User`s Information and Installation Instructions
Contents
1. 500 H a a 475 Remove refrigerent when above curve 450 HHHH 425 400 375 350 Liquid Pressure psig 325 300 Add refrigerent when below curve 250 1 4 4 4 4 H 75 80 85 90 95 100 105 110 115 120 125 Liquid Temperature F 275 N Figure 4 Charging Chart for 3 ton R 410A AC unit with 10 Refrigerant Charging Charts Continued 500 475 450 Remove refrigerent when above curve gt A N O a 350 w N Liquid Pressure psig 300 275 250 4 EEE SEE EE EEE EE EHH Add refrigerent when below curve N 75 80 85 90 95 100 105 110 115 120 Liquid Temperature F Figure 5 Charging Chart for 4 ton R 410A AC unit with TXV 500 475 wo A A A a No O Liquid Pressure psig gt 300 275 250 70 Remove refrigerent when above curve 75 80 85 90 95 100 105 110 115 120 Liquid Temperature F Add refrigerent when below curve 125 Figure 6 Charging Chart for 5 ton R 410A AC unit with TXV 11 INSTALLER PLEASE LEAVE THESE INSTALLATION INSTRUCTIONS WITH THE ENERGY STAR 7083500 Replaces 708282A Speci2. Thermostat demand signal Compressor protector is open 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 8 Yellow ALERT Flash Code 9 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 only briefly Locked Rotor Open Start Circuit Current only in run circuit Open Run Circuit Current only in start circuit Low Voltage Control circuit lt 17VAC 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 low pressure switch present in system check Flash Code 1
3. 2 Set the thermostat temperature to the desired temperature level using the temperature selector Please refer to the separate thermostat user s manual for complete instructions regarding thermostat programming The outdoor unit and indoor blower will both cycle on and off to maintain the indoor temperature at the desired cooling level To Operate Your Furnace for Heating 1 Set the thermostat system switch to HEAT or AUTO and the thermostat fan switch to AUTO See Figure 1 2 Set the thermostat temperature to the desired temperature level using the temperature selector Please refer to the separate user s manual for complete thermostat programming instructions The furnace and indoor blower will cycle on and off to maintain the indoor temperature at the desired heating level To Shut Off Your Air Conditioner Set the thermostat system switch to OFF and the thermostat fan switch to AUTO See Figure 1 The system will not operate regardless of the thermostat temperature setting To Operate the Indoor Blower Continuously Set the thermostat fan switch to ON See Figure 1 The indoor blower will start immediately and will run continually until the fan switch is reset to AUTO SYSTEM SWITCH FAN SWITCH TEMPERATURE SELECTOR TEMPERATURE SCALES Figure 1 Typical Thermostat The continuous indoor blower operation can be obtained with the thermostat system switch set in any position including OF
4. information 1 Thermostat demand signal is intermittent 2 Time delay relay or control board defective 3 If high pressure switch present go to Flash Code 2 information 4 If low pressure switch present go to Flash Code 1 information Run capacitor has failed Low line voltage contact utility if voltage at disconnect is low e Check wiring connection Excessive liquid refrigerant in compressor Compressor bearings are seized Measure compressor oil level Outdoor unit power disconnect is open Compressor circuit breaker or fuse s is open Compressor contactor has failed open e Check compressor contactor wiring and connectors e Check for compressor contactor failure burned pitted or open e Check wiring and connectors between supply and compressor e Check for low pilot voltage at compressor contactor coil 4 High pressure switch is open and requires manual reset 5 Open circuit in compressor supply wiring or connections 6 Unusually long compressor protector reset time due to extreme ambient temperature 7 Compressor windings are damaged e Check compressor motor winding resistance 1 Run capacitor has failed 2 Open circuit in compressor start wiring or connections e Check wiring and connectors between supply and the compressor S terminal 3 Compressor start winding is damaged e Check compressor motor winding resistance 1 Open circuit in compressor run wiring or connections e Check wiring and connector
5. is recommended if cleanliness or adequacy of system evacuation is unknown or compromised Every effort should be made by the installer to ensure that the field installed refrigerant containing components of the sys tem have been installed in accordance with these instructions and sound installation prac tices so as 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 Filter Dryer Installation 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 the one supplied with the unit The filter dryer must be installed in strict accordance with the manufacturer s installation instructions Optional Equipment Optional equipment e g low ambient control etc should be in stalled in strict accordance with the manufacturer s installation instructions 7 MAKING ELECTRICAL CONNECTIONS A WARNING Turn off all electrical power at the main circuit box before wiring electrical power to the outdoor unit Failure to comply may cause severe personnel injury or death Wiring Diagram Schematic A wiring dia gram schematic is located on the inside cover of the electri
6. of the job site to determine the optimum location for mounting the outdoor unit Overhead obstructions poorly ventilated areas and areas subject to accumu lation of debris should be avoided The outdoor unit must be installed in such a manner that airflow through the coil is not obstructed and that the unit can be serviced Facility Prerequisites Electrical power must be supplied to the equipment Electrical power supplied must be adequate for proper operation of the equipment The system must be wired and provided with circuit protection in accor dance with local building codes and the Na tional Electrical Code Minimum Circuit Ampacity Electrical wir ing to the equipment must be compatible and in compliance with the minimum circuit ampacity listed on the outdoor unit data label Maximum Fuse Circuit Breaker Size Circuit protection for the outdoor unit must be compatible with the maximum fuse circuit breaker size listed on the outdoor unit data label 4 INSTALLING THE OUTDOOR UNIT Slab Mount The site selected for a slab mount installation requires a stable foundation and one not subject to erosion The slab should be level and anchored if necessary prior to placing the equipment on the slab Cantilever Mount The cantilever mount should be designed with adequate safety factor to support the weight of the equipment and for loads subjected to the mount during operation Installed equipment should be a
7. ATION Read the following instructions completely be fore performing the installation CAUTION This unit uses R 410A DO NOT under any circumstance use any other refrigerant besides R 410A in this unit Use of another refrigerant will damage this unit Condensing Unit Section Each condens ing unit is shipped with a refrigerant charge adequate to operate the outdoor section with an indoor matching coil or air handler and 15 feet of refrigeration line NOTE DO NOT USE ANY PORTION OF THE CHARGE FOR PURGING OR LEAK TESTING Matching coils and air handlers are shipped with a small pressurized holding charge to pressurize them to keep out contaminants To release the pressure carefully read the instal lation instructions provided with the indoor coil or air handler Liquid and Suction Lines Refrigerant grade copper tubing should be used when installing the system Refrigerant suction line tubing should be fully insulated Field Connections for Electrical Power Supply All wiring must comply with current revisions of the National Electrical Code ANSI NFPA 70 andwith applicable local codes having jurisdiction The minimum size of electrical conductors and circuit protection must be in compliance with information listed on the outdoor unit data label 2 SAFETY CONSIDERATIONS Pressures within the System Split system air conditioning equipment contains liquid and gaseous refrigerant under pressu
8. F The continuous indoor blower operation is typically used to circulate the indoor air to equalize a temperature unbalance due to a sun load cooking or fireplace operation To Maintain Your Air Conditioner CAUTION Be certain the electrical power to the outdoor unit and the furnace air handler is disconnected beforedoing the following recommended maintenance 1 Regularly a Clean or replace the indoor air filter at the start of each heating and cooling season and when an accumulation of dust and dirt is visible on the air filter b Remove any leaves and grass clippings from the coil in the outdoor unit being careful not to damage the aluminum fins c Check for any obstruction such as twigs sticks etc N Before Each Cooling Season If the furnace air handler blower motor and the outdoor unit fan motor s have oil tubes at the motor bearings apply 10 drops of SAE No 20 motor oil to each oil tube CAUTION Do not over oil or oil motors not factory equipped with oil tubes The compressor is hermetically sealed and does not require lubrication 3 Before Calling a Service Technician Be Certain a The unit thermostat is properly set see To Operate Your Air Conditioner for Cooling and To Operate Your Furnace for Heating b The unit disconnect fuses are in good condition and the electrical power to the unit is turned on 1 GENERAL INFORM
9. Outdoor Air Conditioner User s Information Installation Instructions 2 Stage R 410A Split System These units have been designed and tested for capacity and efficiency in accordance with Standards Split System Air Conditioning units are designed for use with a wide variety of fossil fuel furnaces electric furnaces air han dlers and evaporator coil combinations These instructions are primarily intended to assist qualified individuals experienced in the proper installation of heating and or air conditioning appliances Some local codes require licensed installation service personnel for this type of equipment Read all instructions carefully before starting the installation USER S INFORMATION IMPORTANT Read this owner information to become familiar with the capabilities and use of your appliance Keep this with literature on other appliances where you have easy access to it in the future If a problem occurs check the instructions and follow recommendations given If these suggestions don t eliminate your problem call your servicing contractor NOTE For this type of equipment to function as intended for maximum efficiency and adequate capacity a two stage cooling thermostat is required See unit wiring diagram OPERATINGINSTRUCTIONS To Operate Your Air Conditioner for Cooling 1 Set the thermostat system switch to COOL or AUTO and the thermostat fan switch to AUTO See Figure 1
10. Power Wiring page 4 for R and C wiring Verify Y terminal is connected to 24VAC at contactor coil Verify voltage at contactor coil falls below 0 5VAC 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 Check that compressor run and start 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 Check that compressor run and start wires are routed Start Circuit displayed for Code 7 through the correct module sensing holes Open Run Circuit or vice versa ALERT Flash Code 8 Welded Contactor displayed incorrectly 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 reverse wired Verify voltage at contactor coil falls below 0 5VAC when off Table 2 Module Wiring Troubleshooting Cooling Gradually lower the thermostat temperature setpoint below the actual room temperature and observe that the outdoor unit and indoor blower energize Feel the air being circulated by the indoor blower and verify that itis cooler than ambient temperature Listen for any unusual noises If present locate and determine the source of the noise and correc
11. cal box of the outdoor unit The installer should become familiar with the wiring diagram schematic before making any electri cal connections to the outdoor unit Outdoor Unit Connections The outdoor unit requires both power and control circuit electrical connections Refer to the unit wiring diagram schematic for identification and loca tion of outdoor unit field wiring interfaces Control Circuit Wiring The outdoor unit is designed to operate from a 24 VAC Class Il control circuit Control circuit wiring must com ply with the current provisions of the National Electrical Code ANSI NFPA 70 and with appli cable local codes having jurisdiction Thermostat Connections Thermostat con nections should be made in accordance with the instructions supplied with the thermostat and with the instructions supplied with the indoor equipment Electrical Power Wiring Electrical power wiring shall comply with the current provi sions of the National Electrical Code ANSI NFPA 70 and with applicable local codes having jurisdiction Use of rain tight conduit is recommended Electrical conductors shall have minimum circuit ampacity in compli ance with the outdoor unit rating label The facility shall employ electrical circuit protec tion at a current rating no greater than that indicated on the outdoor unit rating label Disconnect Switch An electrically compat ible disconnect switch must be within line of sight of th
12. cutively pause and then repeat the process To identify a Flash Code number count the number of consecutive flashes Every time the module powers up the last ALERT Flash Code that occurred prior to shut down is displayed for one minute The module will continue to display the LED until the condition returns to normal or if24 VAC power is removed from the module Adjustment of Refrigerant Charge CAUTION Split system air conditioner equipment contains liquid and gaseous refrigerant under pressure Adjustment of refrigerant charge should only be attempted by qualified trained personnel thoroughly familiar with the equipment Under no circumstances should the homeowner attemptto install and or service this equipment Failure to comply with this warning could result in equipment damage personal injury or death NOTE The unit must be charged with both first and second stages in operation NOTE To achieve rated capacity and effi ciency the compressor must be exposed to refrigerant for at least 24 hours prior to running and then mustbe run for a minimum of 12 hours NOTE The following Refrigerant Charging Charts are applicable to matched assemblies of our equipment and at listed airflows for the indoor coil Assemblies of indoor coils and outdoor units not listed are not recommended System Charge Tonnage R 410A oz 3 Ton 4 Ton 232 248 Table 3 Split System Air Conditioner Charge 264 and devia
13. dequately se cured to the cantilever mount and levelled prior to operation of the equipment Roof Mount The method of mounting should be designed so as not to overload roof struc tures nor transmit noise to the interior of the structure Refrigerant and electrical line should be routed through suitably waterproofed open ings to prevent water leaking into the structure 5 INSTALLING THE INDOOR UNIT The indoor section should be installed before proceeding with routing of refrigerant piping Consult the installation instructions of the indoor unit i e air handler furnace etc for details regarding installation 6 CONNECTING REFRIGERANT TUBING BETWEEN THE INDOOR AND OUTDOOR UNIT CAUTION This system utilizes R 410A refrigerant with POE oil When servicing cover or seal openings to minimize the exposure ofthe refrigerant system to air to prevent accumulation of moisture and other contaminants General Once outdoor and indoor unit place ment has been determined route refrigerant tubing between the equipment in accordance with sound installation practices Refrigerant tubing should be routed in a manner that mini mizes 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 and installation of a liquid line filter drier
14. e outdoor unit This switch shall be capable of electrically de energizing the outdoor unit Optional Equipment Optional equipment requiring connection to the power or control circuits must be wired in strict accordance with current provisions of the National Electrical Code ANSI NFPA 70 with applicable local codes having jurisdiction and the installation instruc tions provided with the equipment Optional Equip ment e g low ambient control hard start kits etc should be installed in strict accordance with the manufacturer s installation instructions 8 STARTUP AND CHECKOUT A WARNING Ensure electrical power to the unit is off prior to performing the following steps Failure to do so may cause personal injury or death Air Filters Ensure air filters are clean and in place prior to operating the equipment Thermostat Set the room thermostat func tion switch to OFF fan switch to AUTO and move temperature setpoint to its highest set ting Prior to applying electrical power to the outdoor unit ensure that the unit has been properly and securely grounded and that power supply connections have been made at both the facility power interface and outdoor unit Outdoor Unit Ensure the outdoor coil and top of the unit are free from obstructions and debris and all equipment access control pan els are in place Using extreme caution apply power to the unit and inspect the wiring for evidence o
15. f open shorted and or improperly wired circuits Functional Checkout CAUTION These units have a crankcase heater factory installed Wait 24 hours prior to performing a function checkout to allow for heating of the compressor crankcase Failure to comply may result in damage and could cause premature failure of the system Indoor Blower Set the thermostat function switch to COOLING and the fan switch to ON Verify that the indoor blower is operating and that airflow is not restricted Set the fan switch back to AUTO 2 Speed Outdoor Fan Motor Select Models If 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 Low Pressure Switch A low pressure switch is factory installed and located in the suction line internal to the outdoor unit The switch is designed to protect the compressor from aloss of charge Under normal conditions the switch is closed If the suction pressure falls below 5 psig then the switch will open and de energize the outdoor unit The switch will close again once the suction pressure increases above 20 psig Please note that the switch interrupts the thermostat inputs to the unit Thus when the switch opens and then closes there will be a 5 minute short cycling delay bef
16. fications and illustrations subject to change without notice and incurring obligations 7083500 Printed in U S A 03 04
17. nit will energize Short Cycle Protection With the system operating in COOLING mode note the setpoint temperature setting of the thermostat and gradu ally raise the setpoint temperature until the outdoor unit and indoor blower de energize 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 Verify that after approximately 5 minutes the outdoor unit energizes and that the temperature of the air supplied to the facility is cooler than ambient temperature Comfort Alert Diagnostics The Comfort Alert diagnostics module facilitates troubleshooting heat pump and air conditioning system failures This Comfort Alert module is designed only for single phase systems with scroll compressors that have internal overload protection By monitoring and analyzing data from the compressor and the thermostat demand the module can detect the cause of electrical and system related failures without any sensors A flashing LED indicator communicates the ALERT code and guides the service technician more quickly and accurately to the root cause of a problem NOTE This module does not provide safety protection The Comfort Alert module is a monitoring device and cannot control or shut down other devices LED Description See Figure 1 POWER LED Green indicates voltage is present at the power connection
18. of the module ALERT LED Yellow communicates an abnormal system condition through a unique flash code The ALERT LED will flash anumber of times consecutively pause and then repeat the process The number of consecutive flashes defined as the Flash Code correlates to a particular abnormal condition Detailed descriptions of specific ALERT Flash Codes are shown in Table 1 of this manual TRIP LED Red indicates there is a demand signal from the thermostat but no current to the compressor is detected by the module The TRIP LED typically indicates the compressor protector is open or may indicate missing supply power to the compressor The scroll compressor s run R common C and start S wires are routed through the holes in the Comfort Alert module marked R and S 24 VAC Power Wiring The Comfort Alert module requires a constant nominal 24 VAC power supply The wiring to the module s R and C terminals must be directly from the indoor unit or thermostat The Comfort Alert module requires a thermostat demand signal to operate properly NOTE After the thermostat demand signal is connected verify that 24 VAC across Y and C when demand is present Figure 2 Comfort Alert Diagnostics Module Status LED Status LED Description Status LED Troubleshooting Information Green POWER Module has power Supply voltage is present at module terminals Red TRIP
19. ore the outdoor unit will energize Discharge Temperature Limit A discharge temperature limitis factory installed and located on the compressor discharge line internal to the outdoor unit within 5 inches of the compressor discharge The limit is designed to protect the compressor from abnormal temperatures that may occur if there is a loss of charge Under normal conditions the switch is closed If the discharge temperature rises above 270 F then the switch will open and de energize the outdoor unit The switch will close again once the temperature decreases below 190 F Please note that the switch interrupts the thermostat inputs to the unit Thus when the switch opens and then closes there will be a 5 minute short cycling delay before the outdoor unit will energize High Pressure Switch A high pressure switch is factory installed and located in the compressor discharge line internal to the outdoor unit The switch is designed to de energize the system when very high pressures occur during abnormal conditions Under normal conditions the switch is closed If the discharge pressure rises above 575 psig then the switch will open and de energize the outdoor unit The switch will close again once the discharge pressure decreases to 460 psig Please note that the switch interrupts the thermostat inputs to the unit Thus when the switch opens and then closes there will be a 5 minute short cycling delay before the outdoor u
20. re Installa tion and servicing of this equipment should be performed by qualified trained personnel thor oughly familiar with this type of equipment Under no circumstances should the Home owner attempt to install and or service the equipment Labels Tags Precautions When working with this equipment follow all precautions in the literature on tags and on labels provided with the equipment Read and thoroughly under stand the instructions provided with the equip ment prior to performing the installation and operational checkout of the equipment Brazing Operations Installation of equip ment may require brazing operations Safety codes must be complied with Safety equip ment e g safety glasses work gloves fire extinguisher etc must be used when per forming brazing operations A WARNING Ensure all electrical power to the unitis off prior to installing or servicing the equipment Failure to do so may cause personal injury or death 3 SITE PREPARATION Unpacking Equipment Remove the card board carton and User s Manual from the equip ment Take care not to damage the tubing connections when removing the carton Inspect for Damage Inspect the equipment for damage prior to installing the equipment at the job site Ensure coil fins are straight and if necessary comb fins to remove flattened and bent fins Preferred Location of the Outdoor Unit at the Job Site Conduct a survey
21. s between supply and the compressor terminal 2 Compressor run winding is damaged e Check compressor motor winding resistance Welded Contactor 1 Compressor contactor has failed closed Compressor always runs 2 Thermostat demand signal not connected to module 1 Control circuit transformer is overloaded 2 Low line voltage contact utility if voltage at disconnect is low e Check wiring connections e Flash Code number corresponds to a number of LED flashes followed by a pause and then repeated e TRIP and ALERT LEDs flashing at same time means control circuit voltage is too low for operation Table 1 Interpreting the Diagnostic LEDS Miswired Module Indication Recommended Troubleshooting Action Green LED is not on module does not power up Determine if both R and C module terminals are connected Verify voltage is present at module s R and C terminals Review 24VAC Power Wiring page 4 for R and C wiring Green LED intermittent module powers up only when compressor runs TRIP LED is on but system and compressor check OK when off TRIP LED and ALERT LED flashing together ALERT Flash Code 3 Compressor Short Cycling displayed incorrectly off ALERT Flash Code 5 6 or 7 Open Circuit Open Start Circuit or Open Run Circuit displayed incorrectly ALERT Flash Code 6 Open Determine if R and Y terminals are wired in reverse Verify module s R and C terminals have a constant source Review 24VAC
22. t as necessary Heating If provided with heating equipment lower the thermostat setpoint temperature to the lowest obtainable setting and set the ther mostat function switch to HEATING The indoor blower and outdoor unit should stop running Increase the setpoint temperature of the ther mostat to the maximum setting Verify that the heating equipment has been energized i e fossil fuel burner operating etc and that the indoor blower energizes after a short period of time Feel the air being circulated by the indoor blower and verify that it is warmer than ambient temperature Listen for any unusual noises If present locate and determine the source of the noise and correct as necessary NOTE Other sources for heating i e 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 instruc tions for this equipment and perform a functional checkout in accordance with the manufacturer s instructions Optional Equipment A functional check out should be performed in accordance with the checkout procedures supplied with the equipment TROUBLESHOOTING Interpreting The Diagnostic LEDs When an abnormal system condition occurs the Comfort Alert module displays the appropriate ALERT and or TRIP LED will flash a number of times conse
23. tions from rated airflows or non listed equipment combinations may require modifica tions to the expansion device s and refrigerant charging procedures for proper and efficient system operation Procedure for Charging an R 410A unit at outdoor temperatures above 65F 1 With the system operating at steady state measure the liquid refrigerant pressure in psig at the service valve 2 Measure the liquid refrigerant temperature in Fahrenheit at the service valve 3 For the temperature measured determine the required liquid refrigerant pressure from the appropriate charging chart below 4 If the pressure measured in step 1 is greater than the required liquid refrigerant pressure determined in step 4 then there is too much charge in the system Remove refrigerant and repeat steps 1 through 3 until the system is correctly charged 5 If the pressure measured in step 1 is less than the required liquid refrigerant pressure determined in step 4 then there is too little charge in the system Add refrigerant and repeat steps 1 through 3 until the system is correctly charged Refrigerant Charging Charts 500 475 Remove refrigerent when above curve Liquid Pressure psig Se oO D D N 5 300 275 Add refrigerent when below curve 250 70 75 80 85 90 95 100 105 110 115 120 125 Liquid Temperature F Figure 3 Charging Chart for 2 ton R 410A AC unit with TXV
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