INSTALLER`S GUIDE
Contents
1. I D Coil Frosting Compressor Runs Inadequate or No Cooling Htg ELECTRICAL Compressor amp O D Fan Won t Start Compressor Will Not Start But O D Fan Runs O D Fan Won t Start Compressor Hums But Won t Start Compressor Cycles on IOL 1 D Blower Won t Start clolr o x o x o x o x o DEFROST Unit Won t Initiate Defrost Defrost Terminates on Time Unit Icing Up 9 o zlo zlo C Cooling H Heating Primary Causes S Secondary Causes 3 Phase Only Technical Literature Printed in U S A American Standard Inc Troup Highway Tyler TX 75707 9010 PAGE 8 Pub No 11 BC10D1 3 P I 02 052. ercised when opening the Liquid Line Service Valve Turn valve stem counterclockwise only until the stem contacts the rolled edge See Figure 3 No torque is required BRASS GAS LINE SERVICE VALVE The Brass Gas Line Service Valve is shipped in the closed position to hold the factory refrigerant charge The pressure tap service port when depressed opens only to the field brazing side when the valve is in the closed position The Gas Line Service Valve is full open with a 1 4 turn See Figure 4 BRAZING REFRIGERANT LINES 1 Remove lower access cover to access service valves 2 Before brazing remove plugs from external copper stub tubes Clean internal and external surfaces of stub tubes prior to brazing 3 Cut and fit tubing minimizing the use of sharp 90 bends 4 Insulate the entire gas line and its fittings 5 Do NOT allow uninsulated liquid line to come in direct contact with bare gas line LIQUID LINE SERVICE VALVE ROLLED EDGE TO CAPTIVATE STEM HEX HEADED VALVE SYSTEM CAP gt UNIT SIDE OF SERVICE VALVE si SERVICE gt Sy PORT LIQUID LINE CONNECTION Pub No 11 BC10D1 3 GAS LINE SERVICE VALVE 1 4 TURN ONLY COUNTERCLOCKWISE FOR FULL OPEN POSITION CAP UNIT SIDE OF VALVE PRESSURE TAP PORT GAS LINE CONNECTION gt gt gt gt gt HEATING COOLING e eee e e 6 Precautions should b
3. Fully insert hex wrench into the stem and back out counterclockwise until valve stem just touches rolled edge approximately five 5 turns observing WARNING state ment on page 3 See Figure 3 10 Replace liquid service pressure tap port cap and valve stem cap These caps MUST BE REPLACED to prevent leaks Replace valve stem and pressure tap cap finger tight then tighten an additional 1 6 turn 11 The gas valve can now be opened Open the gas valve by removing the shut off valve cap and turning the valve stem 1 4 turn counterclockwise using 1 4 Open End or Adjustable wrench See Figure 4 12 The gas valve is now open for refrigerant flow Replace valve stem cap to prevent leaks Again these caps MUST BE RE PLACED to prevent leaks Replace valve stem and pressure tap cap finger tight then tighten an additional 1 6 turn See Figure 4 If refrigerant lines are longer than 15 feet and or a different size than recommended it will be necessary to adjust system refriger ant charge upon completion of installation See unit Service Facts PAGE 3 INSTALLER S GUIDE E ELECTRICAL CONNECTIONS A WA R N N G When installing or servicing this equipment ALWAYS exercise basic safety precau tions to avoid the possibility of electric shock 1 Power wiring and grounding of equipment must comply with local codes 2 Power supply must agree with equipment nameplate 3 Install a separate disconnect switch at the outdoor unit 4
4. Ground the outdoor unit per local code requirements 5 Provide flexible electrical conduit whenever vibration trans mission may create a noise problem within the structure 6 The use of color coded low voltage wire is recommended to simplify connections between the outdoor unit the thermostat and the indoor unit Table 1 NEC Class II Wiring 24 VOLTS WIRE SIZE MAX WIRE LENGTH 18 AWG 150 FT 16 AWG 225 FT 14 AWG 300 FT 7 Table 1 defines maximum total length of low voltage wiring from outdoor unit to indoor unit and to thermostat 8 Mount the indoor thermostat in accordance with instruction included with the thermostat Wire per appropriate hookup diagram included in these instructions F DEFROST CONTROL The demand defrost control measures heat pump outdoor ambi ent temperature with a sensor located outside the outdoor coil A second sensor located on the outdoor coil is used to measure the coil temperature The difference between the ambient and the colder coil temperature is the difference or delta T measurement This delta T measurement is representative of the operating state and relative capacity ofthe heat pump system By measur ing the change in delta T we can determine the need for defrost The coil sensor also serves to sense outdoor coil temperature for termination of the defrost cycle FAULT IDENTIFICATION A fault condition is indicated by the flashing light on the defrost control inside th
5. Use and Care Manual TYPICAL FIELD WIRING DIAGRAMS VARIABLE SPEED T STAT AIR HAN DLER 2 STAGE HEAT PUMP YI YLo YIY2 PRINTED FROM BI52905P05 Notes Be sure power supply agrees with equipment nameplate Power wiring and grounding of equipment must comply with local codes Low voltage wiring to be No 18 AWG minimum conductor ODT B must be set lower than ODT A If outdoor ODT B is not used connect a jumper wire from W3 to W2 If ODT A is not used connect a jumper wire from W2 to W1 If electric heater does not have a 3rd contactor CH connect a jumper wire from LEGEND FACTORY WIRING W3 to W2 If electric heater does not have a 2nd contactor BH connect a jumper wire from W2 to W1 FIELD WIRING X2 must be connected to variable speed air handler terminal W3 as shown for proper indoor air flow during the defrost cycle Pub No 11 BC10D1 3 PAGE 5 INSTALLER S GUIDE 2A6H8 OUTLINE DRAWING NOTE ALL DIMENSIONS ARE IN MM INCHES SERVICE PANEL ELECTRICAL AND REFRIGERAN COMPONENT CLEARANCES PER PREVAILING CODES TOP DISCHARGE AREA SHOULD BE UNRESTRICTED FOR AT LEAST 1524 5 FEET ABOVE UNIT UNIT SHOULD BE PLACED SO ROOF RUN OFF WATER DOES NOT POUR DIRECTLY ON UNIT AND SHOULD BE AT LEAST 305 12 FR
6. unit under the eaves or other overhead structures as sizeable icicles may form and the unit may be damaged by these falling icicles B LOCATION AND PREPARATION OF THE UNIT 1 When removing unit from the pallet notice the tabs on the basepan Remove tabs by cutting with a sharp tool as shown on page 2 Figure 2 and slide unit off of pallet i ru i INN TL 2 The unit should be set on a level support pad at least as large as the unit base pan such as a concrete slab 3 The support pad must NOT be in direct contact with any structure Unit must be positioned a minimum of 12 from any wallorsurrounding shrubbery to insure adequate airflow Clear ance must be provided in front of control box access panels amp any other side requiring service access to meet National Electri cal Code Also the unit location must be far enough away from any structure to prevent excess roof runoff water from pouring directly on the unit Do not locate unit s close to bedroom s 4 The top discharge area must be unrestricted for at least five 5 feet above the unit Since the manufacturer has a policy of continuous product and product data improvement it reserves the right to change design and specifications without notice INSTALLER S GUIDE BASEPAN TAB REMOVAL 5 When the outdoor unit is mounted on a roof be sure the roof will support the unit s weight Pr
7. American Standard 11 BC10D1 3 INSTALLER S GUIDE ALL phases of this installation must comply with NATIONAL STATE AND LOCAL CODES Heat Pumps 2A6H8030 36 48 60B Models IMPORTANT This Document is customer property and is to remain with this unit Please return to service information pack upon completion of work These instructions do not cover all variations in systems nor provide for every possible contingency to be met in connection with installation All phases of this installa tion must comply with NATIONAL STATE AND LOCAL CODES Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter should be referred to your installing dealer or local distributor A GENERAL The following instructions cover 2A6H8 Heat Pump Units NOTE These outdoor units must be used with indoor units equipped with Thermostatic Expansion Valve only Check for transportation damage after unit is uncrated Report promptly to the carrier any damage found to the unit To determine the electrical power requirements of the unit refer to the nameplate of the unit The electrical power available must agree with that listed on the nameplate The Heat Pump has been designed and manufactured to with stand and operate in severe winter conditions However there are precautionary steps which should be taken at the time of installation which will help
8. N SO COMPRESSOR WILL NOT RUN and apply power by closing the system main disconnect switch This will activate the compressor sump heat where used Do not change the Thermostat System Switch until power has been applied for one 1 hour Following this procedure will prevent potential compressor overload trip at the initial start up Pub No 11 BC10D1 3 H OPERATIONAL AND CHECKOUT PROCEDURES Final phases of this installation are the unit Operational and Checkout Procedures which are found in this instruction on page 8 To obtain proper performance all units must be operated and charge adjustments made in accordance with procedures found in the Service Facts I ELECTRIC HEATERS Electric heaters if used are to be installed in the air handling device according to the instructions accompanying the air han dler and the heaters J START CONTROL These models have quick start components which are factory installed INSTALLER S GUIDE K OUTDOOR THERMOSTAT An outdoor thermostat TAYSTAT250B may be field installed For data see wiring diagram attached to unit and instruction sheet packaged with outdoor thermostat L SEACOAST SALT SHIELD The 2A6H8 models are shipped with a black Seacoast Salt Shield clipped to the top of the outdoor coil Removal of the shield will potentially shorten the life of the joints in the outdoor coil and affect the Limited Warranty See note below IMPORTANT See limited warranty information in
9. OM WALL AND ALL SURROUNDING SHRUBBERY ON TWO SIDES OTHER TWO SIDES UNRESTRICTED a K ELECTRICAL SERVICE _ __ PANEL 22 2 7 8 DIA HOLE LOW VOLTAGE 28 6 1 1 8 DIA K 0 WITH 22 2 71 8 DIA HOLE IN CONTROL BOX BOTTOM FOR ELECTRICAL POWER SUPPLY I LIQUID LINE SERVICE VALVE 1 E 1 D FEMALE BRAZE CONNECTION WITH 1 4 SAE F i FLARE PRESSURE TAP FITTINGS i j FIG 1 Lie FOR ALTERNATE ELECTRICAL ROUTING GAS LINE 1 4 TURN BALL SERVICE VALVE D 1 D FEMALE BRAZED CONNECTION WITH 1 4 SAE FLARE PRESSURE TAP FITTING MODELS BASE FIG A B Cc D E F G H J K 2A6H8030B 4 1 1045 41 1 8 946 37 1 4 870 34 1 4 7 8 3 8 152 6 98 3 7 8 219 8 5 8 86 3 3 8 711 28 From Dwg D152862 Rev 17 PAGE 6 Pub No 11 BC10D1 3 INSTALLER S GUIDE MOUNTING HOLE LOCATION NOTE ALL DIMENSIONS ARE IN MM INCHES 12 20 m 158 6 24 DRILL 4 PLACES 2 48 213 8 39 Lo 23 58 T___ 121 28 64 BASE 4 NOTE For model base size see table on page 6 From Dwg 21D152989 Rev 1 Pub No 11 BC10D1 3 PAGE 7 INSTALLER S GUIDE CHECKOUT PROCEDURE After installation has been completed it is recommended that the entire system be checked against the following list 1 Refrigerant Line Leak checked sii iici
10. assure the efficient operation of the unit It is recommended that these precautions be taken for units being installed in areas where snow accumula tion and prolonged below freezing temperatures occur 1 Units should be elevated 3 to 12 inches above the pad or rooftop depending on local weather This additional height will allow better drainage of snow and ice melted during defrost cycle prior to its refreezing This should prevent a buildup ofice around the unit which occurs when unit is not elevated Insure that drain holes in unit base pan are not obstructed prevent ing draining of defrost water 2 Ifpossible avoid locations that are likely to accumulate snow drifts If not possible a snow drift barrier should be installed around the unit to prevent a buildup of snow on the sides of the unit and should be of sufficient distance from the unit to prevent restriction of airflow to and from the unit Also allow for proper maintenance space The barrier should be constructed of mate rials which will blend in with the building design 3 Avoid locating the unit where condensation and freezing of defrost vapor may annoy the customer For instance installing the unit under a bedroom kitchen or picture window may be annoying to the customer since condensate and fog will occur during the defrost cycle 2005 American Standard Inc All Rights Reserved O 5 FT ABOVE UNIT UNRESTRICTED E Iie INN mi I I 4 Avoid locating the
11. ccscvsciascevsavudalevscisSauesseegsamenceadienecsvcetsaesahessvad cecsubenchwbocenatucepeveenigeayas 2 Suction Lines and Fittings properly insulated araldica 3 Have all Refrigerant Lines been secured and isolated properly i 4 Have passages through masonry been sealed If mortar is used prevent mortar from Coming into direct contact with copper IUDING ici 5 Verity tightness of all electrical CONNEeCis s cnc aio 6 Observe outdoor fan during on cycle for clearance and smooth operation 7 Indoor coil drain line drains freely Pour water into drain pan 8 Supply registers and return grilles open and unobstructed cette ee eeee eee eeeee eee teeaeeeeeeeeeeeeeetaaeeteeea 9 Return airtilter install edi aaeaa iii a a stented 10 Thermostat thermometer is accurate Check against a reliable thermometer Adjust per instructions with THErMOStatiwssscecssiseesdancansseens stan eene EE EEEE EERE 11 ls correct speed tap being used Indoor blower Motor i 12 Operate complete system in each mode to insure safe operation ii TROUBLESHOOTING CHART WHAT TO CHECK REFRIGERANT CIRCUIT Head Pressure Too High Head Pressure Too Low Suction Pressure Too High Suction Pressure Too Low Liquid Refrig Floodback TXV Liquid Refrig Floodback Cap Tube
12. e heat pump control box In normal operation the defrost control light will flash once each second If the light is flashing more than once per second or not at all refer to the service manual for that unit PAGE 4 D m o 4 m n 4 D m TO PIN IDENTIFICATION See Figure 5 1 NORM This wire as shipped is unattached to any pin In this position the defrost control is in normal operation However after checking for proper operation the wire should be returned to the normal pin 2 TST Test Red wire in this position speeds up all defrost board timings 3 FRC DFT Forced Defrost Touch the red test wire to this pin for ten 10 seconds to initiate a forced defrost Return the wire to the normal pin after defrost initiates 4 FRCFLT Forced Fault Touch the red test wire to this pin for ten 10 seconds to demonstrate a fault condition DEFROST CONTROL CHECKOUT Normal operation requires a LED on board flashing 1 time second b 24V AC between R amp B c 24V AC between Y amp B with unit operating d Defrost initiation when test wire is moved to Forced Defrost pin then return to Normal Pin Ifa defrost problem is suspected refer to the service information in the control box A WARNING Do NOT connect 24 VAC to T1 ODS A terminal ODS A thermistor WILL BE BLOWN G COMPRESSOR START UP After all electrical wiring is complete SET THE THERMOSTAT SYSTEM SWITCH IN THE OFF POSITIO
13. e limitations NOTE Large diameter tubing will be very difficult to rebend once it has been shaped 3 Determine the best starting point for routing the refrigerant tubing INSIDE OR OUTSIDE THE STRUCTURE 4 Provide a pull thru hole of sufficient size to allow both liquid and gas lines 5 Be sure the tubing is of sufficient length 6 Uncoil the tubing do not kink or dent 7 Route the tubing making all required bends and properly secure the tubing before making connections PAGE 2 8 To prevent a noise within the building structure due to vibration transmission from the refrigerant lines the following precautions should be taken a When the refrigerant lines have to be fastened to floor joists or other framing in a structure use isolation type hangers b Isolation hangers should also be used when refrigerant lines are run in stud spaces or enclosed ceilings c Where the refrigerant lines run through a wall or sill they should be insulated and isolated d Isolate the lines from all ductwork D SERVICE VALVE OPERATION BRASS LIQUID LINE SERVICE VALVE The Brass Liquid Line Service Valve is factory shipped in the seated position to hold factory charge The pressure tap service port when depressed opens only to the field brazing side of the valve when the valve is in the seated position The liquid line valve is not a back seating valve see WARNING below A WA R N N G Extreme caution should be ex
14. e taken to avoid heat damage to the pressure tap valve core during brazing It is recom mended that the pressure tap port valve core be removed and a wet rag wrapped around the valve body NOTE Use care to make sure that no moisture enters pressure tap port while wet rag is being used NOTE Precautions should be taken to avoid heat damage to basepan during brazing It is recommended to keep the flame directly off of the basepan 7 Use a Dry Nitrogen Purge and Brazing Alloy without flux when brazing the field line to the copper factory connection Flow dry nitrogen into either valve pressure tap port thru the tubing and out the other port while brazing 8 Braze using accepted good brazing techniques LEAK CHECK IMPORTANT Replace pressure tap port valve core before attaching hoses for evacuation After the brazing operation of refrigerant lines to both the outdoor and indoor unit is completed the field brazed connec tions must be checked for leaks Pressurize through the service valve ports the indoor unit and field refrigerant lines with dry nitrogen to 300 psi Use soap bubbles or other leak checking methods to see that all field joints are leak free If not release pressure then repair Pub No 11 BC10D1 3 INSTALLER S GUIDE SYSTEM EVACUATION NOTE Since the outdoor unit has a refrigerant charge the gas and liquid line valves must remain closed 1 Upon completion of leak check evacuate the refrigerant line
15. operly selected isolation is recommended to prevent transmission to the building structure 6 The maximum length of refrigerant lines from outdoor to indoor unit should NOT exceed eighty 80 feet 7 If outdoor unit is mounted above the air handler maximum lift should not exceed twenty five 25 feet suction line If air handler is mounted above condensing unit maximum lift should not exceed twenty five 25 feet liquid line 8 Locate and install indoor coil or air handler in accordance with instruction included with that unit C INSTALLING REFRIGERANT LINES A CAUTION a If using existing refrigerant lines make certain that all joints are brazed not soldered Condensing units have provisions for braze connections Pressure taps are provided on the service valves of outdoor unit for compressor suction and liquid pressures The indoor end of the recommended refrigerant line sets may be straight or with a 90 degree bend depending upon situation requirements This should be thoroughly checked out before ordering refrigerant line sets The gas line must always be insulated The units are factory charged with the system charge required when using fifteen 15 feet of connecting line Unit nameplate charge is the same Final refrigerant charge adjustment is necessary Use the Charging Charts in the outdoor unit Service Facts 1 Determine the most practical way to run the lines 2 Consider types of bends to be made and spac
16. s and indoor coil before opening the gas and liquid line valves 2 Attach appropriate hoses from manifold gauge to gas and liquid line pressure taps NOTE Unnecessary switching of hoses can be avoided and complete evacuation of all lines leading to sealed system can be accomplished with manifold center hose and connecting branch hose to a cylinder of R 22 and vacuum pump 3 Attach center hose of manifold gauges to vacuum pump 4 Evacuate until the micron gauge reads no higher than 350 microns 5 Close off valve to vacuum pump and observe the micron gauge If gauge pressure rises above 500 microns in one 1 minute then evacuation is incomplete or system has a leak 6 If vacuum gauge does not rise above 500 microns in one 1 minute the evacuation should be complete 7 With vacuum pump and micron gauge blanked off open valve on R 22 cylinder and charge refrigerant lines and indoor coil with vapor to tank pressure of R 22 supply NOTE DO NOT VENT REFRIGERANT INTO THE ATMOSPHERE 8 Close valve on R 22 supply cylinder Close valves on manifold gauge set and remove refrigerant charging hoses from liquid and gas pressure tap ports NOTE A 3 16 Allen wrench is required to open liquid line service valve A 1 4 Open End or Adjustable wrench is required to open gas line valve A 3 4 Open End wrench is required to take off the valve stem cap 9 The liquid line shut off valve can now be opened Remove shut off valve cap
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