Goodman Mfg IO-367B Air Conditioner User Manual
Contents
1. CIRCULATING AIR AND FILTERS DucTworRK The supply duct from the unit through a wall may be installed without clearance However minimum unit clearances must be maintained see Clearances section The supply duct should be provided with an access panel large enough to inspect the air chamber downstream of the heat exchanger A cover should be tightly attached to prevent air leaks Ductwork dimensions are shown in the roof curb installation manual If desired supply and return duct connections to the unit may be made with flexible connections to reduce possible unit operating sound transmission VENTING NOTE Venting is self contained CONDENSATE DRAIN CONNECTION CONDENSATE DRAIN CONNECTION A 3 4 NPT drain connection is supplied for condensate pip ing An external trap must be installed for proper condensate drainage DRAIN CONNECTION UNIT DON NI 2 MINIMUM F 1 FLEXIBLE TUBING HOSE NA OR PIPE pen LIQUID SEAL IS REQUIRED i Drain Connection Install condensate drain trap as shown Use 3 4 drain line and fittings or larger Do not operate without trap HoRizoNTAL DRAIN Drainage of condensate directly onto the roof may be ac ceptable refer to local code It is recommended that a small drip pad of either stone mortar wood or metal be provided to prevent any possible damage to the roof CLEANING Due to the fact that drain pans in an2. DEFLECT 1 FORCE ON lt A t Span length inches C Center distance inches D Larger sheave diameter inches d Smaller sheave diameter inches DEFLECTION h Deflection height inches DRIVE BELT TENSION ADJUSTMENT MODEL High Static D 24 4 400 216 216 Percent voltage unbalance MUST NOT exceed 2 3 Percent Voltage Unbalance 100 x 1 896 FigLD Duct CONNECTIONS Verify that all duct connections are tight and that there is no air bypass between supply and return FiLTER SECTION CHECK Remove filter section access panels and check that filters are properly installed Note airflow arrows on filter frames BELT DRIVE BEARING CHECK Prior to energizing any fans check and make sure that all setscrews are tight so that bearings are properly secured to shafts For heat pump units the airflow must be adjusted so that the air temperature rise falls within the ranges given stated on Data Plate see Appendix A Blower Performance NOTE Section on high static tables may require a field motor change TENSION AND ALIGNMENT ADJUSTMENT Correct belt tension is very important to the life of your belt Too loose a belt will shorten its life too tight premature mo tor and bearing failure will occur Check you belt drive for adequate run in belt tension by measuring the force required to deflect the belt at the midpoint of the span length Belt tension force can be measured using a
3. 10 3 7 10 INSTALLATION INSTRUCTIONS FOR LIGHT COMMERCIAL SELF CONTAINED PACKAGED HEATING amp COOLING UNIT 15 amp 20 Ton CPC 9 Liste drecocuze THIS SYMBOL AS A SAFETY PRECAUTION ATTENTION INSTALLING PERSONNEL Prior to installation thoroughly familiarize yourself with this Installation Manual Observe all safety warnings During installation or repair caution is to be observed It is your responsibility to install the product safely and to educate the customer on its safe use All information contained herein is subject to change without notice These installation instructions cover the outdoor NOTE Please contact your distributor or installation of single package electric heating and our website for the applicable cooling units See the Specification Sheet applicable Specification Sheet referred to in to your model for information regarding accessories this manual 2010 Goodman Manufacturing Company L P 67B 5151 San Felipe Suite 500 Houston TX 77056 www goodmanmfg com www amana hac com d Index Replacement Parts 2 Safety Instructions 2 General Information 3 Unit Location c r 4 Clearances eio uu t
4. DURING THE FINISHING PHASES OF CONSTRUCTION ON A NEW STRUCTURE THIS TYPE OF USE MAY RESULT IN PREMATURE FAILURE OF THE UNIT DUE TO EXTREMELY LOW RETURN AIR TEMPERATURE AND EXPOSURE TO CORROSIVE OR VERY DIRTY ATMOSPHERES WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY us DAMAGE PERSONAL INJURY OR DEATH To PREVENT THE RISK OF PROPERTY DAMAGE PERSONAL INJURY OR DEATH DO NOT STORE COMBUSTIBLE MATERIALS OR USE GASOLINE OR OTHER FLAMMABLE LIQUIDS OR VAPORS IN THE VICINITY OF THIS APPLIANCE WARNING HIGH VOLTAGE INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE PERFORMED ONLY BY INDIVIDUALS MEETING AT A MINIMUM THE REQUIREMENTS OF AN ENTRY LEVEL TECHNICIAN AS SPECIFIED BY THE AIR CONDITIONING HEATING AND REFRIGERATION INSTITUTE AHRI ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH BACKGROUND MAY RESULT IN PRODUCT DAMAGE PERSONAL INJURY OR DEATH GENERAL INFORMATION To PREVENT PROPERTY DAMAGE PERSONAL INJURY OR DEATH DUE TO FIRE EXPLOSIONS SMOKE SOOT CONDENSATION ELECTRIC SHOCK OR CARBON MONOXIDE THIS UNIT MUST BE PROPERLY INSTALLED REPAIRED OPERATED AND MAINTAINED This unit is approved for outdoor installation ONLY To assure that your unit operates safely and efficiently it must be installed operated and maintained in accordance with these installation and operating i
5. belt tension gauge available through most belt drive manufacturers RECOMMENDED POUNDS OF FORCE PER BELT New V belts will drop rapidly during the first few hours of use Check tension frequently during the first 24 hours of opera tion Tension should fall between the minimum and maximum force To determine the deflection distance from a normal position measure the distance from sheave to sheave using a straightedge or a cord This is your reference line On mul tiple belt drives an adjacent undeflected belt can be used as a reference EVAPORATOR FAN ROTATION CHECK THREE PHASE MobELs ONLY Check that fan rotates clockwise when viewed from the drive side of unit and in accordance with rotation arrow shown on blower housing If it does not reverse the two incoming power cables at Single Point Power Block In this case repeat bear ing check Do not attempt to change load side wiring Internal wiring assures all motors and compressors will rotate in correct di rection once evaporator fan motor rotation check has been made ELECTRICAL INPUT CHECK Make preliminary check of evaporator fan ampere draw and verify that motor nameplate amps are not exceeded A final check of amp draw should be made upon completion of air balancing of the duct system see Appendix C REFRIGERATION SYSTEM CHECKS Ensure the hold down bolts on the compressor are secure and have not vibrated loose during shipment Check that vi bration grommets h
6. important to your safety that the unit has been properly grounded during installation Check ground lug connection in main control box for tightness prior to closing circuit breaker or disconnect switch Verify that supply voltage on line side of disconnect agrees with voltage on unit identification plate and is within the utilization voltage range as indicated in Ap pendix C Electrical Data System Voltage That nominal voltage value assigned to a circuit or system for the purpose of designating its voltage class Nameplate Voltage That voltage assigned to a piece of equipment for the purpose of designating its voltage class and for the purpose of defining the minimum and maximum voltage at which the equipment will operate Utilization Voltage The voltage of the line terminals of the equipment at which the equipment must give fully satisfac tory performance Once it is established that supply voltage will be maintained within the utilization range under all sys tem conditions check and calculate if an unbalanced condi tion exists between phases Calculate percent voltage un balance as follows Three Phase Models Only 2 MAXIMUM VOLTAGE DEVIATIONS 100 X FROM AVERAGE VOLTAGE 1 AVERAGE VOLTAGE 3 PERCENT VOLTAGE UNBALANCE HOW TO USE THE FORMULA EXAMPLE With voltage of 220 216 and 213 1 Average Voltage 220 216 213 649 3 216 2 Maximum Voltage Deviations from Average Voltage 220 216 4 SPAN LENGTH
7. is reported to the carrier The carrier is responsible for making prompt inspection of damage and for a thorough investigation of each claim The distributor or manufacturer will not accept claims from dealers for transportation damage NOTE When inspecting the unit for transportation damage remove all packaging materials Recycle or dispose of the packaging material according to local codes PRE INSTALLATION CHECKS Carefully read all instructions for the installation prior to in stalling unit Ensure each step or procedure is understood and any special considerations are taken into account be fore starting installation Assemble all tools hardware and supplies needed to complete the installation Some items may need to be purchased locally UNIT LOCATION ame TO PREVENT POSSIBLE EQUIPMENT DAMAGE PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT IMPORTANT NOTE Remove wood shipping rails prior to installation of the unit See important note under Roof Curb Installation Only ALL INSTALLATIONS IMPORTANT NoTE Unit should be energized 24 hours prior to compressor start up to ensure crankcase heater has sufficiently warmed the compressors Compressor dam age may occur if this step is not followed NOTE Appliance is shipped from factory for vertical duct application Proper installation of the unit ensures trouble free operation Improper installat
8. the temperature correspond ing to the compressor saturated discharge pressure Check that compressor RLA corresponds to values shown in Ap pendix C RLA draw can be much lower than values listed at low load conditions and low ambient condensing tempera tures Values in Appendix C can slightly exceed at high load conditions and high ambient condensing temperatures AIR FLOW ADJUSTMENTS The drive on the supply fan is typically set in the middle of the RPM range The drive motor sheave pitch diameter is field adjustable for the required airflow Refer to Drive Adjustments section below When the final adjustments are complete the current draw of the motor should be checked and compared to the full load current rating of the motor The amperage must not ex ceed the service factor stamped on the motor nameplate The total airflow must not be less than that required for op eration of the electric heaters or the furnace If an economizer is installed check the unit operating bal ance with the economizer at full outside air and at minimum outside air Upon completion of the air flow balancing we recommend replacing the variable pitched motor sheave with a properly sized fixed sheave A matching fixed sheave will provide longer belt and bearing life and vibration free opera tion Initially it is best to have a variable pitched motor sheave for the purpose of airflow balancing but once the balance has been achieved fixed sheaves mai
9. ANY PART OF THE CONTROL SYSTEM AND ANY GAS CONTROL HAVING BEEN UNDER WATER REPLACEMENT PARTS ORDERING PARTS When reporting shortages or damages or ordering repair parts give the complete unit model and serial numbers as stamped on the units nameplate Replacement parts for this appliance are available through your contractor or local distributor For the location of your nearest distributor consult the white business pages the yellow page section of the local telephone book or contact CONSUMER AFFAIRS GOODMAN MANUFACTURING COMPANY L P 7401 SECURITY WAY HOUSTON TEXAS 77040 877 254 4729 SAFETY INSTRUCTIONS To THE INSTALLER Before installing this unit please read this manual to familiarize yourself on the specific items which must be adhered to including maximum external static pressure to unit air temperature rise minimum or maximum CFM and motor speed connections Keep this literature in a safe place for future reference caution SHEET METAL PARTS SCREWS CLIPS AND SIMILAR ITEMS INHERENTLY HAVE SHARP EDGES AND IT IS NECESSARY THAT THE INSTALLER AND SERVICE PERSONNEL EXERCISE CAUTION DO NOT CONNECT TO OR USE ANY DEVICE THAT IS NOT DESIGN CERTIFIED BY GOODMAN FOR USE WITH THIS UNIT SERIOUS PROPERTY DAMAGE PERSONAL INJURY REDUCED UNIT PERFORMANCE AND OR HAZARDOUS CONDITIONS MAY RESULT FROM THE USE OF SUCH NON APPROVED DEVICES A WARNING THIS UNIT MUST NOT BE USED AS A CONSTRUCTION HEATER
10. BER Downshot MODEL NUMBER Downshot 5250 5250 EHK7 31 5250 5250 5250 EHK7 46 5250 5250 5250 EHK7 60 5250 EHK3 31 EHK4 31 EHK7 31 EHK3 46 EHK4 46 EHK7 46 EHK3 60 EHK4 60 EHK7 60 EHK3 75 EHK4 75 EHK7 75 When using electric heat kit use of the single point kit installed in the unit is required to meet UL requirements A ATTENTION INSTALLING PERSONNEL Use only the heater kit specified for each model as dictated by the table above 18 APPENDIX C UNIT DIMENSIONS a e ej RETURN SUPPLY VERTICAL DISCHARGE TOP VIEW 19 2010 Goodman Manufacturing Company L P 5151 San Felipe Suite 500 Houston TX 77056 www goodmanmfg com www amana hac com 20
11. EVENT SEVERE DAMAGE TO THE BOTTOM OF THE UNIT DO NOT FORK LIFT UNIT AFTER WOOD STRUTS HAVE BEEN REMOVED Bring condenser end of unit into alignment with the curb With condenser end of the unit resting on curb member and using curb as a fulcrum lower opposite end of the unit until entire unit is seated on the curb When a rectangular cantilever curb is used care should be taken to center the unit Check for proper alignment and orientation of supply and return openings with duct RiGGING REMOVAL Ac TO PREVENT DAMAGE TO THE UNIT DO NOT ALLOW CRANE HOOKS AND SPREADER BARS TO REST ON THE ROOF OF THE UNIT Remove spreader bars lifting cables and other rigging equip ment ELECTRICAL WIRING WARNING HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH am HIGH VOLTAGE TO AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK DO NOT TAMPER WITH FACTORY WIRING THE INTERNAL POWER AND CONTROL WIRING OF TH SE UNITS ARE FACTORY INSTALLED AND HAVE BEEN THOROUGHLY TESTED PRIOR TO SHIPMENT CONTACT YOUR LOCAL REPRESENTATIVE IF ASSISTANCE IS REQUIRED cm TO PREVENT DAMAGE TO THE WIRING PROTECT WIRING FROM SHARP EDGES FOLLOW NATIONAL ELECTRICAL CODE AND ALL LOCAL CODES AND ORDINANCES DO NOT ROUTE WIRES THROUGH REMOVABLE ACCESS PANELS au CONDUIT AND FITTINGS MU
12. MOVE FORK HOLE BRACKETS BOARDS AND SHIPPING BRACE FROM BOTTOM OF UNIT BEFORE PLACING UNIT ONTO CURB 1 Remove wooden struts and shipping brace per installation instructions The struts are located in the fork holes and are used to protect the unit from damage while lifting with forks The shippping brace is located underneath the unit under compressors Also remove the fork hole brackets as shown in the following figure 2 Locate and remove the end brackets as shown below LIFT OVERAPPROXIMATE CENTER OF UNIT BAI El SPREADER BARS MUST BE USED WITH 6 LIFTING STRAPS THAT E LESS ARE LESS THAN 1 FEET LONG REMOVE 2 BRACKETS ON EACH END TO REMOVE REMOVE SHIPPING BRACE WOODEN STRUTS N BOTTOM VIEW OF UNIT X REMOVE 2 BRACKETS ON EACH END TO 3 Lift unit per the Rigging Details section of this manual observing all warnings and cautions When unit is lifted boards and shipping brace will drop if screws have been removed To avoid injury STAND CLEAR 4 Dispose of the boards and brace appropriately Curb installations must comply with local codes and should be done in accordance with the established guidelines of the National Roofing Contractors Association Proper unit installation requires that the roof curb be firmly and permanently attached to the roof structure Check for adequate fastening method prior to setting the unit on the curb Full perimeter roof curbs are available from the factory
13. NLY BY INDIVIDUALS MEETING THE REQUIREMENTS OF AN ENTRY LEVEL TECHNICIAN AS i SPECIFIED BY THE AIR CONDITIONING AND REFRIGERATION INSTITUTE ARI ATTEMPTING TO INSTALL OR REPAIR THIS UNIT WITHOUT SUCH BACKGROUND MAY RESULT IN PRODUCT DAMAGE PERSONAL INJURY OR DEATH THE FOLLOWING INFORMATION IS FOR USE BY QUALI FIED SERVICE AGENCY ONLY OTHERS SHOULD NOT ATTEMPT TO SERVICE THIS EQUIPMENT Common Causes of Unsatisfactory Operation of Heat Pum on the Heating Cycle INADEQUATE AIR VoLUME THROUGH INDOOR CoiL When a heat pump is in the heating cycle the indoor coil is functioning as a condenser The return air filter must always be clean and sufficient air volume must pass through the indoor coil to prevent excessive discharge pressure and high pressure cut out OUTSIDE Air INTO RETURN Duct Do not introduce cold outside air into the return duct of a heat pump installation Do not allow air entering the indoor coil to drop below 65 F Air below this temperature will cause low discharge pressure thus low suction pressure and exces sive defrost cycling resulting in low heating output It may also cause false defrosting UNDERCHARGE An undercharged heat pump on the heating cycle will cause low discharge pressure resulting in low suction pressure and frost accumulation on the outdoor coil Poor TERMINATING SENSOR CONTACT The unit s defrost terminating sensor must make good ther mal contact with the out
14. PERSONAL INJURY DUE TO FIRE USE ONLY COPPER CONDUCTORS caution LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION VERIFY PROPER OPERATION AFTER SERVICING NOTE A weather tight disconnect switch properly sized for the unit total load must be field installed An external field supplied disconnect may be mounted on the exterior panel Ensure the data plate is not covered by the field supplied disconnect switch Some disconnect switches are not fused Protect the power leads at the point of distribution in accordance with the unit s data plate The unit must be electrically grounded in accordance with local codes or in the absence of local codes with the latest edition of the National Electrical Code ANSI NFPA 70 A ground lug is provided for this purpose Size grounding conductor in accordance with Table 250 95 of the National Electrical Code Do not use the ground lug for connecting a neutral conductor Connect power wiring to the Single Point Power block This terminal block is located within the main control box Line voltage connects to middle contactor on 460v and 575v Gas Packs Ground Lug Power Block Coolers amp 230V Gas Packs Only Line voltage connects to power block on Coolers and the 230v Gas Packs Low Voltage Terminal Strip Field wiring enters from this direction T
15. ROOF TOP DUCT CONNECTIONS Install all duct connections on the unit before placing the unit on rooftop RIGGING DETAILS To PREVENT PROPERTY DAMAGE THE UNIT SHOULD REMAIN IN AN UPRIGHT POSITION DURING ALL RIGGING AND MOVING OPERATIONS To FACILITATE LIFTING AND MOVING WHEN A CRANE IS USED PLACE THE UNIT IN AN ADEQUATE CABLE SLING Amm DO NOT LIFT UNITS TWO AT A TIME PROVISIONS FOR FORKS HAVE BEEN INCLUDED IN THE UNIT BASE FRAME MINIMUM FORK LENGTH IS 72 TO PREVENT DAMAGE TO THE UNIT Provisions for forks have been included in the unit base frame No other fork locations are approved To PREVENT POSSIBLE EQUIPMENT DAMAGE PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT Unit must be lifted by the four lifting holes located at the base frame corners Lifting cables should be attached to the unit with shackles The distance between the crane hook and the top of the unit must not be less than 60 Two spreader bars must span over the unit to prevent damage to the cabinet by the lift cables Spreader bars must be of sufficient length so that cables do not come in contact with the unit during transport Remove wood struts mounted beneath unit base frame before setting unit on roof curb These struts are intended to protect unit base frame from fork lift damage Removal is accomplished by extracting the sheet metal retainers and pulling the str
16. ROPER INSTALLATION ADJUSTMENT ALTERATION SERVICE OR MAINTENANCE REFER TO THIS MANUAL FOR ADDITIONAL ASSISTANCE OR INFORMATION CONSULT A QUALIFIED INSTALLER SERVICE AGENCY OR THE GAS SUPPLIER CTO SHEET METAL PARTS SCREWS CLIPS AND SIMILAR ITEMS INHERENTLY HAVE SHARP EDGES AND IT IS NECESSARY THAT THE INSTALLER AND SERVICE PERSONNEL EXERCISE CAUTION Your Self Contained Packaged Air Conditioner and Heat Pump should operate for many years without excessive service calls if the unit is installed properly However it is recommended that the homeowner inspect the unit before a seasonal start up The coils should be free of debris so adequate airflow is achieved The return and supply registers should be free of any obstructions The filters should be cleaned or replaced These few steps will help to keep the product up time to a maximum The Service section that follows should help in identifying problems if the unit does not operate properly FILTERS TO PREVENT PROPERTY DAMAGE DUE TO FIRE AND LOSS OF EQUIPMENT EFFICIENCY OR EQUIPMENT DAMAGE DUE TO DUST AND LINT BUILD UP ON INTERNAL PARTS NEVER OPERATE UNIT WITHOUT AN AIR FILTER INSTALLED IN THE RETURN AIR SYSTEM Every application may require a different frequency of replace ment of dirty filters Filters must be replaced at least every three 3 months during operating seasons Dirty filters are the most common cause of inadequate heat ing or cooling performan
17. ST BE WEATHER TIGHT TO PREVENT WATER ENTRY INTO THE BUILDING For unit protection use a fuse or HACR circuit breaker that is in excess of the circuit ampacity but less than or equal to the maximum overcurrent protection device DO NOT EXCEED THE MAXIMUM OVERCURRENT DEVICE SIZE SHOWN ON UNIT DATA PLATE All line voltage connections must be made through weather proof fittings All exterior power supply and ground wiring must be in approved weatherproof conduit The main power supply wiring to the unit and low voltage wiring to accessory controls must be done in accordance with these instructions the latest edition of the National Electrical Code ANSI NFPA 70 and all local codes and ordinances All field wiring shall conform with the temperature limitations for Type T wire 63 F 35 C rise The main power supply shall be three phase three wire The unit is factory wired for the voltage shown on the unit s data plate NOTE If supply voltage is 208V all leads on primary of trans former TRANS1 must be moved from the 230V to the 208V tap Main power wiring should be sized for the minimum wire ampacity shown on the unit s data plate Size wires in accor dance with the ampacity tables in Article 310 of the National Electrical Code If long wires are required it may be neces sary to increase the wire size to prevent excessive voltage drop Wires should be sized for a maximum of 3 voltage drop To AVOID PROPERTY DAMAGE OR
18. TION SHOWN See the manual shipped with the roof curb for assembly and installation instructions CLEARANCES 36 minimum roof overhang UNIT CLEARANCES Adequate clearance around the unit should be kept for safety service maintenance and proper unit operation A total clear ance of 75 on the main control panel side of the unit is rec ommended to facilitate possible fan shaft coil electric heat and gas furnace removal Aclearance of 48 is recommended on all other sides of the unit to facilitate possible compressor removal to allow service access and to insure proper venti lation and condenser airflow The unit must not be installed beneath any obstruction The unit should be installed re mote from all building exhausts to inhibit ingestion of exhaust air into the unit fresh air intake Insulated y Panels Roof Curb Installation ROOF CURB POST INSTALLATION CHECKS After installation check the top of the curb duct connection frame and duct flanges to make sure gasket has been ap plied properly Gasket should be firmly applied to the top of the curb perimeter duct flanges and any exposed duct con nection frame If gasket is loose re apply using strong weather resistant adhesive PROTRUSION Inspect curb to ensure that none of the utility services elec tric routed through the curb protrude above the curb m IF PROTRUSIONS EXIST DO NO ATTEMPT TO SET UNIT ON CURB
19. Turn the temperature setting to the highest position stopping the unit The indoor blower will continue to run for 65 seconds Turn the thermostat system switch to OFF and disconnect all power when servicing the unit HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH Sli FINAL System CHECKS 10 Check to see if all supply and return air grilles are adjusted and the air distribution system is balanced for the best compromise between heating and cooling 11 Check for air leaks in the ductwork See Sections on Air Flow Adjustments 12 Make sure the unit is free of rattles and the tubing in the unit is free from excessive vibration Also make sure tubes or lines are not rubbing against each other or sheet metal surfaces or edges If so correct the trouble 13 Set the thermostat at the appropriate setting for cooling and heating or automatic change over for normal use 14 Be sure the Owner is instructed on the unit operation filter servicing correct thermostat operation etc REFRIGERATION PERFORMANCE CHECK Under normal summertime full load operating conditions superheat should be between 8 F and 12 F and sub cooling measured at the condenser outlet should be 15 F nominal A 25 F to 35 F temperature difference should exist between the entering condenser air and
20. and are shipped unassembled Field assembly squaring level ing and mounting on the roof structure are the responsibility of the installing contractor All required hardware necessary for the assembly of the sheet metal curb is included in the curb accessory ey NM TO PREVENT POSSIBLE EQUIPMENT DAMAGE PROPERTY DAMAGE PERSONAL INJURY OR DEATH THE FOLLOWING BULLET POINTS MUST BE OBSERVED WHEN INSTALLING THE UNIT e Sufficient structural support must be determined prior to locating and mounting the curb and package unit Ductwork must be constructed using industry guidelines The duct work must be placed into the roof curb before mounting the package unit Our full perimeter curbs include duct connection frames to be assembled with the curb Cantilevered type curbs are not available from the factory Curb insulation cant strips flashing and general roofing material are furnished by the contractor The curbs must be supported on parallel sides by roof mem bers The roof members must not penetrate supply and re turn duct opening areas as damage to the unit might occur NOTE The unit and curb accessories are designed to allow vertical duct installation before unit placement Duct installation after unit placement is not recommended am ALL CURBS LOOK SIMILAR TO AVOID INCORRECT CURB POSITIONING CHECK JOB PLANS CAREFULLY AND VERIFY MARKINGS ON CURB ASSEMBLY INSTRUCTIONS MAY VARY IN CURB STYLES AND SUPERSEDES INFORMA
21. ave been installed Visually check all pip ing and clamps The entire refrigeration system has been factory charged and tested making it unnecessary to field charge Factory charges are shown in Appendix C and on the unit nameplate Install service manifold hoses Gauges should read satura tion pressure corresponding to ambient temperature Charge should be checked to obtain 12 to 15 of sub cooling per system i e compressor circuits Start Up PROCEDURE AND CHECKLIST Begin with power turned off at all disconnects 1 Turn thermostat system switch to Cool and fan switch to Auto and turn temperature setting as high as it will go Inspect all registers and set them to the normal open position Turn on the electrical supply at the disconnect 4 Turn the fan switch to the ON position The blower should operate after a 7 second delay Turn the fan switch to Auto position The blower should stop after a 65 second delay Slowly lower the cooling temperature until first stage COOL LOW COOL starts The blower both fans and first stage compressor should now be operating Allow the unit to run 10 minutes make sure cool air is being supplied by the unit Lower the cooling temperature further until second stage COOL HIGH COOL starts The blower both fans and both compressors should now be operating Allow the unit to run 10 minutes make sure cool air is being supplied by the unit
22. ce Filter inspection should be made at least every two months more often if necessary because of local conditions and usage Dirty throwaway filters should be discarded and replaced with a new clean filter Disposable return air filters are supplied with this unit See the unit Specification Sheet or Technical Manual for the cor rect size and part number To remove the filters remove the filter access panel on return side of the unit CABINET FinisH MAINTENANCE Use a fine grade automotive wax on the cabinet finish to maintain the finish s original high luster This is especially important in installations with extended periods of direct sun light CLEAN OursiDE CoiL QUALIFIED SERVICER ONLY The coil with the outside air flowing over it should be inspected annually and cleaned as frequently as necessary to keep the finned areas free of lint hair and debris CONDENSER EVAPORATOR AND INDUCED DRAFT Motors Bearings on the air circulating blower motor condenser mo tor and the combustion fan motor are permanently lubricated No additional oiling is required LUBRICATION The fan shaft bearings the 1 to 2 HP supply fan motors the condenser fan motors and compressors are permanently lu bricated FUNCTIONAL PARTS Refer to the unit Parts Catalog for a list of functional parts Parts are available from your distributor SERVICE EMEN LL RN HIGH VOLTAGE INSTALLATION AND REPAIR OF THIS UNIT SHOULD BE PERFORMED O
23. door coil tubing Poor contact may not terminate the unit s defrost cycle quickly enough to pre vent the unit from cutting out on high discharge pressure APPENDIX A BLOWER PERFORMANCE DATA BELT DRIVE STANDARD CPC180 STANDARD BELT DRIVE NOTES High static airflow requires installation of high static kit HSKT240 or factory built High Static model Unit factory shipped with sheave set at 2 5 turns open Air flow table represent dry coil with filters installed SCFM correction factor for wet coil is 4 16 APPENDIX A BLOWER PERFORMANCE DATA BELT DRIVE HIGH STATIC CPC180 HIGH STATIC BELT DRIVE NOTES High static airflow requires installation of high static kit HSKT240 or factory built High Static model Unit factory shipped with sheave set at 2 5 turns open Air flow table represent dry coil with filters installed SCFM correction factor for wet coil is 4 17 APPENDIX B ELECTRICAL DATA ELECTRICAL DATA VOLTAGE LARGER SMALLER OD FAN MOTORS ID FAN MOTOR VOLTAGE LIMITATIONS COMPRESSOR COMPRESSOR ea ID MOTOR MODELS APPL NAMEPLATE Jo ou a oy ae Low m Peele nbn Eben or ee ELECTRICAL DATA MODELS a LIMITATIONS ea ea ID MOTOR APpL MOTOR un wx as ma ima av we rua Cw n4 sus oe em 2 e mo s om one NOTE See unit nameplate for proper overcurrent protection UNIT HEATER KIT MINIMUM CFM HEATER KIT MINIMUM CFM HEATER KIT MINIMUM CFM MODEL NUMBER Downshot MODEL NUM
24. eet rete des ere 6 Roof Curb Post Installation Checks 6 Roof Top Duct Connections 6 Rigging Details J 7 Electrical Wiring 8 Circulating Air and Filters 10 VENIDO yuku daras Ca 10 Condensate Drain Connection 10 Startup Adjustments and Checks 10 Air flow Adjustments 13 Motor Sheave Adjustments 14 Maintenance eeeeeeeeeeerner ener 14 SERVICO iii 15 Appendix A Blower Performance Data 16 Belt Drive Standard 16 Belt Drive High Static 17 Appendix B Electrical Data 18 Appendix C Unit Dimensions 19 THIS PRODUCT CONTAINS OR PRODUCES A CHEMICAL OR CHEMICALS WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM To AVOID PROPERTY DAMAGE PERSONAL INJURY OR DEATH DO NOT USE THIS UNIT IF ANY PART HAS BEEN UNDER WATER IMMEDIATELY CALL A QUALIFIED SERVICE TECHNICIAN TO INSPECT THE FURNACE AND TO REPLACE
25. has been re placed the operation of the unit must be checked Check unit operation as outlined in the following instructions If any sparking odors or unusual sounds are encountered shut off electrical power and recheck for wiring errors or ob structions in or near the blower motors Duct covers must be removed before operating unit The Startup Adjustments and Checks procedure provides a step by step sequence which if followed will assure the proper startup of the equipment in the minimum amount of time Air balancing of duct system is not considered part of this procedure However it is an important phase of any air conditioning system startup and should be performed upon completion of the Startup Adjustments and Checks proce dure The Startup Adjustments and Checks procedure at outside ambients below 55 F should be limited to a readi ness check of the refrigeration system with the required final check and calibration left to be completed when the outside ambient rises above 55 F TooLs REQUIRED Refrigeration gauge and manifold Voltmeter Clamp on ammeter Ohmmeter Test lead Minimum 16 AWG with insulated alligator clips Air temperature measuring device General refrigeration mechanics tools TEMPORARY HEATING OR COOLING If the unit is to be used for temporary heating or cooling a Startup Adjustments and Checks must first be performed in accordance with this manual Failure to comply with this
26. hermostat wiring for all units connect to low voltage strip POWER AND LOW VOLTAGE BLOCK LOCATIONS ame FAILURE OF UNIT DUE TO OPERATION ON IMPROPER LINE VOLTAGE OR WITH EXCESSIVE PHASE UNBALANCE CONSTITUTES PRODUCT ABUSE AND WILL VOID YOUR WARRANTY AND MAY CAUSE SEVERE DAMAGE TO THE UNIT ELECTRICAL COMPONENTS Areas Without Convenience Outlet It is recommended that an independent 115V power source be brought to the vicinity of the roof top unit for portable lights and tools used by the service mechanic UNITS INSTALLED ON Roor Tops Main power and low voltage wiring may enter the unit through the side or through the roof curb Install conduit connectors at the desired entrance locations External connectors must be weatherproof All holes in the unit base must be sealed including those around conduit nuts to prevent water leak age into building All required conduit and fittings are to be field supplied Supply voltage to roof top unit must not vary by more than 10 of the value indicated on the unit s data plate Phase voltage unbalance must not exceed 2 Contact your local power company for correction of improper voltage or phase unbalance r LOW VOLTAGE HIGH VOLTAGE ENTRANCE ENTRANCE D y de Jn 3 2 5 3 12 118 lt ELECTRICAL ENTRANCE LOCATIONS Unit is equipped with Si
27. iolation of any code or regulation The mechanical installation of the packaged roof top units consists of making final connections between the unit and building services supply and return duct con nections and drain connections if required The internal systems of the unit are completely factory installed and tested prior to shipment Units are generally installed on a steel roof mounting curb assembly which has been shipped to the job site for installa tion on the roof structure prior to the arrival of the unit The model number shown on the unit s identification plate identi fies the various components of the unit such as refrigeration tonnage heating input and voltage Carefully inspect the unit for damage Any bolts or screws which may have loosened in transit must be re tightened In the event of damage the receiver should 1 Make notation on delivery receipt of any visible damage to shipment or container 2 Notify carrier promptly and request an inspection 3 In case of concealed damage carrier should be notified as soon as possible preferably within 5 days 4 File the claim with the following supporting documents a Original Bill of Lading certified copy or indemnity bond b Original paid freight bill or indemnity in lieu thereof c Original invoice or certified copy thereof showing trade and other discounts or reductions d Copy of the inspection report issued by carrier representative at the time damage
28. ion can result in problems ranging from noisy operation to property or equipment damages danger ous conditions that could result in injury or personal property damage and could void the warranty Give this booklet to the user and explain it s provisions The user should retain these instructions for future reference For proper operation and condensate drainage the unit must be mounted level The flue outlet hood must be at least three feet above any forced air inlet located within ten feet The economizer manual fresh air intake motorized fresh air intake and combustion air inlet mounted on the unit are not affected by this restriction Do not locate the unit in an area where the outdoor air i e combustion air for the unit will be frequently contaminated by compounds containing chlorine or fluorine Common sources of such compounds include swimming pool chemicals and chlorine bleaches paint stripper adhesives paints varnishes sealers waxes which are not yet dried and solvents used during construction and remodeling Various commercial and industrial processes may also be sources of chlorine fluorine compounds To avoid possible illness or death of the building occupants do NOT locate outside air intake device economizer manual fresh air intake motorized fresh air intake too close to an exhaust outlet gas vent termination or plumbing vent outlet For specific distances required consult local codes Allow mi
29. ngle Point Power Block and Low Volt age Block Low VoLTAGE CONTROL WIRING 1 A24V thermostat must be installed for unit operation It may be purchased with the unit or field supplied Thermostats may be programmable or electromechanical as required 2 Locate thermostat or remote sensor in the conditioned space where it will sense average temperature Do not locate the device where it may be directly exposed to supply air sunlight or other sources of heat Follow installation instructions packaged with the thermostat 3 Use 18 AWG wire for 24V control wiring runs not exceeding 75 feet Use 16 AWG wire for 24V control wiring runs not exceeding 125 feet Use 14 AWG wire for 24V control wiring runs not exceeding 200 feet Low voltage wiring may be National Electrical Code NEC Class 2 where permitted by local codes 4 Route thermostat wires from sub base terminals to the unit Control wiring should enter through the duct panel dimple marks entrance location Connect thermostat and any accessory wiring to low voltage terminal block TB1 in the main control box NOTE Field supplied conduit may need to be installed depending on unit curb configuration Use 18 AWG solid conductor wire whenever connecting thermostat wires to terminals on sub base DO NOT use larger than 18 AWG wire A transition to 18 AWG wire may be required before entering thermostat sub base Red REM Optional field installed heat connections CPC240
30. nimum clearances from the enclosure for fire protection proper operation and service access see Unit Clearances These clearances must be permanently maintained Whenthe unitis heating the temperature of the return air entering the unit must be between 50 F and 100 F GROUND LEVEL INSTALLATIONS ONLY When the unit is installed on the ground adjacent to the building a level concrete or equal base is recommended Prepare a base that is 3 larger than the package unit footprint and a minimum of 3 thick The base should also be located where no runoff of water from higher ground can collect in the unit Roor TOP INSTALLATIONS ONLY To avoid possible property damage or personal injury the roof must have sufficient structural strength to carry the weight of the unit s and snow or water loads as required by local codes Consult a structural engineer to determine the weight capabilities of the roof The unit may be installed directly on wood floors or on Class A Class B or Class C roof covering material To avoid possible personal injury a safe flat surface for service personnel should be provided As indicated on the unit s data plate a minimum clearance of 36 to any combustible material is required on the access side of the unit All combustible materials must be kept out of this area This 36 clearance must also be maintained to insure proper combustion air flow The combustion air intake must not be blocked for a
31. nstructions all local building codes and ordinances EPA REGULATIONS IMPORTANT THE UNITED STATES ENVIRONMENTAL PROTECTION AGENCY EPA HAS ISSUED VARIOUS REGULATIONS REGARDING THE INTRODUCTION AND DISPOSAL OF REFRIGERANTS IN THIS UNIT FAILURE TO FOLLOW THESE REGULATIONS MAY HARM THE ENVIRONMENT AND CAN LEAD TO THE IMPOSITION OF SUBSTANTIAL FINES BECAUSE REGULATIONS MAY VARY DUE TO PASSAGE OF NEW LAWS WE SUGGEST A CERTIFIED TECHNICIAN PERFORM ANY WORK DONE ON THIS UNIT SHOULD YOU HAVE ANY QUESTIONS PLEASE CONTACT THE LOCAL OFFICE OF THE EPA NATIONAL CODES This product is designed and manufactured to permit instal lation in accordance with National Codes It is the installer s responsibility to install the product in accordance with Na tional Codes and or prevailing local codes and regulations The heating and cooling capacities of the unit should be greater than or equal to the design heating and cooling loads of the area to be conditioned The loads should be calculated by an approved method or in accordance with ASHRAE Guide or Manual J Load Calculations published by the Air Condi tioning Contractors of America Obtain from American National Standards Institute 1430 Broadway New York NY 10018 System design and installation should also where applicable follow information presented in accepted industry guides such as the ASHRAE Handbooks The manufacturer assumes no responsibility for equipment installed in v
32. ntain alignment and minimize vibration more effectively For direct drive units move green wire for fan NOTE Never run CFM below 350 CFM per ton evaporator freezing or poor unit performance is possible MOTOR SHEAVE ADJUSTMENTS VL Vm amp 2vp VARIABLE PitcH KEY TYPE Motor SHEAVES The driving and driven motor sheaves should be in align ment with each other and the shafts parallel VL amp VM SHEAVES ADJUSTMENT 1 Loosen set screw B using a 5 32 Allen key 2 Making half or full turns from closed position adjust sheave pitch diameter for desired speed DO NOT OPEN MORE THAN SIX FULL TURNS 3 Tighten set screw B securely over flat 4 Carefully put on belts and adjust belt tension DO NOT FORCE BELTS OVER GROOVES 5 Ensure all keys are in place and the set screws tight before starting drive Recheck set screws and belt tension after 24 hours service NOTE Future adjustments should be made by loosening the belt tension and increasing or decreasing the pitch diameter of the sheave by half or full turns as required Readjust belt tension before starting drive NOTE Do not operate sheave with flange projecting beyond the hub end MAINTENANCE Ae HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PERSONAL INJURY OR DEATH di ame To PREVENT PERSONAL INJURY OR DEATH DUE TO IMP
33. ny reason including blockage by snow Adequate clearances from the unit to any adjacent public walkways adjacent buildings building openings or openable windows must be maintained in accordance with National Codes Unit PRECAUTIONS Do not stand or walk on the unit Except for holes in the wiring entrances see Figure below do not drill holes anywhere in panels or in the base frame of the unit Unit access panels provide structural support E B FE LOW VOLTAGE HIGH VOLTAGE ENTRANCE ENTRANCE Ni 1218 fem ELECTRICAL ENTRANCE LOCATIONS Do notremove any access panels until unit has been installed on roof curb or field supplied structure Do not roll unit across finished roof without prior approval of owner or architect Do not skid or slide on any surface as this may damage unit base The unit must be stored on a flat level surface Protect the condenser coil because it is easily damaged Roor Curs INSTALLATIONS ONLY Before installing this unit IMPORTANT NOTE This unit has been equipped with a ship ping brace under the compressor section that MUST BE RE MOVED before installing the unit on a roof curb Please follow the instructions below to remove brace caution WHEN UNIT IS SUSPENDED BOARDS AND SHIPPING BRACE WILL DROP WHEN SCREWS ARE REMOVED TO PREVENT PERSONAL INJURY STAND CLEAR RE
34. requirement will void the warranty After the machines are used for temporary heating or cooling inspect the coils fans and motors for unacceptable levels of construction dust and dirt and install new filters CONTRACTOR RESPONSIBILITY The installing contractor must be certain that All supply and return air ductwork is in place and corresponds with installation instructions All thermostats are mounted and wired in accordance with installation instructions All electric power all gas hot water or steam line connections and the condensate drain installation have been made to each unit on the job These main supply lines must be functional and capable of operating all units simultaneously Roor CURB INSTALLATION CHECK Inspect the roof curb for correct installation The unit and curb assembly should be level Inspect the flashing of the roof mounting curb to the roof especially at the corners for good workmanship Also check for leaks around gaskets Note any deficiencies in a separate report and forward to the contrac tor OBsTRUCTIONS FAN CLEARANCE AND WIRING Remove any extraneous construction and shipping materi als that may be found during this procedure Rotate all fans manually to check for proper clearances and that they rotate freely Check for bolts and screws that may have jarred loose during shipment to the job site Retighten if necessary Re tighten all electrical connections PRE STARTUP PRECAUTIONS It is
35. uts through the base of the unit Refer to rigging label on the unit Important If using bottom discharge with roof curb duct work should be attached to the curb prior to installing the unit Ductwork dimensions are shown in Roof Curb Installa tion Instructions Refer to the Roof Curb Installation Instructions for proper curb installation Curbing must be installed in compliance with the National Roofing Contractors Association Manual Lower unit carefully onto roof mounting curb While rigging unit center of gravity will cause condenser end to be lower than supply air end SEE CAUTION BELOW caution WHEN UNIT IS SUSPENDED BOARDS AND SHIPPING BRACE WILL DROP WHEN SCREWS ARE REMOVED TO PREVENT PERSONAL INJURY STAND CLEAR REMOVE FORK HOLE BRACKETS BOARDS AND SHIPPING BRACE FROM BOTTOM OF UNIT BEFORE PLACING UNIT ONTO CURB To assist in determining rigging requirements unit weights are shown as follows A C ATA Er Es por A COMPRESSOR 1 i Y m M Y O O cc z cc T o c 2 cc Lu o O o aj lt gt ul COMPRESSOR 2 MEE AAA C Bl X gt D CORNER amp CENTER OF GRAVITY LOCATIONS CPC Weights Ibs 15 Tons CPC Weights Ibs 20 Tons Dxwees e NOTE These weights are without accessories installed caution TO PR
36. y air conditioning unit will have some moisture in them algae and fungus will grow due to airborne bacteria and spores Periodic cleaning is necessary to prevent this build up from plugging the drain STARTUP ADJUSTMENTS AND CHECKS A HIGH VOLTAGE THE BUILDING ELECTRICAL GROUND BY USE OF THE GROUNDING TERMINAL PROVIDED OR OTHER ACCEPTABLE MEANS DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT To AVOID PERSONAL INJURY OR DEATH DUE TO ELECTRICAL SHOCK BOND THE FRAME OF THIS UNIT TO yi PRE STARTUP INSTRUCTIONS ANY TO PREVENT PROPERTY DAMAGE OR PERSONAL INJURY DO NOT START THE UNIT UNTIL ALL NECESSARY PRE CHECKS AND TESTS HAVE BEEN PERFORMED Prior to the beginning of Startup Adjustments and Checks procedures the following steps should be completed in the building THERMOSTAT Set the thermostat in the conditioned space at a point at least 10 F below zone temperature On cooling only models set the thermostat system switch on COOL and the fan switch on AUTO On heating cooling models set the thermostat system switch on COOL and the fan switch on AUTO NIGHT SETBACK THERMOSTAT OPTIONAL Set thermostat at a point at least 10 F below zone temperature Aw MOVING MACHINERY HAZARD To PREVENT POSSIBLE PERSONAL INJURY OR DEATH DISCONNECT POWER TO THE UNIT AND PADLOCK IN THE OFF POSITION BEFORE SERVICNG FANS HEATING STARTUP On new installations or if a major component
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