User Manual HXA636GKA100 ICP split-system air conditioner

HXA636GKA100 ICP split-system air conditioner - Use Manual - Use Guide PDF.
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User manual of ICP HXA636GKA100 (16 pages)
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These instructions must be read and understood completely before attempting installation.

IMPORTANT: Effective January 1. 015. all split system and packaged air conditioners must be installed pursuant to applicable regional efficiency standards issued by the Department of Energy.

Safety Labeling and Signal Words

DANGER.

WARNING.

CAUTION. and NOTE

The signal words DANGER.

WARNING.

CAUTION. and NOTE are used to identify levels of hazard seriousness.

The signal word DANGER is only used on product labels to signify an immediate hazard. The signal words WARNING.

CAUTION. and NOTE will be used on product labels and throughout this manual and other 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.

NOTE - Used to highlight suggestions which will result in enhanced installation. reliability. or operation.

Signal Words in Manuals

The signal word WARNING is used throughout this manual in the following manner:

The signal word CAUTION is used throughout this manual in the following manner:

Signal Words on Product Labeling

Signal words are used in combination with colors and/or pictures on product labels.

TABLE OF CONTENTS

Inspect New Unit .

Safety Considerations

Location

Clearances

2 - 3

Unit Support

Refrigeration System

Electrical Wiring

Start-up Procedure

Refrigerant Charge

Sequence of Operation

Troubleshooting

Maintenance

Comfort Alert TM Diagnostics Codes R-410A Quick Reference Guide ..

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. property 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.

421 01 5103 02 02/09/15

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

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in proper ty damage

R-410A systems operate at higher pressures than R-22 systems.

When working with R-410A sys tems. use only service equipment and replace ment components specifically rated or approved for R-410A service.

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.

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.

ELECTRICAL SHOCK HAZARD

Failure to turn off the main (remote) electrical dis connect device could result in personal 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.

Lock out and tag switch with a suitable warning label.

CLEARANCES

When installing. allow sufficient space for airflow clearance. wiring. refrigerant piping. and service. Allow 24 in. (610 mm) clearance to service end of unit and 48 in. (1219.2 mm) above unit. For proper airflow. a 6 in. (152.4 mm) clearance on one side of unit and 12 in. (304.8 mm) on all remaining sides must be maintained.

Maintain a distance of 24 in. (609.6 mm) between units or 18 in. (457.2 mm) if no overhang within 12 ft. (3.66 m). Position so water. snow. or ice from roof or eaves cannot fall directly on unit.

421 01 5103 02

UNIT SUPPORT

NOTE: Unit must be level + 2 degrees [a 3Ainch rise or fall per foot of run (10 mm rise or fall per 305 mm 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 1.

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.

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 (152 mm) 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.

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 1).

Contact local distributor for hurricane hold-down details and the P.E. (Professional Engineer) certification. when required.

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in property damage.

Inadequate unit support may cause excessive vibration. noise. and/or stress on the refrigerant lines. leading to refrigerant line failure.

Figure 1 Tie Down Knockouts

In Base Pan (2 places)

Base Pan Width

Base Pan Width Depth

23 x 23 (584 x 584)

25-11/16 25-11/16 (652 x 652)

31-1/8 31-1/8

(791 x 791)

34-15/16

34-15/16 (887 x 887)

Inches (mm) Tie Down Knockouts

7-3/4 4-7/16 (197) (113)

9-1/16 4-7/16 (230) (113)

9-1/16 6-1/2 (230) (165)

9-1/16 6-1/2

(230) (165)

(457)

21-1/4

(540)

24-5/8 (625)

28-7/16 (722)

Minimum MountingPad Dimensions

23 x 23 (584 x 584)

26 x 26

(660 x 660)

31-1/2 31-1/2 (800 x 800)

35 x 35 (889 x 889)

REFRIGERATION SYSTEM

A. COMPONENT MATCHES

Check to see that the proper system components are in place. especially the indoor coil.

R-410A outdoor units can only be used with R-410A 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.

This outdoor unit is designed for use only with indoor coils that utilize a TXV refrigerant metering device or Piston with Teflon ring metering device. If any other type of metering device is installed on the indoor coil. consult the indoor coil manufacturer to determine if a TXV conversion kit is available.

Installing with TXV

When installing a TXV on an indoor coil. follow the instructions provided with the new TXV.

A typical TXV installation is shown in Figure 2.

421 01 5103 specificationssubjectto changewithout notice.

Figure 2

Typical TXV Installation

EQUALIZER TUBE

SENSING SUCTION BULB TUBE

LIQUID TUBE

_ 00'cl°ck 20.clock

7/8 IN.

OD & SMALLER

SENSING BULB

When changing indoor piston. use a back-up wrench.

Hand tighten hex nut. then tighten with wrench 1/2 turn.

Do not exceed 30 ft-lbs.The indoor piston contains Teflon ring (or seal) which is used to seat against the inside of distributor body. and must be installed properly to ensure proper seating in the direction for cooling operation.

Figure 3 Indoor (cooling) Piston

BRASS'=" HEX NUT\ TEFLON SEAL

TEFLONRING

I!l I'. FLOWIN

II RETAINER

STRAINER

BRASS HEX BODY

L10S017

Installing with Indoor Piston - cooling operation.

Check piston size shipped with indoor unit to see if it matches required indoor piston size.

If it does not match. replace indoor piston with correct piston size. (Indoor pistons are shipped with some outdoor models in the accessory bag and are only qualified for Piston fan coils.)

Example fan coils with piston: FEM4P. FSM4P. FSU4P (12 thru 4 ton).

See Figure 3.

PRODUCT OPERATION HAZARD Failure to follow this caution may result in improper product operation.

If using a TXV in conjunction with a single-phase reciprocat ing compressor. a compressor start capacitor and relay are required. Consult outdoor unit pre-sale literature for start as sist kit part number.

421 01 5103 02

B. REFRIGERANT LINE SETS

The refrigerant line set must be properly sized to assure maximum efficiency and proper oil circulation.

Refer to Product Specifications and Long Line Applications Guideline for line set sizing.

NOTE: Total line set length must not exceed 200 feet (61 m).

A crankcase heater must be used when the refrigerant line length exceeds 80 feet (24.4 m).

If outdoor unit is more than 10 feet (3 m) higher than the indoor coil. refer to the Long Line Applications Guideline for instructions.

When the outdoor unit is higher than the indoor coil. the vertical separation must not exceed 100 feet (30 m).

When the outdoor unit is lower than the indoor coil. the vertical separation must not exceed 50 feet (15.2 m).

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.

PERSONALINJURY HAZARD

Failure to relieve system pressure could result in personal injury and/or death.

Relieve pressure and recover all refrigerant be fore servicing existing equipment. and before fi nal unit disposal.

Use all service ports and open all flow-control devices. including solenoid valves.

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 R-I-V 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" (25 mm) wide to avoid cutting into the tube insulation. Keep the liquid and suction lines separate.

Refer to Figure 4.

UNIT OPERATION HAZARD

Failure to follow this caution may result in im proper product operation.

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.

Figure 4 Routing and Suspending Refrigerant Lines

I'

LIQUID TUBE

THROUGH THE WALL

HANGER STRAP (AROUND SUCTION

TUBE ONLY)

JOiST

1"(25m1 MIN LIQUID TUBE

SUSPENSION

421 01 5103 02 Specifications subject to change without notice.

UNIT OPERATION HAZARD

Failure to follow this caution may result in im proper product operation.

Do not bury more than 36" (lm) of line set under ground. Refrigerant may migrate to cooler buried section during extended periods of unit shut down. causing refrigerant slugging and possible compressor damage at start-up.

If ANY section of the line set is buried under ground. provide a minimum 6" (152mm) 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.

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.

Install the filter-drier with the arrow pointing towards the indoor coil. Refer to Figure 5.

Figure 5 Liquid Line Filter-Drier Installed at Indoor Coil

Filter-Drier (arrow points towards indoor coil) 38-11-84

F. SERVICE VALVES

Service valves are closed and tube stubs are plugged from the factory.

Outdoor units are shipped with a

Service valve bodies are brass and tube stubs are copper.

Figure 6 Service Valve

G. BRAZING CONNECTIONS NOTE: Remove valve core from schrader port on both Service Valves BEFORE brazing.

This helps prevent overheating and damage to valve seals (refer to Figure 6).

Replace valve core when brazing is completed.

FIRE HAZARD

Failure to remove refrigerant and oil charge be fore brazing could result in personal injury. death. and/or property damage.

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 SiI-Fos or Phos-copper alloy.

PRODUCT DAMAGE HAZARD

Failureto follow this caution may result in productdam age.

Braze with SiI-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.

421 01 5103 02

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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.

PRODUCT DAMAGE HAZARD

Failure to follow this caution may result in product dam age.

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 7).

With no leaks in the system. allow the vacuum pump to run for 30 minutes minimum at the deep vacuum level.

Figure 7 Deep Vacuum Gauge Response and System Conditions

4500

4000

3500

3000

2500 2000

1500

1000

TIGHT

DRY SYSTEM

MINUTES

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 (711mm Hg). Refer to Figure 8 and proceed as follows:

Pull system down to inches of mercury (711mm Hg) and allow pump to continue operating for an additional 15 minutes.

Close manifold valves or valve at vacuum pump and shut off vacuum pump.

Connect a nitrogen cylinder and regulator to system and fill with nitrogen until system pressure is 2 psig.

Close nitrogen valve and allow system to stand for 1 hour. During this time. dry nitrogen will diffuse throughout the system absorbing moisture.

Repeat this procedure as indicated in Figure 8.

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 8 Triple Evacuation Sequence

I EVACUATE I

IBREAK VACUUM WITH DRY NITROGEN

I EVACUATE I

IBREAK VACUUM WITH DRY NITROGEN

I EVACUATE I

I CHECK FORTIGHT. DRY SYSTEM (IF IT HOLDS DEEP VACUUM)

I CHARGE SYSTEM

421 01 5103 02 Specifications subject to change without notice.

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.

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.

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

The supply voltage must be 208/230 volts (197 volt minimum to 253 volts maximum) 60 Hz single phase.

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.

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 wires to Contactor and Ground Lug according to Wiring Diagram on unit. Refer to Figure 9.

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 10 for low voltage wiring examples.

ELECTRICAL SHOCK HAZARD

Failure to turn off the main (remote) electrical dis connect device could result in personal 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.

Figure 9

NOTE: Use No.

18 AWG (American Wire Gage) color-coded. insulated °C minimum) wire.

If thermostat is located more than 100 feet (31 m) from unit as measured along the control voltage wires. use No. 16 AWG color-coded wires to avoid excessive voltage drop.

NOTE: Some models are factory equipped with Comfort Alert TM Diagnostics device. If Comfort Alert is used as a field installed option. then a hot bundle must be run for proper connection.

Electrical Supply (Line Voltage) Connections

DISCONNECT PER NEC AND/OR LOCAL CODES L1

FIELD POWER

WIRING L2

FIELD GROUND

WIRING

CONTACTOR

3or13 GROUND LUG

421 01 5103 02

Figure10 TypicalThermostatConnections

THERMOSTAT FURNACE AIR CONDITIONER

24 VAC HOT

24 VAC COM

HEAT STAGE

COOL STAGE

INDOOR FAN

THERMOSTAT

24 MAC HOT

24 MAC COM

HEAT STAGE

COOL STAGE

INDOOR FAN

FAN COIL

AIR CONDITIONER

THERMOSTAT

24 MAC HOT

24 MAC COM

HEAT STAGE 1

COOL STAGE 1

INDOOR FAN

FAN COIL

AC with Comfort Alert

START-UP PROCEDURE

Set indoor thermostat selector switch to OFF.

Turn ON all electrical disconnect devices.

If unit has a crankcase heater. energize the heater and wait 24 hours before proceeding.

Set indoor thermostat at desired temperature.

Be sure setpoint is below indoor ambient temperature or thermostat will not call for cooling.

Set indoor thermostat selector switch to COOL.

Operate unit for minimum 15 minutes. then check the system refrigerant charge.

REFRIGERANT CHARGE

Factory charge amount and desired subcooling are shown on unit rating plate. Charging method is shown on information plate inside unit.

For TXV. use subcooling method.

For Piston. use superheat method.

To properly check or adjust charge. conditions must be favorable for subcooling or superheat charging.

Favorable conditions exist when the outdoor temperature is between 70°F and 100°F (21°C and 38 °C). and the indoor temperature is between 70°F and 80°F (21 °C and 27°C).

Follow the procedure below.

Unit is factory charged for 15 feet (4.6 m) of lineset.

Adjust charge by adding or removing 0.6 oz/ft (17 g/mm) of 3/8 liquid line above or below 15 feet (4.6 m) respectively.

For standard refrigerant line lengths 80 feet (24.4 m) or less. allow system to operate in cooling mode at least 15 minutes.

If conditions are favorable. check system charge by super heat method for fixed metering device and subcooling method for TXV. If any adjustment is necessary. adjust charge slowly and allow system to operate for 15 minutes to stabilize before declaring properly charged system.

421 01 5103 specificationssubjectto changewithout notice.

If the indoor temperature is above 80°F (27°C). and the outdoor temperature is in the favorable range. adjust system charge by weight based on line length and allow the indoor temperature to drop to 80°F (27°C) before attempting to check system charge by subcooling method as described above.

If the indoor temperature is below 70°F (21°C). or the outdoor temperature is not in the favorable range. adjust charge for line set length above or below 15 feet (4.6 m) only. Charge level should then be appropriate for the system to achieve rated capacity. The charge level could then be checked at another time when the both indoor and outdoor temperatures are in a more favorable range.

NOTE: If line length is beyond 80 feet (24.4 m) or greater than 20 feet (6.1 m) vertical separation.

See Long Line Guideline for special charging requirements.

A. UNITS WITH COOLING MODE TXV

Units installed with cooling mode TXV require charging by the subcooling method.

Operate unit a minimum of 15 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.

Measure liquid service valve pressure by attaching an accurate gage to service port.

Measure liquid line temperature by attaching an accurate thermistor type or electronic thermometer to liquid line near outdoor coil.

Refer to unit rating plate for required subcooling temperature.

Refer to Figure 13. Find the point where required subcooling temperature intersects measured liquid service valve pressure.

To obtain required subcooling temperature at a specific liquid line pressure. add refrigerant if liquid line temperature is higher than indicated or reclaim refrigerant if temperature is lower. Allow a

B. UNITS WITH INDOOR PISTON

Units installed with indoor pistons require charging by the superheat method.

The following procedure is valid when indoor airflow is

Operate unit a minimum of 15 minutes before checking charge.

Measure suction pressure by attaching an accurate gage to suction valve service port.

Measure suction temperature by attaching an accurate thermistor type or electronic thermometer to suction line at service valve.

Measure outdoor air dry-bulb temperature with thermometer.

Measure indoor air (entering indoor coil) wet-bulb temperature with a sling psychrometer.

Find outdoor temperature and evaporator entering air wet-bulb temperature.

At this intersection. note superheat.

Where a dash (--) appears on the table. do not attempt to charge system under these conditions or refrigerant slugging may occur. Charge must be weighted in. adding or removing 0.6 oz/ft of 3/8 liquid line above or below 15 feet (4.6 m) respectively.

Find superheat temperature (from #6 above) and suction pressure. At this intersection. note suction line temperature.

If unit has a higher suction line temperature than charted temperature. add refrigerant until charted temperature is reached.

If unit has a lower suction line temperature than charted temperature. reclaim refrigerant until charted temperature is reached.

When adding refrigerant. charge in liquid form into suction service port using a flow-restricting device.

If outdoor air temperature or pressure at suction valve changes. charge to new suction line temperature indicated on chart.

Optimum performance will be achieved when the operating charge produces 10°F suction superheat at suction service valve with 95°F (35°C) outdoor ambient and 80°F (27°C) dry bulb (67°F 19°C) wet bulb) indoor temperature (DOE "A" test conditions) at rated airflow.

421 01 5103 02

Figure 11 Outdoor Temp °F

SUPERHEAT CHARGING TABLE

(SUPERHEAT °FAT LOW-SIDE SERVICE PORT) EVAPORATOR ENTEREING AIR °F AT WB

°F = Fahrenheit

Outdoor Temp °C

SUPERHEAT CHARGING TABLE

(SUPERHEAT °C AT LOW-SIDE SERVICE PORT) EVAPORATOR ENTEREING AIR °C AT WB

°C = Celsius

+Optimum performance point. 95°F (35°C) outdoor ambient and (80°F / 27°C dr bulb). (67°F / 19°C wet bulb) indoor conditions. (DOE A Test Conditions) Where a dash (--) appears do not attempt to charge system under these conditions or refrigerant slugging may occur. Charge must be weighed in.

Note: Superheat °F is at low-side service port. Allow a tolerance of + 3°F ( 1.7°C) Note: Indoor dry bulb between 70°F and 80°F (21°C and 27°C)

Figure 12 SUCTION PRESSURE AT SERVICE PORT PSIG SUCTION PRESSURE AT SERVICE PORT kPA SUPER-108111211171121 SUPER-7431774180518361869190219571971 11005 HEAT REQUIRED SUCTION TUBE TEMPERATURE°F HEAT REQUIRED SUCTION TUBE TEMPERATURE °C TEMP F (MEASURED AT LOW-SIDE SERVICE PORT) TEMP C (MEASURED AT LOW-SIDE SERVICE PORT)

421 01 5103 specificationssubjectto change without notice.

SEQUENCE OF OPERATION

With power supplied to indoor and outdoor units. transformer is energized.

On a call for cooling. the thermostat makes circuits R-Y and R-G.

Circuit R-Y energizes contactor. starting outdoor fan motor and compressor.

Circuit R-G energizes indoor unit blower relay. starting indoor blower motor.

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.

TROUBLESHOOTING

Some models are factory equipped with the Comfort Alert TM Diagnostics device in the control box (refer to Figure 14). 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.

Alert codes are listed in Figure 15.

The device 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).

Figure 14 Comfort Alert TM Diagnostics (some models)

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:

Free flow of air is essential. Keep fences. shrubs. trash cans. and other obstructions at least 18 inches (457 mm) from all coil inlets.

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.

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.

421 01 5103 02 Specifications subject to change without notice.

Figure 15 Status LED Green "POWER"

Red "TRIP"

Yellow "ALERT" Flash Code 1

Yellow "ALERT" Flash Code 2

Yellow "ALERT" Flash Code 3

Yellow "ALERT" Flash Code 4

Yellow "ALERT" Flash Code 5

Yellow "ALERT" Flash Code 6

Yellow "ALERT" Flash Code 7

Yellow "ALERT" Flash Code 9

Comfort Alert TM

Status LED Description

Module has power Thermostat demand signal Y1 is present. but the compressor is not running

Long Run Time Compressor is running extremely long run cycles

System Pressure Trip Discharge or suction pressure out of limits or compressor overloaded

Short Cycling Compressor is running

Locked Rotor

Open Circuit

Open Start Circuit Current only in run circuit

Open Run Circuit Current only in start circuit

Diagnostics (some models)

Status LED Troubleshooting Information

Supply voltage is present at module terminals 1. Compressor protector is open 2. Outdoor unit power disconnect is open

Compressor circuit breaker or fuse(s) is open Broken wire or connector is not making contact

Low pressure switch open if present in system Compressor contactor has failed open

• Low refrigerant charge Evaporator blower is not running Evaporator coil is frozen

Faulty metering device Condenser coil is dirty

Liquid line restriction (filter drier blocked if present in system) Thermostat is malfunctioning

• High head pressure Condenser coil poor air circulation (dirty. blocked. damaged) Condenser fan is not running

Return air duct has substantial leakage

• If high pressure switch open. go to Flash Code 2 information

If low pressure switch open. go to Flash Code 1 information Thermostat demand signal is intermittent

Loose wiring at contactor coil

• Run capacitor has failed

Low line voltage (contact utility if voltage at disconnect is low) Excessive liquid refrigerant in compressor Compressor bearings are seized

• Outdoor unit power disconnect is open Compressor circuit breaker or fuse(s) is open

Compressor contactor has failed open High pressure switch is open and requires manual reset Open circuit in compressor supply wiring or connections

Unusually long compressor protector reset time due to extreme ambient temperature

Compressor windings are damaged

• Run capacitor has failed

Open circuit in compressor start wiring or connections Compressor start winding is damaged

• Open circuit in compressor run wiring or connections Compressor run winding is damaged

Low Voltage 1. Control circuit transformer is overloaded Control circuit < 17VAC 2. Low line voltage (contact utility if voltage at disconnect is low)

• Flash Code number corresponds to a number of LED flashes. followed by a pause and then repeated.

• TRIP and ALERT LEDs flashing at same time means control circuit voltage is too low for operation.

421 01 5103 02

R-410A QUICK REFERENCE GUIDE

R-410A refrigerant operates at 50% - 70% higher pressures than R-22.

Be sure that servicing equipment and replacement components are designed to operate with R-410A.

R-410A refrigerant cylinders are rose colored.

Recovery cylinder service pressure rating must be 400 psig. DOT 4BA400 or DOT BW400.

R-410A systems should be charged with liquid refrigerant.

Use a commercial type metering device in the manifold hose.

Manifold sets should be 750 psig high-side and 200 psig low-side with 520 psig low-side retard.

Use hoses with 750 psig service pressure rating.

Leak detectors should be designed to detect HFC refrigerant.

R-410A. as with other HFC refrigerants. is only compatible with POE oils.

Vacuum pumps will not remove moisture from oil.

Do not use liquid line filter-driers with rated working pressures less than 600 psig.

Do not install a suction line filter-drier in liquid line.

POE oils absorb moisture rapidly.

Do not expose oil to atmosphere.

POE oils may cause damage to certain plastics and roofing materials.

Wrap all filter-driers and service valves with wet cloth when brazing.

A liquid line filter-drier is required on every unit.

Do not use with an R-22 TXV.

If indoor unit is equipped with an R-22 TXV. it must be changed to an R-410A TXV.

Never open system to atmosphere while it is under a vacuum.

When system must be opened for service. break vacuum with dry nitrogen and replace all filter-driers.

Do not vent R-410A into the atmosphere.

Do not use capillary tube indoor coils.

Observe all WARNINGS.

CAUTIONS.

NOTES. and bold text.

421 01 5103 02 Specifications subject to change without notice.



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