Goodman Mfg CONDENSING AC UNIT SINGLE / THREE PHASE AIR CONDITIONERS User's Manual
Contents
1. Use field supplied spreader bars when lifting the unit to mini mize the possibility of lifting cable straps damage To protect the cabinet louvers use protective material such as plywood behind the cable straps Arrange the straps to form a central suspension point NOTE When raising and setting the unit observe all safety rules Remove shipping skid and all protec tion and lifting material after the unit is in place Safe Refrigerant Handling While these items will not cover every conceivable situation they should serve as a useful guide AA WARNING Refrigerants are heavier than air They can push out the oxygen in your lungs or in any enclosed space To avoid possible difficulty in breathing or death e Never purge refrigerant into an enclosed room or space By law all refrigerants must be reclaimed If an indoor leak is suspected throughly ventilate the area before beginning work e Liquid refrigerant can be very cold To avoid possible frostbite or blindness avoid contact and wear gloves and goggles If liquid refrigerant does contact your skin or eyes seek medical help immediately Always follow EPA regulations Never burn refrig erant as poisonous gas will be produced A WARN2. Mounting the condensing unit above the evaporator coil will require an oil trap In the suction line Install one oil trap at the evaporator for a height difference of more than 15 feet between indoor and imi outdoor units Of 2 S amp B Insulation is necessary to prevent condensation from forming and dropping from the suction line Armflex or satisfactory equivalent with 3 8 min wall thickness is recommended In severe conditions hot high humidity areas 1 2 insulation may be required Insulation must be installed in a manner which protects tubing from damage and contamination Where possible drain as much residual compressor oil from existing systems lines and traps pay close attention to low areas where oil may collect NOTE If changing refrigerant types ensure the indoor coil and metering device is compat ible with the type of refrigerant being used otherwise the in door coil must be replaced To facilitate oil return to the com pressor a horizontal suction line should be pitched 1 2 per 10 toward the condensing unit Filter Drier and Sight Glass A liquid line filter drier is factory installed Field
3. 85 5 Power Failure Test Voltage Blown Fuse ele Impact Fuse Size amp Type Loose Connection e Inspect Connection Tighten Shorted or Broken Wires 6 6 6 o Test Circuits with Ohmmeter Open Overload e o Test Continuity of Overloads Faulty Thermostat ele Test Continuity of Thermostat and Wiring Faulty Transformer Check Control Circuit with Voltmeter Shorted or Open Capacitor 6 Test Capacitor Internal Compressor Overload Open Test Continuity of Overload Shorted or Grounded Compressor Test Motor Windings Compressor Stuck Use Test Cord Faulty Compressor Contactor e 6 6 Test Continuity of Coil and Contacts Faulty Fan Relay Test Continuity of Coil and Contacts Open Control Circuit Test Control Circuit with Voltmeter Low Voltage e ele Test Voltage Faulty Evaporator Fan Motor Repair or Replace Shorted or Grounded Fan Motor o e Test Motor Windings Improper Cooling Anticipator Check Resistance of Anticipator Shortage or Refrigerant e o ele Test For Leaks Add Refrigerant Restricted Liquid Line e o e o Replace Restricted Part Undersized Liquid Line Replace Line Undersized Suction Line Replace Line Not Enough Air across Indoor Coil ele Speed Blower Check Duct Static Pressure Too Much Air across Indoor Coil Reduce Blower Speed Overcharge of Refrigerant ele e e Recover Part of
4. d If subcooling is high and superheat is low adjust TXV valve to 8 1 F superheat and remove charge to lower the subcooling to 7 2 F NOTE Do NOT adjust the charge based on suction pres sure unless there is a gross undercharge 4 Disconnect manifold set installation is complete Subcooling Formula Sat Liquid Temp Liquid Line Temp NOTE Check the Schrader ports for leaks and tighten valve cores if necessary Install caps finger tight Troubleshooting Information 3 System Complaint No Cooling ctory Operating Cooling P ressures 5 z 8 2 E 2 2 g 8 2 olojo o POSSIBLE CAUSE rl 59 D DOTS IN ANALYSIS K lgl 6 JEE Test Method GUIDE INDICATE 2 E 8 8 8 5 8 31215 g g Remedy 8l El o zle POSSIBLE CAUSE a g 2 O e e o 8 2 56565 8 vjz 2 2 5 4 9 g 2 53 25 2 5 als 5 58 l elg 5s 5555 2 2 6 3 2585 58285 88525238 8 Slo 68 98
5. ONLY individuals meeting at a minimum the requirements of an Entry Level Technician as specified by the Air Conditioning Heating and Refrigeration Institute AHRI may use this information Attempting to install or repair this unit without such background may result in product damage personal injury or death 2010 2012 Goodman Manufacturing Company L P 5151 San Felipe Suite 500 Houston TX 77056 www goodmanmfg com or www amana hac com P N 10 402G Date May 2012 CAUTION Scroll equipped units should never be used to evacuate the air conditioning system Vacuums this low can cause internal electrical arcing resulting in a damaged or failed compressor Important Note to the Owner Regarding Product Warranty Your warranty certificate is supplied as a separate document with the unit installed by your contractor Read the limited war ranty certificate carefully to determine what is and is not cov ered and keep the warranty certificate in a safe place If you are unable to locate the warranty certificate please contact your installing contractor or contact customer service 877 254 4729 to obtain a copy Shipping Inspection Always keep the unit upright laying the unit on its side or top may cause equipment damage Shipping damage and subse quent investigation is the responsibility of the carrier Verify the model number specifications electrical characteristics and accessories are correct prior to i
6. SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH OUTDOOR POWER SUPPLY ofo THERMOSTAT FAN SWITCH CONTACTOR 001 ON AUTO THERMOSTAT THERMOSTAT COOL ANTICIPATOR FAN RELAY COIL THERMOSTAT SYSTEM BULB SWITCH HEAT THERMOSTAT COIL ADJ HEAT oO O ANTICIPATOR 24V Ww z LOW VOLTAGE TRANSFORMER INDOOR POWER SUPPLY
7. amana hac com P N 10 404A Date May 2012 THIS UNIT IS SHIPPED WITH A NITROGEN HELIUM HOLDING CHARGE ONLY UNIT MUST BE EVACUATED AND CHARGED PER INSTALLATION INSTRUCTIONS WITH REFRIGERANT LISTED ON SERIAL RATING PLATE NOTICE I UNITS SHIPPED WITH A HOLDING CHARGE ARE INTENDED FOR COMPONENT REPLACEMENT ONLY ON EXISTING SYSTEMS AND NOT INTENDED FOR USE IN NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES NOTICE UNITS MUST ONLY BE USED AS REPLACEMENT COMPONENTS FOR PRE 2010 INSTALLED SYSTEMS Important Safety Instructions The following symbols and labels are used throughout this manual to indicate immediate or potential safety hazards Itis the owner s and installer s responsibility to read and comply with all safety information and instructions accompanying these symbols Failure to heed safety information increases the risk of personal injury property damage and or product damage AA WARNING lt b HIGH VOLTAGE Disconnect ALL power before servicing Multiple power sources may be present Failure to do so may cause property damage ersonal injury or death A WARNING ONLY individuals meeting the requirements of an Entry Level Technician at a minimum as specified by the Air Conditioning Heating and Refrigeration Institute AHRI may use this information Attempting to install or repair this unit without such background may result in product damage personal injury or death Sh
8. and ground wires through the high voltage port and terminate in accordance with the wiring diagram pro vided inside the control panel cover Low Voltage Connections Condensing unit control wiring requires 24 Volt minimum 25VA service from the indoor transformer Route control wires through the low voltage port and terminate in accordance with the wir ing diagram provided inside the control panel cover Thermostat fo a Single Stage Heating DEHUM with o Y B C G R wi TWIN Single Stage Coolin 0 me Cm we Cau FURNACE OR AIR HANDLER REMOTE Single Stage Thermostat with Two Low Voltage Wires to Remote System Start Up AA CAUTION POSSIBLE REFRIGERANT LEAK To avoid a possible refrigerant leak open the service valves until the top of the stem is 1 8 from the retainer When opening valves with retainers open each valve only until the top of the stem is 1 8 from the retainer To avoid loss of refrigerant DO NOT apply pressure to the retainer When open ing valves without a retainer remove service valve cap and in sert a hex wrench into the valve stem and back out the stem by turning the hex wrench counterclockwise Open the valve until it contacts the rolled lip of the valve body 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 the secondary seal for the valves and must be
9. be used with a purchased single stage room thermostat with 24 VAC control circuitry Do not operate the unit in a structure that is not complete either as part of new construction or renovation Such opera tion will void the warranty Installation Clearances This unit is designed for outdoor installations only Special consideration must be given to location of the condensing unit s in regard to structures obstructions other units and any all other factors that may interfere with air circulation Where possible the top of the unit should be completely unobstructed however if vertical conditions require placement beneath an obstruction there should be a minimum of 60 inches be tween the top of the unit and the obstruction s The speci fied dimensions meet requirements for air circulation only Consult all appropriate regulatory codes prior to determining final clearances Another important consideration in selecting a location for the unit s is the angle to obstructions Either side adjacent the valves can be placed toward the structure provided the side away from the structure maintains minimum service clearance Corner installations are strongly discouraged WLLL LLL LL 60 Me ee SS This unit c
10. finish charging the system to working pressure then apply the detector to suspect areas If leaks are found repair them After repair repeat the pressure test If no leaks exist proceed to system evacuation System Evacuation Condensing unit liquid and suction valves are closed to contain the charge within the unit The unit is shipped with the valve stems closed and caps installed AA WARNING REFRIGERANT UNDER PRESSURE Failure to follow proper procedures may cause property damage personal injury or death NOTICE THIS UNIT IS SHIPPED WITH A NITROGEN HELIUM HOLDING CHARGE ONLY UNIT MUST BE EVACUATED AND CHARGED PER INSTALLATION INSTRUCTIONS WITH REFRIGERANT LISTED ON SERIAL RATING PLATE NOTICE UNITS SHIPPED WITH A HOLDING CHARGE ARE INTENDED FOR COMPONENT REPLACEMENT ONLY ON EXISTING SYSTEMS AND NOT INTENDED FOR USE IN NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES NOTICE UNITS MUST ONLY BE USED AS REPLACEMENT COMPONENTS FOR PRE 2010 INSTALLED SYSTEMS NOTE Holding charge must be removed before brazing 1 Openservice valves before attaching vacuum pump 2 Connect the vacuum pump with 250 micron capability to the service valves 3 Evacuate the system to 250 microns or less using suc tion and liquid service valves Using both valves is nec essary aS some compressors create a mechanical seal separating the sides of the system 4 Close pump valve and hold vacuum for 10 minutes Typi
11. material to be placed or installed between tubing and foundation Any gap between foundation or wall and refrigerant lines should be filled with a pliable silicon based caulk RTV or a vibration damping material Avoid suspending refrigerant tubing from joists and studs with rigid wire or straps that would come in contact with the tubing Use an insulated or suspension type hanger Keep both lines separate and always insulate the suction line These sizes are recommended for line lengths of 79 feet or less For other line sizing option or runs of more than fifty feet refer to Remote Cooling Service Manual or TP 106 Long Line Set Application R 22 or contact your distributor for assistance RECOMMENDED INTERCONNECTING TUBING Ft Cond 0 24 2549 50 79 Unit Line Diameter In OD Mee isnt Pie se va a4 38 3 4 38 o fa fae ae foe fa 21 2 se va 34 38 79 38 aaa eae ep ae 312 vs 38 118 38 118 38 4 7 ae 118 38 118 32 5 s 38 s 38 tie 30 Lines greater than 79 feet in length or vertical elevation changes more than 50 feet refer to the Remote Cooling Service Manual or contact your distributor for assistance Liquid Line Ss Suction Line Mounting the evaporator coil above the condensing unit will require an inverted 1111111111 UAC loop in the suction line adjacent or near the connection to the evaporator The top of the lo
12. steady the system is considered leak free proceed to startup 5000 4500 4000 LEAK S PRESENT 3500 3000 2500 2000 VACUUM IN MICRONS CONDENSIBLES OR SMALL LEAK PRESENT 1500 1000 NO LEAKS NO CONDENSIBLES 500 MINUTES e f pressure rises above 1000 microns but holds steady below 2000 microns moisture and or noncondensibles may be present or the system may have a small leak Return to step 2 If the same result is encountered check for leaks as previously indicated and repair as necessary then repeat evacuation e lf pressure rises above 2000 microns a leak is present Check for leaks as previously indicated and repair as nec essary then repeat evacuation Electrical Connections AA WARNING HIGH VOLTAGE Disconnect ALL power before servicing N Multiple power sources may be present Failure to do so may cause property damage personal injury or death due to electric shock Wiring must conform with NEC or CEC and all local codes Undersized wires could cause ponr equipment performance equipment damage or fire AA WARNING To avoid the risk of fire or equipment damage use copper conductors NOTICE UNITS WITH RECIPROCATING COMPRESSORS AND NON BLEED TXV S REQUIRE A HARD START KIT The condensing unit rating plate lists pertinent electrical data necessary for proper electrical service and overcurrent protec tion Wires shou
13. CONDENSING AC UNIT SINGLE THREE PHASE AIR CONDITIONERS INSTALLATION amp SERVICE REFERENCE NOTICE THIS UNIT IS SHIPPED WITH A NITROGEN HELIUM HOLDING CHARGE ONLY UNIT MUST BE EVACUATED AND CHARGED PER INSTALLATION INSTRUCTIONS WITH REFRIGERANT LISTED ON SERIAL RATING PLATE NOTICE UNITS SHIPPED WITH A HOLDING CHARGE ARE INTENDED FOR COMPONENT REPLACEMENT ONLY ON EXISTING SYSTEMS AND NOT INTENDED FOR USE IN NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES EPA REGULATIONS PROHIBIT THE SALE OR DISTRIBUTION OF APPLIANCES PRE CHARGED WITH THE REFRIGERANT R 22 IF THOSE APPLIANCES ARE MANUFACTURED AFTER JANUARY 1 2010 COMPONENTS OF EXISTING R 22 SYSTEMS MAY BE REPAIRED AND OR REPLACED NOTICE UNITS MUST ONLY BE USED AS REPLACEMENT COMPONENTS FOR PRE 2010 INSTALLED SYSTEMS See unit rating plate for initial charge Important Safety Instructions The following symbols and labels are used throughout this manual to indicate immediate or potential safety hazards It is the owner s and installers responsibility to read and com ply with all safety information and instructions accompanying these symbols Failure to heed safety information increases the risk of personal injury property damage and or product damage A WARNING HIGH VOLTAGE Disconnect ALL power before servicing Multiple power sources may be present Failure to do so may cause property damage personal injury or death A WARNING
14. Charge Noncondensibles e _ Recover Charge Evacuate Recharge Recirculation of Condensing Air e Remove Obstruction to Air Flow Infiltration of Outdoor Air e 6 Check Windows Doors Vent Fans Etc Improperly Located Thermostat Relocate Thermostat Air Flow Unbalanced Readjust Air Volume Dampers System Undersized Refigure Cooling Load Broken Internal Parts Replace Compressor Broken Valves Test Compressor Efficiency Inefficient Compressor ele Test Compressor Efficiency High Pressure Control Open Reset and Test Control Unbalanced Power 3PH e o Test Voltage Wrong Type Expansion Valve ele 5 Replace Valve Expansion Valve Restricted e ele ele Replace Valve Oversized Expansion Valve Replace Valve Undersized Expansion Valve 4 ele Replace Valve Expansion Valve Bulb Loose e Tighten Bulb Bracket Inoperative Expansion Valve Check Valve Operation Loose Hold down Bolts Tighten Bolts For detailed service information refer to the Remote Condensing Unit Service manual NOTICE UNITS WITH ROTARY OR RECIPROCATING COMPRESSORS AND NON BLEED TXV S REQUIRE A HARD START KIT 10 THIS PAGE INTENTIONALLY LEFT BLANK SPLIT SYSTEMS AIR CONDITIONING AND HEAT PUMP HOMEOWNER S ROUTINE MAINTENANCE RECOMMENDATIONS We strongly recommend a bi annual maintenance checkup be performed before the heating and cooling seasons begin by a qualified servicer REPLACE OR CLEAN FIL
15. ING To avoid possible explosion Never apply flame or steam to a refrigerant cylinder If you must heat a cylinder for faster charging partially immerse it in warm water e Never fill a cylinder more than 80 full of liquid re frigerant Never add anything other than R 22 to an R 22 cy linder The service equipment used must be listed or certified for the type of refrigerant used Store cylinders in a cool dry place Never use a cy linder as a platform or a roller AA WARNING To avoid possible explosion use only returnable not disposable service cylinders when removing refrig erant from a system Ensure the cylinder is free of damage which could lead to a leak or explosion Ensure the hydrostatic test date does not exceed 5 years Ensure the pressure rating meets or exceeds 400 Ibs When in doubt do not use cylinder Refrigerant Lines NOTE For improved refrigerant management equip the evaporator coil with a field supplied thermal expansion valve TXV and the liquid line with a field supplied liquid line solenoid Ensure the solenoid is installed as close as possible to the evaporator coil to prevent refrigeration migration in the compressor OFF cycle Use only refrigerant grade dehydrated and sealed copper tub ing to connect the condensing unit with the indoor evaporator After cutting the tubing install plugs to keep refrigerant tubing c
16. OF EQUIPMENT DAMAGE OR FIRE INSTALL THE SAME AMPERAGE BREAKER OR FUSE AS YOU ARE REPLACING IF THE CIRCUIT BREAKER OR FUSE SHOULD OPEN AGAIN WITHIN THIRTY DAYS CONTACT A QUALIFIED SERVICER TO CORRECT THE PROBLEM IF YOU REPEATEDLY RESET THE BREAKER OR REPLACE THE FUSE WITHOUT HAVING THE PROBLEM CORRECTED YOU RUN THE RISK OF SEVERE EQUIPMENT DAMAGE Check the electrical panel for tripped circuit breakers or failed fuses Reset the circuit breakers or replace fuses as necessary Check the disconnect switch near the indoor furnace or blower to confirm that it is closed Check for obstructions on the outdoor unit Confirm that it has not been covered on the sides or the top Remove any obstruction that can be safely removed If the unit is covered with dirt or debris call a qualified servicer to clean it Check for blockage of the indoor air inlets and outlets Confirm that they are open and have not been blocked by objects rugs curtains or furniture Check the filter If it is dirty clean or replace it Listen for any unusual noise s other than normal oper ating noise that might be coming from the outdoor unit If you hear unusual noise s coming from the unit calla qualified servicer CONDENSING AC UNIT 52010 Goodman manutacturing Company L P 3 PHASE 7 5 amp 10 TON AIR CONDITIONER INSTALLATION amp SERVICE REFERENCE NOTICE 5151 San Felipe Suite 500 Houston TX 77056 www goodmanmfg com or www
17. T IS SHIPPED WITH A NITROGEN HELIUM HOLDING CHARGE ONLY UNIT MUST BE EVACUATED AND CHARGED PER INSTALLATION INSTRUCTIONS WITH REFRIGERANT LISTED ON SERIAL RATING PLATE NOTICE UNITS SHIPPED WITH A HOLDING CHARGE ARE INTENDED FOR COMPONENT REPLACEMENT ONLY ON EXISTING SYSTEMS AND NOT INTENDED FOR USE IN NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES EPA REGULATIONS PROHIBIT THE SALE OR DISTRIBUTION OF APPLIANCES PRE CHARGED WITH THE REFRIGERANT R 22 IF THOSE APPLIANCES ARE MANUFACTURED AFTER JANUARY 1 2010 COMPONENTS OF EXISTING R 22 SYSTEMS MAY BE REPAIRED AND OR REPLACED NOTICE UNITS MUST ONLY BE USED AS REPLACEMENT COMPONENTS FOR PRE 2010 INSTALLED SYSTEMS NOTE Holding charge must be removed before brazing AQ CAUTION Prolonged operation at suction pressures less than 20 psig for more than 5 seconds will result in overheating of the scrolls and permanent damage to the scroll tips drive bearings and internal seal 1 Open service valves before attaching vacuum pump 2 Connect the vacuum pump with 250 micron capability to the service valves 3 Evacuate the system to 250 microns or less using suc tion and liquid service valves Using both valves is nec essary aS some compressors create a mechanical seal separating the sides of the system 4 Close pump valve and hold vacuum for 10 minutes Typi cally pressure will rise during this period e Ifthe pressure rises to 1000 microns or less and remains
18. TER IMPORTANT NOTE Never operate unit without a filter installed as dust and lint will build up on internal parts resulting in loss of efficiency equipment damage and possible fire An indoor air filter must be used with your comfort system A properly maintained filter will keep the indoor coil of your com fort system clean A dirty coil could cause poor operation and or severe equipment damage Your air filter or filters could be located in your furnace ina blower unit or in filter grilles in your ceiling or walls The installer of your air conditioner or heat pump can tell you where your filter s are and how to clean or replace them Check your filter s at least once a month When they are dirty replace or clean as required Disposable type filters should be replaced Reusable type filters may be cleaned You may want to ask your dealer about high efficiency filters High efficiency filters are available in both electronic and non electronic types These filters can do a better job of catching small airborne particles COMPRESSOR The compressor motor is hermetically sealed and does not require additional oiling Motors Indoor and outdoor fan motors are permanently lubricated and do not require additional oiling CLEAN 7 108 Coit QUALIFIED SERVICER ONLY A WARNING HIGH VOLTAGE Air must be able to flow through the outdoor unit of your com fort system Do not construct a fence n
19. an R 22 cy linder The service equipment used must be listed or certified for the type of refrigerant used e Store cylinders in a cool dry place Never use a cy linder as a platform or a roller AA WARNING To avoid possible explosion use only returnable not disposable service cylinders when removing refrig erant from a system Ensure the cylinder is free of damage which could lead to a leak or explosion Ensure the hydrostatic test date does not exceed 5 years Ensure the pressure rating meets or exceeds 400 Ibs When in doubt do not use cylinder Refrigerant Lines AX CAUTION The compressor mineral oil for R 22 units is susceptible to moisture absorption and could cause compressor failure Do not leave system open to atmosphere any longer than necessary for installation Use only refrigerant grade dehydrated and sealed copper tub ing to connect the condensing unit with the indoor evaporator After cutting the tubing install plugs to keep refrigerant tubing clean and dry prior to and during installation Tubing should always be cut square keeping ends round and free from burrs Clean the tubing to prevent contamination Do NOT let refrigerant lines come in direct contact with plumb ing ductwork floor joists wall studs floors and walls When running refrigerant lines through a foundation or wall openings should allow for sound and vibration absorbing
20. an be located at ground floor level or on flat roofs At ground floor level the unit must be on a solid level foundation that will not shift or settle To reduce the possibility of sound transmission the foundation slab should not be in contact with or be an integral part of the building foundation The foundation slab should be a minimum of 6 wider than the unit in all direc tions Ensure the foundation is sufficient to support the unit A concrete slab raised above ground level provides a suitable base The selected site should be no greater than 50 below or 70 above the evaporator section For optimum performance the minimum length interconnecting tubing is preferred When pos sible minimize the amount of bends and turns Rooftop Installations If it is necessary to install this unit on a roof structure ensure the roof structure can support the weight and that proper con sideration is given to the weather tight integrity of the roof Since the unit can vibrate during operation sound vibration transmis sion should be considered when installing the unit Vibration absorbing pads or springs can be installed between the con densing unit legs or frame and the roof mounting assembly to reduce noise vibration Rigging A WARNING To avoid possible injury or death all panels must be in position and secured before lifting this equipment
21. and insu late for best possible reading 3 Check subcooling and superheat Systems with TXV ap plication should have a subcooling of 11 2 F and su perheat of 9 1 F a If subcooling and superheat are low adjust TXV to 9 1 F superheat then check subcooling NOTE To adjust superheat turn the valve stem clock wise to increase and counter clockwise to decrease b If subcooling is low and superheat is high add charge to raise subcooling to 11 2 F then check superheat c If subcooling and superheat are high adjust TXV valve to 9 1 F superheat then check subcooling d If subcooling is high and superheat is low adjust TXV valve to 9 1 F superheat and remove charge to lower the subcooling to 11 2 F NOTE Do NOT adjust the charge based on suction pres sure unless there is a gross undercharge 4 Disconnect manifold set installation is complete Subcooling Formula Sat Liquid Temp Liquid Line Temp NOTE Check the Schrader ports for leaks and tighten valve cores if necessary Install caps finger tight NOTE Subsequent opening and replace of the cap will require only 1 2 to 1 hex flat See the table below for the torque required for an effective seal on the valve bonnet 1 6 turn past finger tight TORQUE TUBING SIZE ft lbs After closing the valve bonnet perform a final refrigerant leak test on the valves and sweat connections Return the room thermostat to the desired settings Trouble
22. ased on the wire size The conduit enters the control box through the hole provided in the bottom NOTE The control box hole is sized for 3 4 conduit If permitted by code a flexible conduit is preferred to minimize vibration transmission from the unit to the building Connect the line voltage wires to the L1 L2 and L3 terminals of the definite purpose contactor located in the unit control box Refer to the wiring diagram attached to the unit when making these connections Three Phase Compressor Rotation AX CAUTION Use care when handling scroll compressors Dome temp eratures could be hot Three phase scrolls are power phase dependent and can com press in more than one direction Verify proper rotation for three phase compressors by ensuring the suction pressure drops and discharge pressure rises when the compressor is energized NOTE When operated in re verse a three phase scroll compressors is noisier and its cur rent draw substantially reduced compared to marked values To correct disconnect power and switch any two leads at the unit contactor and re observe High Voltage Connections Route power supply and ground wires through the high voltage port and terminate in accordance with the wiring diagram pro vided inside the control panel cover Low Voltage Connections Condensing unit control wiring requires a two conductor low voltage circuit from the room thermostat The wiring should be no smaller than 18 AWG a
23. cally pressure will rise during this period 5000 4500 4000 LEAK S PRESENT 3500 3000 2500 VACUUM IN MICRONS 2000 CONDENSIBLES OR SMALL 1 500 LEAK PRESENT 1000 NO LEAKS NO CONDENSIBLES MINUTES e Ifthe pressure rises to 1000 microns or less and remains steady the system is considered leak free proceed to startup e f pressure rises above 1000 microns but holds steady below 2000 microns moisture and or noncondensibles may be present or the system may have a small leak Return to step 2 If the same result is encountered check for leaks as previously indicated and repair as necessary then repeat evacuation e lf pressure rises above 2000 microns a leak is present Check for leaks as previously indicated and repair as nec essary then repeat evacuation Refer to the Remote Condensing Unit Service Manual for more detailed instructions on system evacuation preliminary charge adjustment and final charge adjustment Electrical Connections AA WARNING HIGH VOLTAGE Disconnect ALL power before servicing Multiple power sources may be present nT Failure to do so may cause property damage personal injury or death due to electric shock Wiring must conform with NEC or CEC and all local codes Undersized wires could cause poor equipment performance equipment damage or fire AA WARNING To avoid the risk of fire or equipment damage use copper
24. conductors NOTICE Units with reciprocating compressors and non bleed TXV s require a Hard Start Kit This unit is designed for three phase operation DO NOT OP ERATE ON A SINGLE PHASE POWER SUPPLY Measure the power supply to the unit The supply voltage must be in agreement with the unit rating plate power requirements RATED MINIMUM SUPPLY MAXIMUM SUPPLY VOLTAGE VOLTAGE VOLTAGE The condensing unit rating plate lists pertinent electrical data necessary for proper electrical service and overcurrent protec tion Wires should be sized to limit voltage drop to 2 max from the main breaker or fuse panel to the condensing unit Consult the NEC CEC and all local codes to determine the correct wire gauge and length The wire size must be sufficient to carry the Minimum Circuit Ampacity MCA listed on the serial plate The supply voltage can be unbalanced phase to phase within 2 The following formula can be used to determine the per centage of voltage unbalance for your unit Percentage Max Voltage Deviation Form Voltage Average Voltage Unbalance Average Voltage Example L1 L2 220V L2 L3 216V Average Voltage 220 216 213 649 3 Maximum Deviation from Average 220 216 4 Voltage Unbalance 100 x 4 216 400 216 MAXIMUM ALLOWABLE LENGTH IN FEET TO LIMIT VOLTAGE DROP TO 2 Minimum Circuit Ampacity MCA Based on NEC 1996 Example A 7 12 Ton u
25. damage Do NOT make final refrigerant line connection until plugs are removed from refrigerant tubing NOTE Before brazing verify indoor piston size by checking the piston kit chart packaged with indoor unit Leak Testing Nitrogen or Nitrogen Traced AA WARNING To avoid the risk of fire or explosion never use oxygen high pressure air or flammable gases for leak testing of a refrigeration system AA WARNING To avoid possible explosion the line from the nitrogen cylinder must include a pressure regulator and a pressure relief valve The pressure relief valve must be set to open at no more than 150 psig Pressure test the system using dry nitrogen and soapy water to locate leaks If you wish to use a leak detector charge the system to 10 psi using the appropriate refrigerant then use nitrogen to finish charging the system to working pressure then apply the detector to suspect areas If leaks are found repair them After repair repeat the pressure test If no leaks exist proceed to system evacuation System Evacuation Condensing unit liquid and suction valves are closed The unit is shipped with the valve stems closed and caps installed AA WARNING REFRIGERANT UNDER PRESSURE Failure to follow proper procedures may cause property damage personal injury or death NOTE Scroll compressors should never be used to evacuate or pump down a heat pump or air conditioning system NOTICE THIS UNI
26. e unit can vibrate during operation sound vibration transmis sion should be considered when installing the unit Vibration absorbing pads or springs can be installed between the con densing unit legs or frame and the roof mounting assembly to reduce noise vibration Safe Refrigerant Handling While these items will not cover every conceivable situation they should serve as a useful guide AA WARNING To avoid possible injury explosion or death practice safe handling of refrigerants AA WARNING Refrigerants are heavier than air They can push out the oxygen in your lungs or in any enclosed space To avoid possible difficulty in breathing or death e Never purge refrigerant into an enclosed room or space By law all refrigerants must be reclaimed If an indoor leak is suspected throughly ventilate the area before beginning work Liquid refrigerant can be very cold To avoid possible frostbite or blindness avoid contact and wear gloves and goggles If liquid refrigerant does contact your skin or eyes seek medical help immediately Always follow EPA regulations Never burn refrig erant as poisonous gas will be produced AX WARNING To avoid possible explosion Never apply flame or steam to a refrigerant cylinder If you must heat a cylinder for faster charging partially immerse it in warm water e Never fill a cylinder more than 80 full of liquid re frigerant Never add anything other than R 22 to
27. ear the unit or build a deck or patio over the unit without first discussing your plans with your dealer or other qualified servicer Restricted airflow could lead to poor operation and or severe equipment damage DISCONNECT ALL POWER BEFORE SERVICING MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH Likewise it is important to keep the outdoor coil clean Dirt leaves or debris could also restrict the airflow If cleaning of the outdoor coil becomes necessary hire a qualified servicer Inexperienced people could easily puncture the tubing in the coil Even a small hole in the tubing could eventually cause a large loss of refrigerant Loss of refrigerant can cause poor operation and or severe equipment damage Do not use a condensing unit cover to protect the outdoor unit during the winter unless you first discuss it with your dealer Any cover used must include breathable fabric to avoid moisture buildup BEFORE CALLING Your SERVICER Check the thermostat to confirm that it is properly set Wait 15 minutes Some devices in the outdoor unit or in programmable thermostats will prevent compressor op eration for awhile and then reset automatically Also some power companies will install devices which shut off air conditioners for several minutes on hot days If you wait several minutes the unit may begin operation on its own AA CAUTION TO AVOID THE RISK
28. f tubing fittings will have an impact on final unit charge amount Turn the elec trical power on and let the system run Wait for the refrigerant pressures to stabilize Charge Verification AA WARNING REFRIGERANT UNDER PRESSURE Do not overcharge system with refrigerant Do not operate unit in a vacuum or at negative pres sure Failure to follow proper procedures may cause property damage personal injury or death Ad CAUTION Use refrigerant certified to AHRI standards Use of used refrigerant may cause compressor damage that is not covered under warranty Most portable machines cannot clean used refrigerant to meet AHRI standards NOTICE Violation of EPA regulations may result in fines or other penalties AX CAUTION Operating the compressor with the suction valve closed may cause serious compressor damage Final Charge Adjustment The outdoor temperature must be 60 F or higher Set the room thermostat to COOL fan switch to AUTO and set the tem perature control well below room temperature After system has stabilized per startup instructions check subcooling and superheat as detailed in the following section Expansion Valve System 1 Purge gauge lines Connect service gauge manifold tobase valve service ports Run system at least 10 min utes to allow pressure to stabilize 2 Temporarily install thermometer on liquid small line near liquid line service valve with adequate contact
29. final unit disposal 1 Purge gauge lines Connect service gauge manifold to base valve service ports Run system at least 10 minutes to allow pressure to stabilize 2 Temporarily install thermometer on suction large line near suction line service valve with adequate contact and insulate for best possible reading 3 Refer to the superheat table provided for proper system superheat Add charge to lower superheat or recover charge to raise superheat 4 Disconnect manifold set installation is complete Superheat Formula Suct Line Temp Sat Suct Temp Expansion Valve System 1 Purge gauge lines Connect service gauge manifold tobase valve service ports Run system at least 10 min utes to allow pressure to stabilize 2 Temporarily install thermometer on liquid small line near liquid line service valve with adequate contact and insu late for best possible reading 3 Check subcooling and superheat Systems with TXV ap plication should have a subcooling of 7 2 F and super heat of 8 1 F a If subcooling and superheat are low adjust TXV to 8 1 F superheat then check subcooling NOTE To adjust superheat turn the valve stem clock wise to increase and counter clockwise to decrease b 1540000100 is low and superheat is high add charge to raise subcooling to 7 2 F then check super heat c If subcooling and superheat are high adjust TXV valve to 8 1 F superheat then check subcooling
30. install the sup plied sight glass moisture indicator on the liquid line as close as practical to the service valve Burying Refrigerant Lines If burying refrigerant lines can not be avoided use the following checklist 1 Insulate liquid and suction lines separately 2 Enclose all underground portions of the refrigerant lines in waterproof material conduit or pipe sealing the ends where tubing enters exits the enclosure 3 If the lines must pass under or through a concrete slab ensure lines are adequately protected and sealed Refrigerant Line Connections NOTICE THIS UNIT IS SHIPPED WITH A NITROGEN HELIUM HOLDING CHARGE ONLY UNIT MUST BE EVACUATED AND CHARGED PER INSTALLATION INSTRUCTIONS WITH REFRIGERANT LISTED ON SERIAL RATING PLATE NOTE Holding charge must be removed before brazing Open service valves slowly to remove holding charge Close valves before brazing to prevent contaminants from entering system IMPORTANT To avoid overheating the service valve TXV valve or filter drier while brazing wrap the component with a wet rag or use a thermal heat trap compound as recommended by the compound manufacturer Use a brazing alloy of 2 minimum silver content Do not use flux 1 The ends of the refrigerant lines must be cut square de burred cleaned and be round and free from nicks or dents Any other condition increases the chance of a refrigerant leak 2 Sweep the refrigerant line with nitroge
31. ipping Inspection Always keep the unit upright laying the unit on its side or top may cause equipment damage Shipping damage and subse quent investigation is the responsibility of the carrier Verify the model number specifications electrical characteristics and accessories are correct prior to installation The distribu tor or manufacturer will not accept claims from dealers for trans portation damage or installation of incorrectly shipped units BE Codes amp Regulations This product is designed and manufactured to comply with national codes Installation in accordance with such codes and or prevailing local codes regulations is the responsibility of the installer The manufacturer assumes no responsibility for equip ment installed in violation of any codes or regulations Rated performance is achieved after 72 hours of operation The United States Environmental Protection Agency EPA has issued various regulations regarding the introduc tion and disposal of refrigerants Failure to follow these regulations may harm the environment and can lead to the imposition of substantial fines Should you have any questions please contact the local office of the EPA If replacing a condensing unit or air handler the system must be manufacturer approved and Air Conditioning Heating and Refrigeration Institute AHRI matched Refer to the unit Specification Sheet for the recommended in door model selection NOTE This unit must
32. lation Where possible the top of the unit should be completely unob structed however if vertical conditions require placement be neath an obstruction there should be a minimum of 60 inches between the top of the unit and the obstruction s The specified dimensions meet requirements for air circulation only Consult all appropriate regulatory codes prior to deter mining final clearances Another important consideration in selecting a location for the unit s is the angle to obstructions Either side adjacent the valves can be placed toward the structure provided the side away from the structure maintains minimum service clearance Corner installations are strongly discouraged L NOT RECOMMENDED Minimum Airflow Clearance A BJ C Aa This unit can be located at ground floor level or on flat roofs At ground floor level the unit must be on a solid level foundation that will not shift or settle To reduce the possibility of sound transmission the foundation slab should not be in contact with or be an integral part of the building foundation Ensure the foundation is sufficient to support the unit A concrete slab raised above ground level provides a suitable base Rooftop Installations If it is necessary to install this unit on a roof structure ensure the roof structure can support the weight and that proper con sideration is given to the weather tight integrity of the roof Since th
33. ld be sized to limit voltage drop to 2 max from the main breaker or fuse panel to the condensing unit Consult the NEC CEC and all local codes to determine the correct wire gauge and length Local codes often require a disconnect switch located near the unit do not install the switch on the unit Refer to the installa tion instructions supplied with the indoor furnace air handler for specific wiring connections and indoor unit configuration Like wise consult the instructions packaged with the thermostat for mounting and location information Overcurrent Protection The following overcurrent protection devices are approved for use e Time delay fuses e HACR type circuit breakers These devices have sufficient time delay to permit the motor compressor to start and accelerate its load Three Phase Compressor Rotation AX CAUTION Use care when handling scroll compressors Dome temp eratures could be hot Three phase compressors are power phase dependent and can rotate in either direction Verify proper rotation for three phase compressors by ensuring the suction pressure drops and discharge pressure rises when the compressor is energized NOTE When operated in re verse a three phase scroll compressors is noisier and its cur rent draw substantially reduced compared to marked values To correct disconnect power and switch any two leads at the unit contactor and re observe High Voltage Connections Route power supply
34. lean and dry prior to and during installation Tubing should always be cut square keeping ends round and free from burrs Clean the tubing to prevent contamination Do NOT let refrigerant lines come in direct contact with plumb ing ductwork floor joists wall studs floors and walls When running refrigerant lines through a foundation or wall openings should allow for sound and vibration absorbing material to be placed or installed between tubing and foundation Any gap between foundation or wall and refrigerant lines should be filled with a pliable silicon based caulk RTV or a vibration damping material Avoid suspending refrigerant tubing from joists and studs with rigid wire or straps that would come in contact with the tubing Use an insulated or suspension type hanger Keep both lines separate and always insulate the suction line REFRIGERANT LINE LENGTH ft Cond Unit 24 2549 50 747 Line Diameter In OD Suet Liq Suct Liq Suct Liq Full rating line size Lines greater than 74 feet in length or vertical elevation changes more than 50 feet refer to the Remote Cooling Service Manual or contact your distributor for assistance Liquid Line Ul Suction Line Mounting the evaporator coil above the condensing unit will require an inverted loop in the suction line adjacent or near the connection to the evaporator The top m of the loop must be slightly higher than the top of the coil
35. lves Use a brazing alloy of 2 minimum silver content Do not use flux Torch heat required to braze tubes of various sizes is proportional to the size of the tube Tubes of smaller size require less heat to bring the tube to brazing temperature before adding brazing alloy Applying too much heat to any tube can melt the tube Service personnel must use the appropriate heat level for the size of the tube being brazed Note The use of a heat shield when brazing is recommended to avoid burning the serial plate or the finish on the unit 1 The ends of the refrigerant lines must be cut square de burred cleaned and be round and free from nicks or dents Any other condition increases the chance of a refrigerant leak 2 Sweep the refrigerant line with nitrogen or inert gas dur ing brazing to prevent the formation of copper oxide in side the refrigerant lines This may cause a blockage or failure of the metering device 3 After brazing quench the joints with water or a wet cloth to prevent overheating of the service valve 4 Ensure the filter drier paint finish is intact after brazing If the paint of the steel filter drier has been burned or chipped repaint or treat with a rust preventative This is especially important on suction line filter driers which are continu ally wet when the unit is operating NOTE Be careful not to kink or dent refrigerant lines Kinked or dented lines will cause poor performance or compressor
36. n or inert gas dur ing brazing to prevent the formation of copper oxide in side the refrigerant lines 3 After brazing quench the joints with water or a wet cloth to prevent overheating of the service valve 4 Ensure the filter drier paint finish is intact after brazing If the paint of the steel filter drier has been burned or chipped repaint or treat with a rust preventative This is especially important on suction line filter driers which are continu ally wet when the unit is operating NOTE Be careful not to kink or dent refrigerant lines Kinked or dented lines will cause poor performance or compressor damage Do NOT make final refrigerant line connection until plugs are removed from refrigerant tubing NOTE Before brazing verify indoor piston size by checking the piston kit chart packaged with indoor unit Leak Testing Nitrogen or Nitrogen Traced AA WARNING To avoid the risk of fire or explosion never use oxygen high pressure air or flammable gases for leak testing of a refrigeration system AA WARNING To avoid possible explosion the line from the nitrogen cylinder must include a pressure regulator and a pressure relief valve The pressure relief valve must be set to open at no more than 150 psig Pressure test the system using dry nitrogen and soapy water to locate leaks If you wish to use a leak detector charge the system to 10 psi using the appropriate refrigerant then use nitrogen to
37. nd the field connection for this cir cuit must be made in the unit control box using solderless connectors i e wire nuts See the following diagram for a typical low voltage hook up SINGLE STATE LOW VOLTAGE HOOK UP THERMOSTAT CHT18 60 AIR HANDLER AH090 120 CONDENSING A GREEN UNIT CKL090 120 B RED YELLOW BLACK LA WHITE BLUE A A BLUE NOTES 1 THERMOSTAT TO AIR HANDLER CABLE MUST HAVE A MINIMUM OF 4 CONDUCTORS 2 AIR HANDLER TO CONDENSING UNIT CABLE WIRE NUT MUST HAVE A MINIMUM OF 2 CONDUCTORS System Start Up Never operate the compressor with the suction valve closed to test the compressor s pumping efficiency In some cases this can result in serious compressor damage and loss of warranty coverage THIS UNIT IS SHIPPED WITH A NITROGEN HELIUM HOLDING CHARGE ONLY UNIT MUST BE EVACUATED AND CHARGED PER INSTALLATION INSTRUCTIONS WITH REFRIGERANT LISTED ON SERIAL RATING PLATE NOTICE UNITS SHIPPED WITH A HOLDING CHARGE ARE INTENDED FOR COMPONENT REPLACEMENT ONLY ON EXISTING SYSTEMS AND NOT INTENDED FOR USE IN NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES NOTICE UNITS MUST ONLY BE USED AS REPLACEMENT COMPONENTS FOR PRE 2010 INSTALLED SYSTEMS For the 7 1 2 ton unit starting charge should be 15 Ib of R 22 and 18 Ibs for the 10 ton unit The length of line set indoor unit airflow condensing unit location and number o
38. nit is to be installed The distance from the building to the unit is 75 Calculate the minimum wire size assuming no more than 2 voltage drop MCA for 7 1 2 Ton 230V unit 43 3 from S amp R plate Applying previous table wire sizes less than 8 AWG cannot be used for circuits which have a rating of 45A The 8 wire is not suitable since the maximum length for a 45A circuit is 68 Solution Use a 6 AWG wire suitable up to 110 NOTE It is the contractors s responsibility to follow the NEC USA or CEC Canada when sizing the service wire for this unit Local codes often require a disconnect switch located near the unit do not install the switch on the unit Refer to the installa tion instructions supplied with the indoor furnace air handler for specific wiring connections and indoor unit configuration Like wise consult the instructions packaged with the thermostat for mounting and location information Overcurrent Protection The following overcurrent protection devices are approved for use e Time delay fuses e HACR type circuit breakers These devices have sufficient time delay to permit the motor compressor to start and accelerate its load Refer to the unit serial plate and this table for the maximum overcurrent protection permitted Run all line voltage wiring a conduit from the service discon nect box to the unit Refer to the NEC USA or CEC Canada codes for the correct size conduit b
39. nstallation The distributor or manufacturer will not accept claims from dealers for transpor tation damage or installation of incorrectly shipped units Codes amp Regulations This product is designed and manufactured to comply with na tional codes Installation in accordance with such codes and or prevailing local codes regulations is the responsibility of the installer The manufacturer assumes no responsibility for equip ment installed in violation of any codes or regulations Rated performance is achieved after 72 hours of operation The United States Environmental Protection Agency EPA has issued various regulations regarding the introduction and disposal of refrigerants Failure to follow these regu lations may harm the environment and can lead to the imposition of substantial fines Should you have any ques tions please contact the local office of the EPA If replacing a condensing unit or air handler the system must be manufacturer approved and Air Conditioning Heating and Refrigeration Institute AHRI matched NOTE Installation of unmatched systems is strongly discouraged Operating the unit in a structure that is not complete either as part of new construction or renovation will void the warranty Bib Installation Clearances Special consideration must be given to location of the con densing unit s in regard to structures obstructions other units and any all other factors that may interfere with air circu
40. op must be slightly higher than the top of the coil Mounting the condensing unit above the evaporator coil will require an oil trap In the suction line Install one oil trap at the evaporator for a height difference of more than 15 feet between indoor and outdoor units Of Insulation is necessary to prevent condensation from forming and dropping from the suction line Armflex or satisfactory equivalent with 3 8 min wall thickness is recommended In severe conditions hot high humidity areas 1 2 insulation may be required Insulation must be installed in a manner which protects tubing from damage and contamination Where possible drain as much residual compressor oil from existing systems lines and traps pay close attention to low areas where oil may collect NOTE If changing refrigerant types ensure the indoor coil and metering device is compatible with the type of refrigerant being used otherwise the indoor coil must be replaced Burying Refrigerant Lines If burying refrigerant lines can not be avoided use the following checklist 1 Insulate liquid and suction lines separately 2 Enclose all underground portions of the refrigeran
41. perate unit in a vacuum or at negative pres sure Failure to follow proper procedures may cause property damage personal injury or death AX CAUTION Use refrigerant certified to AHRI standards Use of used refrigerant may cause compressor damage that is not covered under warranty Most portable machines cannot clean used refrigerant to meet AHRI standards NOTICE VIOLATION OF EPA REGULATIONS MAY RESULT IN FINES OR OTHER PENALTIES AX CAUTION Operating the compressor with the suction valve closed may cause serious compressor damage Final Charge Adjustment The outdoor temperature must be 60 F or higher Set the room thermostat to COOL fan switch to AUTO and set the tem perature control well below room temperature After system has stabilized per startup instructions check subcooling and superheat as detailed in the following section SYSTEM SUPERHEAT Indoor Wet Bulb Temperature F Outdoor Dry Bulb Temperature F SATURATED SUCTION PRESSURE SATURATED LIQUID PRESSURE TEMPERATURE CHART TEMPERATURE CHART SATURATED SUCTION SATURATED LIQUID SUCTION PRESSURE TEMPERATURE F LIQUID PRESSURE TEMPERATURE F 200 101 210 220 Fixed Orifice AX CAUTION To prevent personal injury carefully connect and disconnect manifold gauge hoses Escaping liquid refrigerant can cause burns Do not vent refrigerant into the atmosphere Recover all refrigerant during system repair and before
42. 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 addi tional 1 6 of a turn 1 wrench flat or to the following specifica tion to properly seat the sealing surfaces 1 3 8 valve to 5 10 in lbs 2 5 8 valve to 5 20 in lbs 3 3 4 valve to 5 20 in lbs 4 7 8 valve to 5 20 in lbs Do not introduce liquid refrigerant from the cylinder into the crankcase of the compressor as this may damage the compressor AX CAUTION POSSIBLE REFRIGERANT LEAK To avoid a possible refrigerant leak open the service valves until the top of the stem is 1 8 from the retainer NOTICE REFRIGERANT MUST BE ADDED TO THE SYSTEM AFTER EVACUATION IS COMPLETE AA WARNING REFRIGERANT UNDER PRESSURE e Do not overcharge system with refrigerant Do not operate unit in a vacuum or at negative pres sure Failure to follow proper procedures may cause property damage personal injury or death 1 Add refrigerant amount for the unit being installed See unit rating plate for initial charge 2 Set thermostat to call for cooling Check indoor and out door fan operation and allow system to stabilize for 10 minutes for fixed orifices and 20 minutes for expansion valves Charge Verification AA WARNING REFRIGERANT UNDER PRESSURE Do not overcharge system with refrigerant Do not o
43. shooting Qualified Installer Servicer Only When troubleshooting the first step should always be to check for clean coils clean filter s and proper airflow Indoor airflow should be 375 to 425 CFM per ton of cooling based on the size of the outdoor unit The most common way of establishing indoor airflow is heating temperature rise Indoor airflow will then be Heating output of equipment 1 1 x temp rise In other cases measurement of external static pressure is help ful For details see the Installation Instructions for your indoor unit TROUBLESHOOTING ANALYSIS TABLE COMPLAINT PROBABLE CAUSE 1 Excessive charge of refrigerant in system 2 Inadequate supply of air across the condenser coil 3 Non condensate gases in the system 1 High Head Pressure REMEDY 1 Purge or pump down excessive charge 2 Make certain that coil is not fouled in any way or that air is not re circulating 3 Purge these gases from the system Recharge system if necessary 2 Pressure 1 System low on refrigerant 1 Charge system until sight glass is clear of bubbles 2 Compressor valves broken 2 Replace compressor 1 Liquid line valve closed 2 Restricted liquid line 3 The bulb of the thermal expansion valve has lost its charge 3 Low Suction Pressure 4 System low on refrigerant 5 Dirty filters 6 Coil frosted up 7 Flash gas in the liquid line 8 Quantity of air through evaporator not adequate 1 Expan
44. sion valve stuck open 2 Expansion valve bulb not in contact with 4 High Suction Pressure suction line 3 Suction and or discharge valve leaking or broken 1 Disconnect switch open 2 Blow fuse or fuse at disconnect switch 3 Thermostat set too high 4 Selector switch in Off position 5 Contactor and or relay coils burned out 6 Loose or open electrical connection in either the control or power circuit 5 Compressor will not start Wiring Diagram HIGH VOLTAGE 1 Open the liquid line valve 2 Replace filter dryer 3 Detach the bulb from the suction line and hold in one hand If no liquid refrigerant goes through the valve replace the valve 4 Test the unit for leaks Add refrigerant until sight glass is free from bubbles after repairing leak 5 Clean or replace filter 6 Defrost and clean coil Clean or replace filters 7 Excessive liquid line drop Check liquid line size 8 Increase the blower speed 1 Correct valve action or replace the valve 2 Fasten bulb securely to suction line 3 Replace compressor 1 Close the disconnect switch 2 Check the cause of failure and replace the fuse 3 Adjust to lower temperature 4 Tum selector switch knob to Cool position 5 Replace contactor and or relay 6 Inspect and secure all electrical connections A WARNING DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO
45. t lines in waterproof material conduit or pipe sealing the ends where tubing enters exits the enclosure 3 If the lines must pass under or through a concrete slab ensure lines are adequately protected and sealed Refrigerant Line Connections NOTICE THIS UNIT IS SHIPPED WITH A NITROGEN HELIUM HOLDING CHARGE ONLY UNIT MUST BE EVACUATED AND CHARGED PER INSTALLATION INSTRUCTIONS WITH REFRIGERANT LISTED ON SERIAL RATING PLATE NOTICE UNITS SHIPPED WITH A HOLDING CHARGE ARE INTENDED FOR COMPONENT REPLACEMENT ONLY ON EXISTING SYSTEMS AND NOT INTENDED FOR USE IN NEW SYSTEMS OR NEWLY CONSTRUCTED HOMES EPA REGULATIONS PROHIBIT THE SALE OR DISTRIBUTION OF APPLIANCES PRE CHARGED WITH THE REFRIGERANT R 22 IF THOSE APPLIANCES ARE MANUFACTURED AFTER JANUARY 1 2010 COMPONENTS OF EXISTING R 22 SYSTEMS MAY BE REPAIRED AND OR REPLACED NOTICE UNITS MUST ONLY BE USED AS REPLACEMENT COMPONENTS FOR PRE 2010 INSTALLED SYSTEMS NOTE Holding charge must be removed before brazing Open service valves slowly to remove holding charge Close valves before brazing to prevent contaminants from entering system IMPORTANT To avoid overheating the service valve TXV valve or filter drier while brazing wrap the component with a wet rag or use a thermal heat trap compound Be sure to follow the manufacturer s instruction when using the heat trap compound Note Remove Schrader valves from service valves before brazing tubes to the va
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