coil blockages or return air fi lter)
• Check ductwork or registers for blockage
4. Faulty metering device
• Check TXV bulb installation (size, location and contact)
• Check if TXV/fi xed orifi ce is stuck closed or defective
5. Liquid line restriction (fi lter drier blocked if present in system)
6. Thermostat is malfunctioning
• Check thermostat sub-base or wiring for short circuit
• Check thermostat installation (location, level)
1. Condenser fan is not running
• Check fan capacitor
• Check fan wiring and connectors
• Check fan motor for failure or blockage
2. High head pressure
• Check high pressure switch if present in system
• Check if system is overcharged with refrigerant
• Check for non-condensable in system
3. Condenser coil poor air circulation (dirty, blocked, damaged)
4. Return air duct has substantial leakage
1. Time delay relay or control board defective
2. If high pressure switch present go to Flash Code 2 information
1. Run capacitor has failed
2. Low line voltage (contact utility if voltage at disconnect is low)
• Check wiring connections
3. Excessive liquid refrigerant in compressor
4. Compressor bearings are seized
• Measure compressor oil level
1. Evaporator blower is not running
• Check blower relay coil and contacts
• Check blower motor capacitor
• Check blower motor for failure or blockage
• Check evaporator blower wiring and connectors
• Check indoor blower control board
• Check thermostat wiring for open circuit
2. Faulty metering device
• Check TXV bulb installation (size, location and contact)
• Check if TXV/fi xed orifi ce is stuck closed or defective
3. Condenser coil poor air circulation (dirty, blocked, damaged)
4. Low refrigerant charge
Table 5. CoresenseTM Diagnostics & LED Troubleshooting
15
CORESENSE TROUBLESHOOTING - CONTINUED
STATUS LED
STATUS LED DESCRIPTION
STATUS LED TROUBLESHOOTING INFORMATION
Yellow “ALERT”
Flash Code 8
Welded Contactor
Compressor always runs
1. Compressor contactor has failed closed
2. Thermostat demand signal not connected to module
Yellow “ALERT”
Flash Code 9
Low Supply Voltage
Voltage below 18V
1. Control Circuit transformer is overloaded
2. Low line voltage (contact utility if voltage at disconnect is low)
LOCKOUT Flash Codes
Red
“LOCKOUT”
Flash Code 2
Yellow Off
Compressor (Pressure) Trip
Compressor is locked out
after 4 consecutive or 10 total
compressor (pressure) trip events
1. Condenser fan is not running
• Check fan capacitor
• Check fan wiring and connectors
• Check fan motor for failure or blockage
2. High head pressure
• Check high pressure switch if present in system
• Check if system is overcharged with refrigerant
• Check for non-condensable in system
3. Condenser coil poor air circulation (dirty, blocked, damaged)
4. Return air duct has substantial leakage
Red
“LOCKOUT”
Flash Code 3
Yellow Off
Pressure Switch Cycling
Compressor is locked out after 4
consecutive or 10 total pressure
cycling events
1. Time delay relay or control board defective
2. If high pressure switch present go to Flash Code 2 information
Locked Rotor
Compressor is locked out after 10
consecutive locked rotor events
1. Run capacitor has failed
2. Low line voltage (contact utility if voltage at disconnect is low)
• Check wiring connections
3. Excessive liquid refrigerant in compressor
4. Compressor bearings are seized
• Measure compressor oil level
Red
“LOCKOUT”
Flash Code 5
Yellow Off
Compressor (Moderate Run)
Trip
1. Evaporator blower is not running
• Check blower relay coil and contacts
• Check blower motor capacitor
• Check blower motor for failure or blockage
• Check evaporator blower wiring and connectors
• Check indoor blower control board
• Check thermostat wiring for open circuit
2. Faulty metering device
• Check TXV bulb installation (size, location and contact)
• Check if TXV/fi xed orifi ce is stuck closed or defective
3. Condenser coil poor air circulation (dirty, blocked, damaged)
4. Low refrigerant charge
Red
“LOCKOUT”
Flash Code 6
Yellow Off
Open Start Circuit
Current only in run circuit
1. Run capacitor has failed
2. Open circuit in compressor start wiring or connections
• Check wiring and connectors between supply and the compressor “S” terminal
3. Compressor start winding is damaged
• Check compressor motor winding resistance
Red
“LOCKOUT”
Flash Code 7
Yellow Off
Open Run Circuit
Current only in start circuit
1. Open circuit in compressor run wiring or connections
• Check wiring and connectors between supply and the compressor “R” terminal.
Confirm proper wire routing as shown in Figure 2, (page 5).
2. Compressor run winding is damaged
• Check compressor motor winding resistance
Red
“LOCKOUT”
Flash Code 10
Over Current Protection
Current to PROT is greater than
2A mps
1. Check for contactor shorted to ground
2. Check for mis-wiring to the PROT terminal
Red
“LOCKOUT”
Flash Code 4
Yellow Off
* Flash code number corresponds to a number of LED flashes, followed by a pause and then repeated. Trip and
alert LED’s flashing at same time means control circuit voltage is too low for operation.
Table 4. Coresense Diagnostics & LED Troubleshooting - Continued
16
17
18
19
INSTALLATION CHECKLIST
INSTALLATION ADDRESS:
CITY:
ELECTRICAL SYSTEM
STATE:
UNIT MODEL #
YES
NO
Line voltage polarity correct?
YES
NO
Rated Voltage:.................................................................. VOLTS
UNIT SERIAL #
Max. deviation of voltage
from avg. volts:................................................................. VOLTS
INSTALLER NAME:
CITY________________________
Electrical connections tight?
STATE_________________
Unit installed minimum clearances
shown on page 3?
YES
NO
Has the owner’s information been
reviewed with the customer?
YES
NO
Has the literature package been left
with the unit?
YES
NO
PROPOSITION 65 WARNING:
WARNING:This product contains chemicals known
to the state of California to cause cancer.
WARNING:This product contains chemicals known
to the state of California to cause birth defects or
other reproductive harm.
Has the thermostat been calibrated?
YES
NO
Is the thermostat level?
YES
NO
Is the heat anticipator setting
correct? (If Applicable)
YES
NO
REFRIGERATION SYSTEM
Was unit given 24 hr warm up period
for crankcase heaters?
YES
NO
Stage-1 Liquid Pressure (high side).................................
Stage-1 Suction Pressure (low side)................................
REPLACEMENT PARTS
Replacement parts are available through your distributor.
Please have the complete model and serial number of
the unit when ordering replacement parts.
Electrical:
• Capacitors
• Temperature Limit Switches
• Compressors
• Thermostats
• Contactors
• Time Delay Relays
• Pressure Switches
• Transformers
• Relays
Motors:
• Blower Motor
• Fan Motor
Components:
• Blower Assembly
• Fan Grille
• Cabinet Panels
• Filter/Driers
• Expansion Valves
Specifications & illustrations subject to change without notice or incurring obligations (07/18).
O’Fallon, MO, © Nortek Global HVAC LLC 2018. All Rights Reserved.
1016546D
(Replaces 1016546C)
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