Allied Air Enterprises 4AC16LT User's Manual
Contents
1. Unit Model No Serial No Service Technician Nameplate Voltage Rated Load Ampacity Compressor Outdoor Fan Maximum Fuse or Circuit Breaker Electrical Connections Tight C Indoor Filter Clean Supply Voltage Unit Off Indoor Blower RPM S P Drop Over Indoor Dry Outdoor Coil Entering Air Temperature Voltage with Compressor Operating Discharge Pressure Vapor Pressure Refrigerant Charge Checked C Outdoor Fan Checked L Refrigerant Lines Leak Checked L Properly Insulated L Service Valves Fully Opened C Caps Tight Thermostat Calibrated C Properly Set L Level L 506467 01 Issue 1008 Page 21 LT BLUE DUAL CAPACITOR OUTDOOR TO 24 VAC POWER SOURCE 20 VA MINIMUM NEC CLASS 2 Y1 COMPRESSOR CRANKCASE HEATER IF USED WA COMPRESSOR CONTACTOR I i GROUND l 208 230 60 1 I l GROUND 5 S4 HIGH S24 LOSS A132 PRESSURE OF CHARGE SWITCH SWITCH 208 230 60 1 gi YELLOW RED BLACK ji 2 K1 rh EQUIPMENT GOU 6 3 L R ci B4 GROUND 2 LO ayy C PURPLE TO 24 VAC POWER SOURCE FOR USE WITH COPPER CONDUCTORS ONLY REFER TO UNIT RATING 20 VA MINIMUM PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURR2. The following equipment is needed to flush the existing line set and indoor coil see Figure 8 Two clean R22 recovery bottles an oil less recovery machine with a pump down feature and two sets of gauges one for use with R22 and one for use with R410A Flushing Procedure IMPORTANT The line set and or indoor coil must be flushed with at least the same amount of refrigerant that previously charged the system Check the charge in the flushing cylinder before flushing the unit 1 Remove existing R22 refrigerant using the appropriate procedure If the existing outdoor unit is not equipped with shutoff valves or if the unit is not operational AND the existing R22 refrigerant will be used to flush the system Disconnect all power to the existing outdoor unit Connect the existing unit a clean recovery cylinder and the recovery machine according to the instructions provided with the recovery machine Remove all R22 refrigerant from the existing system Refer to the gauges after shutdown to confirm that the entire system is completely void of refrigerant Disconnect the liquid and suction lines from the existing outdoor unit If the existing outdoor unit is equipped with manual shutoff valves AND new R22 refrigerant will be used to flush the system Start the existing R22 refrigerant system in cooling mode and close the liquid line valve Pump all the existing R22 refrigerant back into the outdoor unit Flushing Co
3. Miswired Module Codes Depending on the system configuration some ALERT flash codes may not be active The presence of safety switches affects how the system alerts are displayed by the module Miswiring the diagnostic module will cause false LED codes Table 11 on page 19 describes LED operation when the module is miswired and what troubleshooting action is required to correct the problem Page 16 Flash Codes LED vee z Fault Description Troubleshooting Information Ga Module has power Supply voltage is present at module terminals TRIP Red ALERT Yellow Flash Code 1 ALERT Yellow Flash Code 2 506467 01 Thermostat demand signal Y1 is present but the compressor is not running Long Run Time Compressor is running extremely long run cycles System Pressure Trip Discharge or suction pressure out of limits or compressor overloaded 1 Compressor protector is open Check for high head pressure Check compressor supply voltage 2 Outdoor unit power disconnect is open 3 Compressor circuit breaker or fuse s is open 4 Broken wire or connector is not making contact 5 Low pressure switch open if present in system 6 Compressor contactor has failed open 1 Low refrigerant charge 2 Evaporator blower is not running Check blower relay coil and contacts Check blower motor capacitor Check blower motor for failure or blockage Check evaporator blower wiring and connector Check indoo
4. 3 only briefly 4 If low pressure switch present go to Flash Code 1 info 1 Run capacitor has failed ALERT 2 Low line voltage contact utility if voltage at disconnect is low Yellow Check wiring connections Locked Rotor a os Flash 3 Excessive liquid refrigerant in compressor Code 4 4 Compressor bearings are seized Measure compressor oil level 1 Outdoor unit power disconnect is open 2 Compressor circuit breaker or fuse s is open 3 Compressor contactor has failed open Check compressor contactor wiring and connectors ALERT Check for compressor contactor failure burned pitted or open Yellow Check wiring and connectors between supply and compressor Flash Open Circuit Check for low pilot voltage at compressor contactor coil Code 5 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 Check compressor motor winding resistance 1 Run capacitor has failed Open Start Circuit 2 Open circuit in compressor start wiring or connections Current only in run Check wiring and connectors between supply and the compressor S terminal circuit 3 Compressor start winding is damaged Check compressor motor winding resistance ALERT Yellow Flash Code 6 ALERT re 1 Open circuit in compressor run wiring or connections Open Run Circuit A
5. 463 5 6 Compare the approach value with those shown in Table 7 If the values do not agree with those provided in Table 7 add refrigerant to lower the approach temperature or recover eee refrigerant from the system to increase the approach 487 8 temperature 469 5 475 6 a N a a 494 0 a o 500 2 a w 506 5 a N ete Check Charge Using Normal Operating Pressures 519 3 Use Table 8 to perform maintenance checks Table 8 is not 525 8 a procedure for charging the system Minor variations in E these pressures may be due to differences in installations Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the system a a A NI a 539 0 a 545 6 La Ea Em Em ed mon En Bo 552 3 559 1 565 9 Approach Values for TXV Systems o w 572 8 o N 579 8 o 586 8 o FS 593 8 o a 601 0 608 1 Approach value is the liquid line temperature minus the outdoor ambient temperature 1 F o 615 4 622 7 Note For best results use the same digital thermometer to check both outdoor ambient and liquid temperatures 630 1 o 637 5 645 0 Table 7 sa w Ras Le ae e o e p ee TAEA EE A a Ie ESSA A EE Rio RI ee EM Aea ASA ZEN KON RI ES pana EE ETI oo RI EE KISE EE EE EGZ KE EN w D o o Table 5 506467 01 Issue 1008 Page 14 No
6. Failure to confirm proper charge and airflow may reduce energy efficiency and shorten equipment life When servicing or repairing HVAC components ensure the fasteners are appropriately tightened Table 1 shows torque values for fasteners Torque Table Stem Caps 8 ft Ibs Service Port Caps 8 ft Ibs Sheet Metal Screws 16 in Ibs 8 Machine Screws 16 in Ibs 10 Machine Screws 28 in Ibs Table 1 506467 01 Inspection of Shipment Upon receipt of equipment carefully inspect it for possible shipping damage If damage is found it should be noted on the carrier s freight bill Take special care to examine the unit inside the carton if the carton is damaged Any concealed damage discovered should be reported to the last carrier immediately preferably in writing and should include a request for inspection by the carrier s agent If any damages are discovered and reported to the carrier DO NOT INSTALL THE UNIT as claim may be denied Check the unit rating plate to confirm specifications are as ordered Location of Unit Refer to Figure 1 for installation clearances Installation Clearances A service clearance of 30 must be maintained on one of the sides adjacent to the control box Clearance to one of the other three sides must be 36 Clearance to one of the remaining two sides may be 12 and the final side may be 6 A clearance of 24 must be maintained between units 48 clearance required on top o
7. a Yellow i Check wiring and connectors between supply and the compressor R terminal Current only in start Sao Flash circuit 2 Compressor run winding is damaged Code 7 Check compressor motor winding resistance ALERT Yellow Flash Code 8 Welded Contactor Compressor always runs 1 Compressor contactor has failed closed 2 Thermostat demand signal not connected to module ALERT Yellow Flash Code 9 Low Voltage 1 Control circuit transformer is overloaded Control circuit less 2 Low line voltage contact utility if voltage at disconnect is low than 17VAC Check wiring conditions Table 10 506467 01 Issue 1008 Page 18 Miswired Module Troubleshooting Miswired Module Indication Recommended Troubleshooting Action 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 section on page 16 for R and C wiring Green LED is not on module does not power up Green LED intermittent Determine if R and Y terminals are wired in reverse Verify module s R and C module powers up only terminals have a constant source Review 24VAC Power Wiring section on page 16 when compressor runs for R and C wiring TRIP LED is on but system Verify Y terminal is connected to 24VAC at contactor coil Verify voltage at contactor and compressor check OK coils falls below 0 5VAC when off Tle LED co SET UED Verify R and C terminals are supplied with 19 2
8. high level of sound transmission Figure 4 shows how to place the outdoor unit and line set to reduce line set vibration Line Set Isolation Illustrations on the pages 6 and 7 demonstrate procedures which ensure proper refrigerant line set isolation Figure 6 shows how to install line sets on horizontal runs Figure 7 shows how to make a transition from horizontal to vertical Figure 9 shows how to install line sets on vertical runs Brazing Connection Procedure 1 Cut ends of refrigerant lines square free from nicks or dents Debur the ends The pipe must remain round do not pinch end of line 2 Before making line set connections use dry nitrogen to purge the refrigerant piping This will help to prevent oxidation and the introduction of moisture into the system 3 Use silver alloy brazing rods 5 or 6 silver alloy for copper to copper brazing or 45 silver alloy for Issue 1008 Page 4 Outside Unit Placement and Installation Install unit away o from windows mo DONNE a Mn Two 90 elbows installed in lineset will reduce lineset vibration Figure 4 copper to brass or copper to steel brazing which are rated for use with R410A refrigerant Remove the Schrader core assemblies before brazing to protect them from damage due to extreme heat Replace the cores when brazing is complete Remove light maroon washers from service valves and shield light maroon stickers to protect them during brazing Wra
9. high pressure 506467 01 Issue 1008 2 With both manifold valves closed connect the cylin der of R410A refrigerant Open the valve on the R410A cylinder vapor only 3 Open the high pressure side of the manifold to allow R410A into the line set and indoor unit Weigh in a trace amount of R410A A trace amount is a maxi mum of 2 oz of refrigerant or 3 Ibs pressure Close the valve on the R410A cylinder and the valve on the high pressure side of the manifold gauge set Discon nect the R410A cylinder 4 Connect a cylinder of nitrogen with a pressure regulat ing valve to the center port of the manifold gauge set When using high pressure gas such as nitrogen for this purpose be sure to use a regulator that can control the pressure down to 1 or 2 psig 5 Adjust nitrogen pressure to 150 psig Open the valve on the high side of the manifold gauge set to pressur ize the line set and the indoor coil 6 After a short period of time open a refrigerant port to make sure that an adequate amount of refrigerant has been added for detection refrigerant requirements will vary with lengths Check all joints for leaks Purge nitrogen and R410A mixture Correct any leaks and recheck Evacuation Evacuating the system of noncondensables is critical for proper operation of the unit Noncondensables are defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning sy
10. is in the bottom of the control box Connect conduit to the control box using a proper conduit fitting Units are approved for use only with copper conductors 24V Class II circuit connections are made in the low voltage junction box Acomplete unit wiring diagram is located inside the unit control box cover see also page 22 of this instruction 3 Install room thermostat on an inside wall that is not subject to drafts direct sunshine or other heat sources 4 Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit See Figure 3 506467 01 Thermostat Designations Thermostat Indoor Unit Outdoor Unit See unit wiring diagram for power supply connections If the indoor unit is not equipped with a blower relay one must be field supplied and installed Do not connect C common connection between indoor unit and thermostat except when required by the indoor thermostat Refer to thermostat installation instructions C common connection between indoor unit and outdoor unit required for proper operation Figure 4 5 Do not bundle any excess 24V control wire inside control box Run control wire through installed wire tie and tighten wire tie to provide low voltage strain relief and to maintain seperation of field installed low and high voltage circuits Refrigerant Piping A WARNING Refrigerand can be harmful if inhaled Refrigerant must always be used and recover
11. over 50 Refrigerant Line Set Diameters in eri Line Set Length and Size Suction Line Line Set Length and Size BTUH For installations exceeding 50 contact Technical Services Table 2 506467 01 A WARNING Polyolester POE oils used with R 410A refrigerant absorb moisture very quickly It is very important that the refrigerant system be kept closed as much as possible DO NOT remove line set caps or service valve stub caps until ready to make connections Installing Refrigerant Line During the installation of an air conditioning system it is important to properly isolate the refrigerant line to prevent unnecssary vibration Line set contact with the structure wall ceiling or floor may cause objectionable noise when vibration is translated into sound As a result more energy or vibration can be expected Close attention to line set isolation must be observed If refrigeration lines are routed through a wall seal and isolate the opening so vibration is not transmitted to the building Following are some points to consider when placing and installing a high efficiency outdoor unit Placement Be aware that some localities are adopting sound ordinances based on how noisy the unit is at the neighbor s home not at the original installation Install the unit as far as possible from the property line When possible do not install the unit directly outside a bedroom window Glass has a verry
12. the compressor protector is open or may indicate missing supply power to the compressor Interpreting the Diagnostic LEDs When an abnormal system condition occurs the diagnostic module displays the appropriate ALERT and or TRIP LED The yellow ALERT LED will flash a number of times consecutively pause and then repeat the process To identify a flash code number count the number of consecu tive flashes Refer to Table 9 on page 17 and Table 10 on page 18 for information on the flash codes Every time the module powers up the last ALERT LED flash code that occurred prior to shutdown is displayed for 60 seconds The module will continue to display the previous flash code until the condition returns to normal or 24VAC is removed from the module TRIP and ALERT LEDs flashing at the same time means control circuit voltage is too low for operation 24VAC Power Wiring The diagnostic module requires a constant nominal 24VAC power supply The wiring to the module s R and C terminals must be directly from the indoor unit or thermostat 506467 01 Issue 1008 Thermostat Demand Wiring The diagnostic module requires a thermostat demand signal to operate properly The thermostat demand signal input labeled Y on the module should always be con nected to the compressor contactor coil so that when the coil is energized the demand signal input is 24VAC When the coil is not energized the demand signal input should be less than 0 5VAC
13. 8VAC flashing together ALERT Flash Code 3 Compressor Short Cycling displayed incorrectly Verify Y terminal is connected to 24VAC at contactor coil Verify voltage at contactor coil falls below 0 5VAC when off ALERT Flash Code 5 6 or 7 Open Circuit Open Start Circuit or Open Run Circuit displayed incorrectly 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 ALERT Flash Code 6 Open Start Circuit displayed for Code 7 Open Run Circuit or vice versa Check that compressor run and start wires are routed through correct module sensing holes 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 Review Thermostat Demand Wiring on page 16 for Y and C wiring ALERT Flash Code 8 Welded Contactor displayed incorrectly Table 11 506467 01 Issue 1008 Page 19 MAINTENANCE AWARNING Before performing maintenance operations on system turn the electric power to unit OFF at disconnect switch es Unit may have multiple power supplies Electrical shock could cause personal injury or death Maintenance and service mus
14. Ball Type Service Valve Suction line ball type service valves function the same way as the other valves the difference is in the construction The ball valve is equipped with a service port with a factory installed Schrader valve A service port cap protects the Schrader valve from contamination and serves as the primary seal Issue 1008 Page 9 Ball Type Service Valve Valve Open Stem Cap To outdoor coil Service ss xX Port Cap we k i Service Port Schrader Valve Use adjustable wrench To open rotate stem counterclockwise 1 4 turn 90 To close rotate stem clockwise 1 4 turn 90 Figure 11 Leak Testing After the line set has been connected to the indoor and outdoor units the line set connections and indoor unit must be checked for leaks AWARNING Fire Explosion and Personal Safety Hazard Failure to follow this warning could result in damage personal injury or death Never use oxygen to pressurize or purge refrigeration lines Oxygen when exposed to a spark or open flame can cause damage by fire and or an explosion that could result in personal injury or death Using an Electronic Leak Detector 1 Connect the high pressure hose of the manifold gauge set to the suction valve service port Normally the high pressure hose is connected to the liquid line port however connecting it to the suction ports helps to protect the manifold gauge set from damage caused by
15. ENT NEC CLASS 2 PROTECTION SIZE DESCRIPTION piece SAG R HAZARD CAN CAUSE INJURY OR DEATH COMRONENT UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL CONTROL TIMED OFF AND LOCAL CODES DIAGNOSTIC MODULE COMPRESSOR LINE VOLTAGE FACTORY INSTALLED MOTOR OUTDOOR FAN CAPACITOR DUAL LINE VOLTAGE FIELD INSTALLED HEATER COMPRESSOR 24 VOLT FACTORY INSTALLED CONTACTOR COMPRESSOR CLASS II VOLTAGE FIELD INSTALLED SWITCH HIGH PRESSURE SWITCH LOSS OF CHARGE Wiring Diagram P N 48440 002 Figure 13 506467 01 Issue 1008 Page 22
16. INSTALLATION AND MAINTENANCE INSTRUCTIONS 4AC16LT SERIES Split System Air Conditioner Save these instructions for future reference A WARNING The equipment covered in this manual is to be installed by trained and experienced service and installation technicians Improper installation modification service or use can cause electrical shock fire explosion or other conditions which may cause personal injury death or property damage Use appropriate safety gear including safety glasses and gloves when installing this equipment A WARNING Risk of electrical shock Disconnect all remote power supplies before installing or servicing any portion of the INSTALLATION system Failure to disconnect power supplies can result in property damage personal injury or death START UP TABLE OF CONTENTS OPERATION A WARNING MAINTENANCE Installation and servicing of air conditioning equipment CONNECTION DIAGRAM can be hazardous due to internal refrigerant pressure and live electrical components Only trained and qualified service personnel should install or service this equipment Installation and service performed by unqualified persons can result in property damage personal injury or death Manufactured By Allied Air Enterprises Inc A Lennox International Inc Company 215 Metropolitan Drive West Columbia SC 29170 L se 1 Sharp metal edges can cause injury When installing the unit use c
17. Liquid Line Vapor Line Wrapped Metal SI i Vapor Line Wrapped SAL in Artmaflex Metal Sleeve in Armaflex Figure 6 Refrigerant Line Sets Installing Vertical Runs new construction shown IMPORTANT Refrigerant lines must not contact wall Outside Wall Vapor Line Liquid Line NOTE Similar installation practices should be used if line set is to be installed on exterior of outside wall Wood Block Between Studs a Vapor Line Wrapped with Armaflex aoe Liquid Line Outside Wall Wood Block IMPORTANT Refrigerant lines must not contact structure a Wire Tie Strap ZZ VV 7 I 7 Caulk PVC Pipe Fiberglass Insulation Sleeve on Figure 7 506467 01 Issue 1008 Page 6 Flushing Existing Line Set and Indoor Coil This procedure should not be performed on systems which contain contaminants such as compressor burn out A CAUTION When flushing existing line set and or indoor coil be sure to empty all existing traps Residual mineral oil can act as an insulator preventing proper heat transfer It can also clog the thermal expansion valve reducing system performance and capacity Failure to properly flush system as explained in these instructions will void warranty Required Equipment
18. are to avoid sharp edges 5 06467 Oo 506467 01 Issue 1008 Page 1 INSTALLATION General Read this entire instruction manual as well as the instructions supplied in separate equipment before starting the installation Observe and follow all warnings cautions instructional labels and tags Failure to comply with these instructions could result in an unsafe condition and or premature component failure These instructions are intended as a general guide only for use by qualified personnel and do not supersede any national or local codes in any way The installation must comply with all provincial state and local codes as well as the National Electrical Code U S or Canadian Electrical Code Canada Compliance should be determined prior to installation 4AC16LT condensing units use R410A which is an ozone friendly HFC refrigerant The unit must be installed with a matching indoor coil and line set 4AC16LT units are designed for use in expansion valve TXV systems only A filter drier approved for use with R410A is installed in the unit IMPORTANT This product has been designed and manufactured to meet ENERGY STAR criteria for energy efficiency when matched with appropriate coil components However proper refrigerant charge and proper air flow are critical to achieve rated capacity and efficiency Installation of this product should follow the manufacturer s refrigerant charging and air flow instructions
19. e F 5 Compare the subcooling value with those shown in Table 6 on page 14 If subcooling is greater than 1 Recover the refrigerant from the unit shown recover some refrigerant If subcooling is less than shown add some refrigerant 2 Conducta leak check then evacuate as previously outlined Charge Using Approach Method Outdoor Temperatures 65 F or Above 3 Weigh in the charge according to the total amount shown on the unit nameplate If weighing facilities are not available use one of the following procedures to charge the unit Charge Using Subcooling Method Outdoor Temperatures Below 65 F When the outdoor ambient temperature is below 65 F the subcooling method can be used to charge the unit It may The following procedure is intended as a general guide and is for use on expansion valve systems only For best results indoor temperature should 70 F to 80 F Monitor system pressures while charging 1 Record outdoor ambient temperature using a digital thermometer 2 Attach high pressure gauge set and operate unit for several minutes to allow system pressures to stabilize be necessary to restrict the air flow through the outdoor coil to achieve pressures in the 200 250 psig range 3 These higher pressures are necessary for checking the charge Block equal sections of air intake panels and Compare stabilized pressures with those provided in Table 8 on page 15 Minor variations in these pres sures
20. ecovery machine to pull a vacuum on the system at the end of the procedure 506467 01 9 Close the valve on the inverted R 22 cylinder and the gauge set valves Pump the remaining refrigerant out of the recovery machine and turn the machine off 10 Use nitrogen to break the vacuum on the refrigerant lines and indoor coil before removing the recovery machine gauges and R 22 refrigerant drum Re install pressure tap valve cores into the 4AC16LT unit s service valves 11 Install the refrigerant expansion valve approved for use with R410A refrigerant in the liquid line at the indoor coil Refrigerant Metering Device 4AC16LT units are designed for use with TXV systems only Expansion valves equipped with Chatleff type fittings are available from the manufacturer See Table 3 for proper TXV for each unit TXV Data MODEL PART NUMBER 4ACI6LT 24 36 A4TXVO1 4AC16LT 48 A4TXVO2 4AC16LT 60 A4TXVO2 Table 3 To install an expansion valve See Figure 9 above 1 Separate the distributor assembly and remove the piston orifice and used teflon seal Insert nozzle end of the expansion valve along with a new teflon seal into the distributor and tighten to 20 30 ft lbs Use backup wrench on all wrench flats Overtightening will crush the teflon seal and may cause a leak 2 Attach liquid line portion of distributor assembly along with new teflon seal to the inlet of the expansion valve Tighten to 20 30 ft Ibs Use backu
21. ed responsibly Incorrect or irresponsible use of refrigerant can result in personal injury or death If the 4AC16LT unit is being installed with a new indoor coil and line set the refrigerant connections should be made as outlined in this section If an existing line set and or indoor coil will be used to complete the system refer to this section as well as the section that follows entitled Flushing Existing Line Set and Indoor Coil If this unit is being matched with an approved line set or indoor coil which was previously charged with R 22 refrigerant the line set and coil must be flushed prior to installation If the unit is being used with and existing indoor coil which was equipped with a liquid line which served as a metering device RFCI the liquid line must be replaced prior to the installation of the 4AC16LT unit Field refrigerant piping consists of liquid and suction lines from the outdoor unit sweat connections to the indoor coil flare or sweat connections Issue 1008 Page 3 Select line set diameters from Table 2 to ensure that oil return to the compressor Size vertical suction riser to maintain minimum velocity at minimum capacity Recommended line length is 50 or less If more than 50 line set is required contact Technical Service Table 2 shows the diameters for line sets up to 100 although vertical lift applications and trapping requirements need to be reviewed with Technical Service for line sets
22. f unit Maximum soffit overhang is 36 Figure 1 Slab Mounting When installing a unit at grade level install on slab high enough above grade so that water from higher ground will not collect around the unit See Figure 2 Roof Mounting Install unit at a minimum of 4 above surface of the roof Care must be taken to ensure weight of unit is properly distributed over roof joists and rafters Either redwood or steel supports are recommended Issue 1008 Page 2 Slab Mounting Discharge Air Building Structure Mounting Slab Ground Level Figure 2 Electrical Wiring All field wiring must be done in accordance with the National Electrical Code NEC recommendations Canadian Electrical Code CEC and CSA Standards or local codes where applicable A WARNING Unit must be grounded in accordance with national and local codes Failure to ground unit properly can result in personal injury or death Refer to the furnace or blower coil installation instructions for additional wiring application diagrams and refer to unit rating plate for minimum circuit ampacity and maximum overcurrent protection size 1 Install line voltage power supply to unit from a properly sized disconnect switch Any excess high voltage field wiring should be trimmed or secured away from the low voltage field wiring 2 Ground unit at unit disconnect switch or to an earth ground To facilitate conduit a hole
23. fold gauge center port hose to a nitrogen cylinder with pressure regulator set to 150 psig and purge the hose Open the manifold gauge valves to break the vacuum in the line set and indoor unit Close the manifold gauge valves Shut off the nitrogen cylinder and remove the manifold gauge hose from the cylinder Open the manifold gauge valves to release the nitrogen from the line set and indoor unit Reconnect the manifold gauge to the vacuum pump turn the pump on and continue to evacuate the line set and indoor unit until 500 microns is maintained within a 20 minute period after shutting off the vacuum pump and closing the manifold gauge valves When the requirements above have been met disconnect the manifold hose from the vacuum pump Open the service valves to break the vacuum in the line set and indoor unit Issue 1008 Page 11 START UP A CAUTION If unit is equipped with a crankcase heater it should be energized 24 hours before unit start up to prevent compressor damage as a result of slugging 1 Rotate fan to check for frozen bearings or binding 2 Inspect all factory and field installed wiring for loose connections 3 After evacuation is complete open liquid line and suction line service valves to release refrigerant charge contained in outdoor unit into system 4 Replace the stem caps and secure finger tight then tighten an additional 1 6 of a turn 5 Check voltage supply at the d
24. isconnect switch The voltage must be within the range listed on the unit nameplate If not do not start equipment until the power company has been consulted and the voltage condition corrected 6 Set thermostat for cooling demand turn on power to indoor blower and close the outdoor unit disconnect switch to start the unit 7 Recheck unit voltage with unit running Power must be within range shown on unit nameplate Refrigerant Charging This system is charged with R410A refrigerant which operates at much higher pressures than R22 The liquid line drier provided with the unit is approved for use with R410A Do not replace it with one designed for use with R22 This unit is NOT approved for use with coils which use capillary tubes as a refrigerant metering device R410A refrigerant cylinders are rose colored Refriger ant should be added through the vapor valve in the liquid state Certain R410A cylinders are identified as being equipped with a dip tube These allow liquid refriger ant to be drawn from the bottom of the cylinder without inverting the cylinder Do not turn this type of cylinder upside down to draw refrigerant Units are factory charged with the amount of R410A refrigerant indicated on the unit rating plate This charge is based on a matching indoor coil and outdoor coil with 15 line set For varying lengths of line set refer to Table 4 for refrigerant charge adjustment 506467 01 Issue 1008 Refrigera
25. may be expected due to differences in installa move obstructions sideways until the liquid pressure is in the 200 250 psig range see Figure 12 tions Significant differences could mean that the system is not properly charged or that a problem exists with some component in the system 1 With the manifold gauge hose on the liquid service Pressures higher than those listed indicate that the port and the unit operating stably use a digital ther system is overcharged Pressures lower than those mometer to record the liquid line temperature listed indicate that the system is undercharged Verify adjusted charge using the approach method 2 Atthe same time record the liquid line pressure reading 4 Use the same digital thermometer to check liquid line 3 Use the temperature pressure chart Table 5 on page 14 temperature to determine the saturation temperature for the liquid line pressure reading 5 Subtract the outdoor ambient temperature from the liquid line temperature to determine the approach temperature 506467 01 Issue 1008 Page 13 R410A Temperature Pressure Chart Pressure Pressure Temp Pressure Psig Psig bal Psig Subcooling Values N a 396 0 w 401 3 w o 406 7 412 2 417 7 Table 6 423 2 Q w ka w 428 8 434 5 Liquid Line Temperature F kai T Outdoor Ambient Temperature F nee Approach Temperature F a a 451 8 a a 457 6 a
26. n valve before continuing with flushing procedures R 22 flow control devices are not approved for use with R410A refrigerant and may prevent proper flushing Use a field provided fitting to reconnect the lines 5 Remove the pressure tap valve cores from the 4AC16LT units service valves Connect an R 22 cylinder with clean refrigerant to the suction service valve Connect the R 22 gauge set to the liquid line valve and connect a recovery maching with an empty recovery tank to the gauge set 6 Set the recovery machine for liquid recovery and start the recovery machine Open the gauge set valves to allow the recovery machine to pull a vacuum on the existing system line set and indoor coil 7 Invert the cylinder of clean R 22 and open its valve to allow liquid refrigerant to flow in to the system through the suction line valve Allow the refrigerant to pass from the cylinder and through the line set and the indoor coil before it enters the recovery machine 8 After all of the liquid refrigerant has been recovered switch the recovery machine to vapor recovery so that all of the R 22 vapor is recovered Allow the recovery machine to pull a vacuum on the sytem NOTE Asingle system flush should remove all of the mineral oil from the existing refrigerant lines and indoor coil Asecond flushing may be done using clean refrigerant if insufficient amounts of mineral oil were removed during the first flush After each system flush allow the r
27. nnections INVERTED R22 CYLINDER Contains clean R22 to be used for flushing L HIGH PRESSURE PRESSURE OUTDOOR UNIT SUCTION LINE EXISTING SUCTION LINE SERVICE VALVE EXISTING INDOOR COIL EXISTING LIQUID LINE LIQUID LINE OPENED CLOSED SERVICE VALVE RECOVERY CYLINDER F TANK RETURN F DISCHARGE RECOVERY MACHINE The inverted R22 cylinder must contain at least the same amount of refrigerant as was recovered from the existing system Figure 8 506467 01 Issue 1008 Page 7 It may be necessary to bypass the low pressure switches to ensure complete refrigerant evacuation When the low side system pressures reach 0 psig close the suction line valve Disconnect all power to the existing outdoor unit Refer to the gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system Disconnect the liquid and suction lines from the existing outdoor unit 2 Remove the existing outdoor unit Set the new R410A unit and follow the brazing connection procedure outlined previously on this page to make line set connections Do not install the R410A thermal expansion valve at this time 3 Make low voltage and line voltage connections to the new outdoor unit Do not turn on power to the unit or open the outdoor unit service valves at this time 4 Remover the existing R 22 refrigerant flow control orifice or thermal expansio
28. nt Charge Adjustment Liquid Line Set Diameter Oz per 5 ft adjust from 15 ft line set 3 8 in 3 oz per 5 ft If line length is greater than 15 ft add this amount If line length is less than 15 ft remove this amount Table 4 A IMPORTANT Mineral oils are not compatible with R410A If oil must be added it must be a polyol ester oil If the system is void of refrigerant clean the system using the procedure described below 1 Use dry nitrogen to pressurize the system and check for leaks Repair leaks if possible 2 Evacuate the system to remove as much of the moisture as possible 3 Use dry nitrogen to break the vacuum 4 Evacuate the system again 5 Weigh the appropriate amount of R410A refrigerant listed on unit nameplate into the system D Monitor the system to determine the amount of moisture remaining in the oil Use a test kit to verify that the moisture content is within the kits dry color range It may be necessary to replace the filter drier several times to achieve the required dryness level If system dryness is not verified the compressor will fail in the future The outdoor unit should be charged during warm weather However applications arise in which charging must occur in the colder months The method of charging is deter mined by the outdoor ambient temperature Measure the liquid line temperature and the outdoor ambient temperature as outlined below 1 C
29. onnect the manifold gauge set to the service valve ports as follows e Low pressure gauge to suction line service valve e High pressure gauge to liquid line service valve Page 12 Close manifold gauge set valves Connect the center manifold hose to an upright cylinder of R410A Blocking Outdoor Coil 3 If room temperature is below 70 F set the room thermo Outdoor coil should be stat to call for heat This will create the necessary load blocked one side at a time for properly charging the system in the cooling cycle with cardboard or plastic sheet until proper testing 4 Use a digital thermometer to record the outdoor pressures are reached ambient temperature 5 When the heating demand has been satisfied switch Gabon Or Plastic shegt the thermostat to cooling mode with a set point of 68 F When pressures have stabilized use a digital thermometer to record the liquid and suction line Figure 12 temperatures 4 Subtract the liquid line temperature from the satura 6 The outdoor temperature will determine which charg tion temperature according to the chart to determine ing method to use Proceed with the appropriate charging method Charge Using Weigh In Method If the system is void of refrigerant or if the outdoor ambient temperature is cool first locate and repair any leaks then use the weigh in method to charge the unit subcooling Saturation Temperature F Liquid Line Temperature F o Subcooling Valu
30. p a wet cloth around the valve body and copper tube stub to protect it from heat damage Braze the line set to the service valve Quench the joints with water or a wet cloth to prevent heat damage to the valve core and opening port The tube end must stay bottomed in the fitting during final assembly to ensure proper seating sealing and rigidity Install a thermal expansion valve which is sold separately and which is approved for use with R410A refrigerant in the liquid line at the indoor coil see Refrigerant Metering Device on page 8 Refrigerant Line Sets Installing Horizontal Runs To hang line set from joist or rafter use either metal strapping material or anchored heavy nylon wire ties Strapping Material around vapor line only Floor Joist or Roof Rafter ee EN lt A Metal Sleeve anit Wire Tie around vapor line only Tape or Wire Tie Strap the vapor line to the joist or rafter at 8 intervals then strap the liquid line to the vapor line Floor Joist or Roof Rafter YIN a n An ai ae va or Wire Tie i Mittin nn ne 0 A 506467 01 Figure 5 Issue 1008 Page 5 Refrigerant Line Sets Transition from Vertical to Horizontal Automotive Anchored Muffler Type Heavy Nylon Wire Tie Strap Liquid Line to Vapor Line Strap Liquid Line to Vapor Line bani Liquid Line
31. p wrench on all wrench flats Overtightening will crush the teflon seal and may cause a leak 3 Connect the external equalizer line to the equalizer port on the suction line and tighten to 8 ft lbs 4 Strap the superheat sensing bulb to the suction header If installing an expansion valve on an indoor coil that previously used a fixed orifice be sure to remove the existing fixed orifice Failure to remove a fixed orifice when installing an expansion valve to the indoor coil will result in improper operation and damage to the system Issue 1008 Page 8 Metering Device Installation Distributor Swe ki Strainer Liquid Line Stub If necessary remove R22 flow control device fixed orifice thermal expansion valve from existing line set before installing R41 0A approved orifice or expansion valve Figure 9 Manifold Gauge Set Manifold guage sets used with systems charged with R410A refrigerant must be capable of handling the higher system operating pressures The gauges should be rated for use with pressures 1 800 on the high side and a low side of 30 vacuum to 250 psi with dampened speed to 500 psi Gauge hoses must be rated for use at up to 800 psi of pressure with a 4000 psi burst rating Liquid and Suction Line Service Valves The liquid line and suction line service valves See Figure 11 and service ports are used for leak teating evacuation charging and checking charge Each valve is equipped with a se
32. r blower control board Check thermostat wiring for open circuit 3 Evaporator coil is frozen Check for low suction pressure Check for excessively low thermostat setting Check evaporator airflow coil blockages or return air filter Check ductwork or registers for blockage 4 Faulty metering device Check TXV bulb installation size location and contact Check if TXV fixed orifice is stuck closed or defective 5 Condenser coil is dirty 6 Liquid line restriction filter drier blocked if present in system 7 Thermostat is malfunctioning Check thermostat sub base or wiring for short circuit Check thermostat installation location level 1 High head pressure Check high pressure switch if present in system Check if system is overcharged with refrigerant Check for non condensable in system 2 Condenser coil poor air circulation dirty blocked damaged 3 Condenser fan is not running Check fan capacitor Check fan wiring and connectors Check fan motor for failure or blockage 4 Return air duct has substantial leakage 5 If low pressure switch present in system check Flash Code 1 info Table 9 Issue 1008 Flash Codes cont pee Fault Description Troubleshooting Information Status ALERT Short Cycling 1 Thermostat demand signal is intermittent Yellow Compressor is 2 Time delay relay or control board defective Flash running 3 If high pressure switch present go to Flash Code 2 info Code
33. rmal Operating Pressures Model Temperature of the Outdoor Coil 7 1 Stage Low Capacity 2 Stage High Capacity C e o AK AKI KA KK L Liquid S Suction Values provided above are typical pressures Indoor unit matchup indoor air quality and indoor load will cause pressures to vary Table 8 506467 01 Issue 1008 Page 15 OPERATION Outdoor unit and indoor blower cycle on demand from the room thermostat When the thermostat blower switch is moved to the ON position the indoor blower operates continuously System Diagnostic Module 4AC16LT units contain a diagnostic module for trouble shooting air conditioning system failures By monitoring and analyzing data from the compressor and thermostat demand the module can accurately detect the cause of electrical and system related failure without any sensors If a system problem occurs a flashing LED indicator communicates the failure code LED Description POWER LED Green indicates voltage is present at the power connection of the module ALERT LED Yellow communicates an abnormal system condition through a unique flash code The ALERT LED will flash a number of times consecutively pause and then repeat the process The number of consecutive flashes correlates to a particular abnormal condition TRIP LED Red indicates there is a demand signal from the thermostat but no current to the compressor is de tected by the module The TRIP LED typically indicates
34. rvice port which has a factory installed Schrader valve Aservice port cap protects the Schrader valve from contamination and serves as the primary leak seal To Access the Schrader Port 1 Remove the service port cap with an adjustable wrench 2 Connect gauge to the service port 3 When testing is completed replace service port cap Tighten finger tight then an additional 1 6 turn To Open Liquid or Suction Line Service Valve Remove stem cap with an adjustable wrench Use service wrench with a hex head extension to back the stem out counterclockwise as far as it will go Use a 3 16 hex head extension for liquid line service valves and a 5 16 extension for suction line service valves Replace the stem cap Tighten finger tight then tighten an additional 1 6 turn 506467 01 Service Valve Valve Closed Stem Cap r Service Port E X Insert hex To outdoor coil wrench here Service Port Cap To indoor coil Schrader valve open to line set when valve is closed front seated valve front seated Insert hex Stem Cap To indoor coil Schrader Valve Valve Open Figure 10 To Close Liquid or Suction Line Service Valve 1 Remove the stem cap with an adjustable wrench 2 Use a service wrench with a hex head extension to turn the stem clockwise to seat the valve Tighten firmly 3 Replace the stem cap Tighten finger tight then tighten an additional 1 6 turn Suction Line
35. stem Noncondensables and water vapor combine with refrigerant to produce substances that corrode copper piping and compressor parts AWARNING Do not use a compressor to evacuate a sys tem Avoid deep vacuum operation Extremely low vacuums can cause internal arcing and compressor failure Danger of equipment damage Damage caused by deep vacuum operation will void warranty Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns Use an instrument that reads down to 50 microns 1 Connect the manifold gauge set to the service valve ports as follows e Low pressure gauge to suction line service valve e High pressure gauge to liquid line service valve Page 10 of 22 of 222 Connect micron gauge 3 506467 01 Connect the vacuum pump with vacuum gauge to the center port of the manifold gauge set Open both manifold valves and start vacuum pump Evacuate the line set and indoor unit to a minimum of 500 microns or lower During the early stages of evacuation it is desirable to close the manifold gauge valve at least once to determine if there is a rapid rise in pressure A rapid rise in pressure indicates a relatively large leak If this occurs the leak testing procedure must be repeated When 500 microns or lower is maintained close the manifold gauge valves turn off the vacuum pump and disconnect the manifold gauge center port hose from the vacuum pump Attach the mani
36. t be performed by a quali fied installer or service agency At the beginning of each cooling season the system should be checked as follows 1 2 Outdoor fan motor is pre lubricated and sealed No further lubrication is needed 3 Visually inspect connecting lines and coils for evi dence of oil leaks 4 Check wiring for loose connections 5 Check for correct voltage at unit with unit operating 6 Check amp draw outdoor fan motor Unit nameplate Actual NOTE If owner complains of insufficient cooling the unit should be gauged and refrigerant charge checked Refer to the Refrigerant Charging section on page 12 Indoor Coil 1 Clean coil if necessary 2 Check connecting lines and coils for evidence of oil leaks 3 Check condensate pan line and clean if necessary Indoor Unit 1 Clean or change filters 2 Adjust blower speed for cooling Measure the pressure drop over the coil to determine the correct blower CFM 3 Belt drive blowers Check belt for wear and proper tension 506467 01 Clean and inspect condenser coil Coil may be flushed with a water hose Be sure the power is off before using water to clean the coil Issue 1008 Check all wiring for loose connections Check for correct voltage at unit with unit operating Check amp draw on blower motor Unit nameplate Actual Page 20 Start Up and Performance Checklist Job Name Job No Job Location City Installer City
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