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Bolens BL 100/ BL 150 Trimmer User Manual

1. M AL IN Y R 410A MODELS 90 Thru 240 PD180 Thru 240 SS OS LZ DS TCU hb LEE EM 515 1 1 LL ABS DEA UM 1 J 2A1 280 D 4 NM OO 1 A Be we III A DU M ww I LL IA4 1 IL AM NM M b lI S LAADP M mm BE OO A EE EE ee O A 1 WW LLLA D 42 LL EE OC UZ EE 0 ae ee m LL 0 M WW U ll A LAM M LL Dill L mS LL M ISO uu U FL 7 5 20 Ton 60 Hertz TABLE OF CONTENTS Nomenclature 2 Electrical Dala es due ono XV ia 9 E LTD 2 Refrigerant 5 10 Renewal 222 008 00 2808 bebe te wee wbx 3 Piping And Electrical Connections 17 Agency 5 3 De 17 3 Crankcase 5 17 PAV CaA Dale sta ue eee 4 asd toe chet eee 18 Installation
2. Figure 2 Typical Rigging 430645 YIM D 0610 Power Wiring Check the available power and the unit nameplate for correct voltage Run the necessary number of properly sized wires to the unit Provide a disconnect switch if not included with the unit and fusing as required Factory disconnect is a fused disconnect breaker Route the conduit through the large knockout located near the electrical box See Table 5 for Electrical Data The disconnect switch may be bolted to the side of the unit but not to any of the removable panels which would interfere with access to the unit Make sure that no refrigerant lines will be punctured when mounting the disconnect switch and note that it must be suitable for outdoor installation All power and control wiring must be in accordance with National and Local electrical codes Control Wiring Route the necessary low voltage control wires from the Simplicity control board to the thermostat and also between the terminal blocks inside the heat pump and evaporator control boxes Refer to Figures 3 thru 6 for field wiring diagrams Compressors The scroll compressors used in this product are specifically designed to operate with R 410A Refrigerant and cannot be interchanged A CAUTION This system uses R 410A Refrigerant which operates at higher pressures than R 22 No other refrigerant may be used in this system The
3. See 7 000 23 000 7 000 37 000 2 933 1 664 58 500 RIGHT 2X 8 0 875 KNOCKOUT 2 1 375 KNOCKOUT 12 000 o 10 000 9090 9 of gt s nm 00 CD cb ds 5 4 132 2 382 LEFT 1 882 Figure 7 PCO090 PC120 Unit Dimensions NOTE Use System 1 piping dimensions when applying a PC090 120 model system Table 7 PCO090 PC120 Unit Height Dimensions Johnson Controls Unitary Products 15 430645 YIM D 0610 LEFT SYSTEM 2 SYSTEM 1 2X 1 375 KNOCKOUT 2X 0 875 KNOCKOUT PIPING DETAIL Figure 8 PC PD180 amp PC PD240 Unit Dimensions and Piping amp Electrical Dimensions NOTE Use System 1 piping dimensions when applying a PC180 240 model system Table 8 PC PD180 amp PC PD240 Unit Height Dimensions MODEL A PC180 44 5 PD180 44 5 PC240 50 0 PD240 50 0 16 Johnson Controls Unitary Products Table 9 Piping and Electrical Connection Sizes MODEL No Refrigeration Circuits Suction Line OD in 1 1 8 1 3 8 8 7 8 Liquid Line OD in Power Wiring Knockout Control Wiring Knockout Piping And Electrical Connections Piping connections are made from the rear of 7 5 thru 12 5 Ton units and from the front of 15 thru 20 Ton units Stubouts are provided on the suction and liquid line service valves Piping can be routed to the unit from the left or right side Electric
4. wanes ld 414905 83MOd Loc 3 321A30 9NIHUIM A8012V 4 53 1430 ONY ONIYIM 1YNO 1d0 j 9 S j Q 9 YOVIG 13 ddid dNfldLV dH LINA 9SNISNJON PO o A 08 Ll ov jJ Sv1 Johnson Controls Unitary Products iagram D iring Typical PC180 240 Heat Pump Wi Figure 19 32 V 6 mE j C 49 812 VA SL VA SL 235 LINN SIHL ONIDIAYSS 390138 LE dq PEE Il Il si 1 ud 09 123 2 10 N3dO NOILAVO an nis 2 2U A LII QVO I12V1 OL 2 128 WOYS LD3NNOD TOYLNOD LN3IGNY MO 803 y 01 vS2 QS quvOS TOYLNOD OL 3123NNOD 51 8 12 Q311V1SNI LON 51 YOLINON 5501 3SVHd v1 ALIOVdMV 1102812 NYOMI IN 77 77 77 mr Dore 3215 8 1102812 YO GNY 39503 803 31V1d3NVN LINN 335 5 9 FO 21 TVNINH3I LIOA 802 OL 3HIM 0 161 11 NO VNIWH3I 1101 PEE 8340 COR SW 902 Ol O 12 A802 803 110 802 NOILVYIdO LIOA 062 503 O3 1M KUOLI d v 9 962 19 6 um 18 82 3SvHd 319NIS AYVWIYd 031231084 471N383HN 38V SHOIOM 3SVHd 33NHl 3 9 ONI2IANJS 3137
5. 3 M 68 4191012 3 M4 69 18 692 31091 aav 1ON S3HSV1 v FAR T Dane 1004201 YOSSIYdNOD ISdH 53 5913 Garo e Q2SV ONILIVM TONINOD S3HSV1i 2 e oe 318 917189 109 HSV14 11192 u 622 NO 1VU3dO IWNYON 1938 LYV3H GO 18 t 1081NO2 32vV1d38 JYNTIVS TOYLNOD AQV31S NO 2 s 0 992 u 922 NOTIdIN2S30 3002 HSV14 ZAY 205 9 E 1 H GNYOS 1081NO2 NO Nid 9 NOILJJNNOJ 9014 1 34205 115 05 18 09 Mure G 61 1OYLNOD NO Nid OI AVZ NOILD3NNOD 9014 13320S 6S 6s QuvOg NO Nid L 2 NOILD3NNOD 9 14 1 34305 55 98 952 105 1OHINOO NO Nid NOILD3NNOD 9014 11 34205 015 5 0 TOYLNOD NO Nid ave o1 1 90147131308 c 281 E EE ION ONISYJAJY 010 3105 105 G EQ ray pag 1509330 211 28195 1081009 1809330 20 48 w2018 TVNIWH3L 2089 Av2_ 310d 01 42018 1 281 MT B MEET 8023 1 AuvITI 12V1 ZW 24 12V1NOO IN 3 1 0401 1VNOILdO 5501 3SVHd YOLINOW SHd 3v1 100 14 u34v3u8 1102312 23182 D 9 N31GHY MOT HDLIAS EU 0 1 Av2dH QN9dH 180 LN3IGNY MOT 8311081 02 e 65 MOD IS
6. C Standard Efficiency 2 Pipe R 410A D Standard Efficiency 4 Pipe R 410A Product Options Installation Options AA None Nominal Cooling Capacity MBH Due AB Phase Monitor None B Option 1 C Option 2 AC Coil Guard AE Phase Monitor Coil Guard LA Low Ambient S Options 5 LB Low Ambient Phase Monitor T Options 1 amp 5 LC Low Ambient Coil Guard LD Low Ambient Phase Monitor Options ___ Coil Guard Heat Type amp Nominal Heat Capacity 1 Disconnect LE Low Ambient Technicoat Cond Coil Cooling Only 2 Non Pwr d Conv Outlet LF Low Ambient Technicoat Cond Coil 5 Pwr d Conv Outlet Phase Monitor LG Low Ambient Technicoat Cond Coil Coil Guard LH Low Ambient Technicoat Cond Coil Phase Monitor Coil Guard TA Technicoat Condenser Coil TB Technicoat Condenser Coil Phase Monitor TC Technicoat Condenser Coil Coil Guard TE Technicoat Condenser Coil Coil Guard A Standard Motor 090 7 5 Ton 120 10 Ton 150 12 5 Ton D Options 1 amp 2 180 15 Ton 240 20 Ton Voltage 2 208 230 3 60 4 460 3 60 5 575 3 60 7 380 415 3 50 General m M CAUTION These condensing units are designed for outdoor installation on a roof or at ground level Every unit is completely piped and wired at the factory and is shipped ready for immediate installation Only the liquid and suction lines to the evaporator coil
7. 5 Sequence of 18 LilriltdllollS dae ed eae ea gon 5 Cooling Sequence Of Operation 18 EOCANOMs s 2 5 Heating Sequence of Operation 20 Clearances 7 Unit Control Board Option 23 5 1 7 Troubleshooting 23 8 Typical Wiring Diagrams 30 LIST OF TABLES 1 90 240 and PD180 240 Physical Data 4 7 9 PC120 Unit Height Dimensions 15 2 Unit Application 5 8 PC PD180 amp PC PD240 Unit Height Dimensions 16 3 Corner Weights amp Center of Gravity 6 9 Piping and Electrical Connection Sizes 17 4 Minimum Clearances 7 10 thru 240 Unit Control Board Flash Codes 21 5 Electrical Data Outdoor Unit HP Without Powered 11 PD180 thru 240 Unit Control Board Flash Codes 22 Convenience 6 Electrical Data Outdoor Unit HP With Powered Convenience 9 LIST OF FIGURES 1 Corner Weights amp Center Of Gravity 6 9 Fan Orientation Control Box End 21 2 Typical Ri
8. 13390 O igi Sle r Y3JdOYd AJIYIA NOILVOIJILN3QI 803 0O3838W nN3J ATYVIID INJIVAINOJ YO JYIM LIOA 009 1 lisan 253 338930 S0 41 HLIM 032 1438 38 ISAW 11 G3AON3Y 38 LSNW LINN JHL HLIM 031144 2195 18 m Sv 30 31 NOIIVH3dO _ SNOYIONVG u3dOHdW 3ShV2 Nv2 580883 9NINIM 5103102 9NI2IAN3S N3HM NOII23NNOOSIQ Ol sOlud S3HIM 11V 138V1 NOI10VO LINM STHL 30 NOILVTIVISNI JO 3WIL JHL 193443 v2 9 m um NI 53002 1VNOILVN HO QNV 1V201 ALI2 9NIMO1103 G3HSI1dNODDV 38 01 9NIUIM 01313 pA 49 162 T 193 S310N QIYOS 1081NO2 NO Nid 9 NO 123NNO2 9014 13420S 115 5 290 nie m ud Dae QUVOS 1081NO2 NO Nid OI AVZ NOII23NNOD 9014 134205 65 OYLNOD 1508330 u 1G2 S QuvO8 1JOUINOD NO Nid 1 Ave NOI123NNOD 9 14 1 34205 55 ud r62 1 112 2 v mm 1081NO2 NO Nid NOII23NNO2 91197137205 015 1081NO2 NO Nid P NOII23NNOO 9014 11 34205 5 ud t62 010 310 JAIVA AJY AV13U JAA ON ISYJAJY 70103105 211105 18 992 4 2 M 69 191012 M 68 18 692 QuvoS 1091902 1508330 22120 112 5 901 i QNNOYD 42018 TWNINYIL 2089 49 91 2 um 140 5501 35 NOLINOM SHd 65 64 Av2_ 310d 01 42018 1VNINN3I 281 4u3MOd NIVN 2018 TVNIWYIL 181 49
9. When the call for cooling Y2 is satisfied the UCB disables the signal to RY2 and M2 as long as the specified minimum run time ASCD has elapsed When the call for cooling Y1 is satisfied the UCB disables the signal to RY1 and M1 as long as the specified minimum run time ASCD has elapsed Dual Stage Heat Pump 4 pipe PD180 240 A two stage thermostat is required to operate the heat pump in cooling mode Both reversing valves are energized during cooling mode Continuous 24V signals are passed through the normally closed contacts of relays RY2 and RY3 to the O terminals of their respective Defrost Control Boards DC1 and DC2 The normally closed relays DR 2 within DC1 and DC2 energize the solenoids SOL1 and SOL2 of the reversing valves When the thermostat calls for first stage cooling Y1 the Simplicity control board UCB closes the coils of relay RY1 and contactor M1 while sending a signal to one of the CFAN terminals on DC1 Relay RY1 has two functions 1 control the crankcase heater CCH1 2 control the 24V output signal to 51 on terminal block TB2 e Contactor M1 controls compressor COMPH1 The output signal from the remaining CFAN terminal on DC1 closes the coil of contactor M3 e Contactor controls outdoor fans ODFAN 1 2 After completing the specified time for fan on delay UCB closes the coil of relay BR1 Relay BR1 sends a 24V signal to G1 of terminal block TB2 It may be use
10. 2541 1081NO2 1509330 20 19 9 622 45 s X a 11831 140 5501 38VHd YOL INOW 2S 0 9922 H 8 822 5 01 100 1B fat eAu 2SdH 83MOd NIVW Y VNIWYIL 1112819 185 05 18 092 48 utes 4 Y INYO JSNVHI 11 ee ee I 1N3IGRY MO HOLIMS sv ug 9c2 CIVNOILdO 1N3 BNY MOT 8311 081NO2 61662 HOLIMS ORIO uU34018 YOOGNI iv13H 188 J 155 282 TOYLNOD LINN gon 9N11002 29148 i TEN E 17 ums ECT NM 3SVOXNVUD 21H22 M EN AUVITMIX 12V1 IN 5 YOLIVINOD 3911 0901 NOD3 1A 8055 39 YOLIVLNOD 2v1 II oxo 1 18 8 28 VLI UOION NYJ y INvd 3055 33909 291 4 02 2455 er Av2dH 2 HOD 15 acm 18 0 81 20 110 9 _ 99 98 162 Wvubvig ES wo rvNv400 e NUS 5 gt He tNvsdo 87122 004 H no 3 u 818 and SHd NY 9 310N 335 19 062 S39V 110 U3H10 803 11v130 335 PO othe JV 18 902 u8 669 0 ug oi2 aay 019 QYVO8 1081NO2 I NV 300 8 1 130 11V130 _ ANO 012NGNOD 2 SHd YA SL VA SL T EERE BSCS 0 592 48 192 225 0 592 s saroi
11. 120 Heat Pump W Figure 18 31 Johnson Controls Unitary Products 430645 YIM D 0610 V Add 339 LINN SIHL 9NIOIASJ3S 390338 S123NNOOSIO 390 NOILAVD QvO1 2v1 OL 2 128 WOYJ 611 123NNO2 1OYLNOD 1 3 8 MO 803 05 TOYLNOD OL Q3123NNOO S 8 122 3HIM Q311VISNI LON SI YOLINOW 5501 3SVHd N3HM ALI2VdNV 11093919 1N3S34d3H LON 00 53002 HSV1j 3S3Hl jo 3UNTIV4 TOULNOD YO u3MOd 330 3un1iv3 JOVYOLS WOYd33 S3HSV13 v 39V110A MOT OL 3NG 330 Q13H suOSS3udWOD S3HSV13 AV134 QvO1u3AO u34O018 S3HSV14 2 9N11002 3344 ONISN 51 H321NO0NO23 3Shv238 LNO 034201 Suoss3udwOD 53 5 13 s JYNLVYIdNIL MOI NO 034201 SsoSS3udwOD S3HSvV13 OI 4181 11011 TOYLNOD NOIIINOI LNO Q34201 1OU1NOO NOILINDI S3HSV143 6 PWD TddV 106 S3HSY14 8 NOI1dO L1N3IONV MO Pf aso 9154 3unSS3ud ONILVYIdO 331430 S1081NOD 3915533 WAWINIW ONY 3215 u34V3u8 1 n2812 8O ONV 3503 W NIXVN 803 31V1d3AVN LINNA 33S NO 1VNINSU3I 110A 802 OL 3UIM 1591 1 IVNIWYJL 110A 1004201 YOSSIYdWOD 153 S3HSV13 L OL 3UIM 0 121 ABOZ YOI 170 NOILVYIdO LIOA 062 GIYIM AYOLIVI r 31gvol1dgv 10N S3HSV1j 9 m S3usvii 5 JINIS 031231084 1
12. est HN a 24 5 L5 Figure 10 Unit Control Board 22 Johnson Controls Unitary Products Flash Codes Various flash codes are utilized by the unit control board UCB to aid in troubleshooting Flash codes are distinguished by the short on and off cycle used approximately 200ms on and 200ms off To show normal operation the control board flashes a 1 second on 1 second off heartbeat during normal operation This is to verify that the UCB is functioning correctly Do not confuse this with an error flash code To prevent confusion a 1 flash flash code is not used Alarm condition codes are flashed on the UCB lower left Red LED See Figure Table 11 While the alarm code is being flashed it will also be shown by the other LEDs lit continuously while the alarm is being flashed The total of the continuously lit LEDs equates to the number of flashes and is shown in the table Pressing and releasing the LAST ERROR button on the UCB can check the alarm history The UCB will cycle through the last five 5 alarms most recent to oldest separating each alarm flash code by approximately 2 seconds In all cases a flashing Green LED will be used to indicate non alarm condition In some cases it may be necessary to zero the ASCD for the compressors in order to perform troubleshooting To reset all ASCDs for one cycle press and release the UCB TEST RESET button once Flash codes that do and do not represent alarms ar
13. 1 IZ _ 589 EE TE 9952 705 55 QHUVOS 10H1NO2 NO Nid 01 NOILD3NNOD 9 14 13 20 65 1041 0 NO Nid L NOI123NNOD 9014 11 34205 SS QuVOS NO Nid NOI123NNOD 9n1d 1320S 01S QuVOB 10N1NO2 NO Nid P NOILD3NNOD 9119 1 37205 S 58 108 ue v N023 14 41013105 3A1VA AJY AV13H 248 318 908 18 162 3A1VA 9NISu3A38 QION310S 105 LNO 1A 1508330 HOLIMS 29145 14 QuvOS 109100 1508330 20 1VNOILdO 5501 3SVHd YOLINOW SHd 106 42Nvan22ol c gt b 2 Av2 3104 01 M9019 3 281 WAN 3N11 0901 100 9 NIVN E 3v1 vd D 11 1 E m ur Sl E E 35055334 HOLIAS 141 38 344 HOIH HOLIMS dH T u3MO18 YOOGNI Av13U 188 u8 662 7 QuVOS LINN aon 9N11002 AV134 140 123 02 10 211 150 ug cvz g 1ug v x Jav TAX VINOS TA 83 30 2 YOLIVLNOD 8 16 505533402 YOLIVINOD IW M E ra z 5 4055 144105 1139 838 182 0N3931 89 122 3 rs 2 EE and _0 u 122 818 nus C 1 SHd NU 234 2 Q 9 310N 335 Vos A 134 o SHd r Pr 5 05 118 diis 300 9 88 182 80 012 e 539
14. 29 275 so 340 w DIMENSIONS inches Length 59 1 Width Height 500 WEIGHTS ib Shipping 1090 Operating 1126 COMPRESSORS Single Scrol Quantity UT DH T LU 1 2 Cooling ___ __ ___ _____ ______ EN System 1 0 _ T o System f Madii ds Heating Nominal Capacity Tons System 1 8 2 20 Capacity Stages System 1 8 2 SYSTEM DATA _ No Refrigeration Circuits 3 3 CR Suction Line OD EE Liquid Line OD in 5 8 7 8 7 8 5 8 7 8 7 8 OUTDOOR COIL DATA cq Face area Sq Fi 58 1 Flows 2 Fins per inch ee m 20 Tube diameter in NIN 038710 Circuitry Type interlaced Refrigerant Contra TXV CONDENSER FAN DATA No Fans Diameter 4124 Drive type Direc No speeds System 1 2 S gt 2 Motor HP Rotation OW RPM 1100 System 1 9800 Holding Charge is the amount in the unit as shipped from the factory Includes matched evaporator unit with 25 ft of piping All Compressors include crankcase heater When viewing the shaft end of the motor pego wc 4 Johnson Controls Unitary
15. 430645 YIM D 0610 Table 3 Corner Weights amp Center of Gravity um Point Load Location bs Shipping Operating X Y A D 090 87 PC120 PD180 34 PC240 PD240 LEFT FRONT WIDTH LENGTH RIGHT 090 PC120 Figure 1 Corner Weights amp Center Of Gravity NOTE Front of unit is considered the side having the control box Concrete piers can also support ground level units These piers should 1 extend below the frost line 2 be located under each of the section s four corners and 3 be sized to carry the load of the corner it supports On either rooftop or ground level installations rubber padding can be applied under the unit to lessen any transmission of vibration 7116 1152 127 199 276 275 1090 1126 267 LEFT LENGTH RIGHT PC180 PD180 PC240 PD240 Holes are provided in the base rails for bolting the unit to its foundation For ground level installations precautions should be taken to protect the unit from tampering and unauthorized persons from injury Screws on access panels will prevent casual tampering Further safety precautions such as a fenced enclosure or locking devices on the panels may be advisable Check local authorities for safety regulations Johnson Controls Unitary Products Clearances The unit must be installed with sufficient clearance for air to enter the condenser coils for air discharge and for servicing acces
16. the filter drier the thermostat wiring and the main power wiring are required to complete the installation Each unit is dehydrated evacuated leak tested and pressure tested at 450 This Split System Air Condensing Heat Pump Air Handling unit is one component of an entire system As such it requires specific application considerations with regard to the rest of the system air handling unit duct design condensing unit refrigerant piping and control scheme psig before being pressurized with a holding charge of refrigerant R 410A for shipment and or storage Failure to properly apply this equipment with the rest of the system may result in premature failure and or All controls are located in the front of the unit and are readily reduced performance increased costs Warranty accessible for maintenance adjustment and service All wiring coverage specifically excludes failures due to improper power and control can be made through the front of the unit application and Unitary Products specifically disclaims any liability resulting from improper application Please refer to the equipment Technical Guide Installation Manual and the piping applications bulletin 247077 or call the applications department for Unitary Products 1 877 UPG SERV for guidance 2 Johnson Controls Unitary Products Safety Considerations Installer should pay particular attention to the words NOTE CAUTION and WARNING Note
17. 110 18 062 Na 8 503 U8 669 O ug oee g z4u v 18 992 i nal rer v 11v130 335 049 eg H d 038 1 820 1081NO2 300 5 NOILdO 1N3ISNWNV 1 22 u os 11 o o se e CDM oos sa ses i el os sv ER pref aso ref pep ome pep owe 7 18 20 77 09 09v 9154 3 3 4 9u11va340 p21A3d 3 930 3un1vu3dm3l 9N 1v33d0 321 30 09 0 2 802 lt 101 AladfS H3MOd 51041 02 35155334 STOYLNOD JYNLVYIdN3L IW 181 WVYOVIG AYVINAWG 13 Jdid dWNdlVdH LINN SNISN3ONOO 8 1 9 l 3 l1 3 l1 Johnson Controls Unitary Products iagram D iring Typical PC090 Heat Pump W Figure 17 30 430645 YIM D 0610 OL 2 128 123NNO2 TONINO2 IN3IGRY Y7 V VI661G 99 COSI 1081NO2 01 Q3123NNOD 51 JYIM Q311VISNI LON SI YOLINOW 5501 3SVHd N3HM 9 93S Ape VA SL ALIDVdWV 1103815 WAWININW 98 182 0 S92 u8 192 235 v 0 692 LINA SIHL ONIDIAYSS 3480438 3215 W34V388 1102812 ISNA 31V d3YN LINN 33 5 jp IA lt SLOINNOODSIG 11 N3dO NOILAVD LIOA 802 Ol O IS 3AOM 11 NO 1vNIWH3I LIOA 902 OL 331A saoti Y Y O onii Y YY O ov tai 07121 110 80
18. 35155389 MOT HOLIMS 141 ino 9 330553599 HOIH HOLIMS dH u3MO18 YOOONI Av13U 158 8 _ Sal 1081NO2 LINN gon 9811002 1v138 29148 i El CIYNOILdJO 123NNODSIQ HILIMS 150 JSVIWNVYD 21H22 5 14 Y3SNIGNOD YOLIVLNOD uOSS3UdNO2 YOLIVLNOD 2W IN 3 B SOLI2VdVO 29138 10 H Y3SN3GNOD 2Y 1NV 400 300 803 NOD 238 8055 344405 291 7 8 11 130 335 __ XJ 0N3911 1 gt 24 9 uv T 23S Av H Sen aet ive u 122 3 182 SHd 9 310N 339 Nuga C 5 39VL10A 13 u3H10 503 TIEN v 11v130 335 a 49 082 ORNO 18 992 ug us U8 669 O u8 012 T 140 300 AINO 301 11v130 phe EHE u8 201L NON 09 0 2 902 id 19415 H3MOd JIAIG ONIYIM AYOLIVG NVHOVIQ AUVIN3W313 dali 1 903 og L pj o9 A xw D 9 3 9 p 4 930 3univu3dW31 9N 1V3H340 321430 9154 34 55344 9 11 340 331430 STOYLNOD 35155399 STOYLNOD JYNLVYIDWIL Jald dWildiVan LENM ONTSNIJNOJ Typical
19. 430645 YIM D 0610 Reference This instruction covers the installation and operation of the basic condensing unit For refrigerant piping installation instructions refer to document 247077 Application Data General Piping Recommendations for Split System Air Conditioning and Heat Pumps For information on the installation and operation of the evaporator blower units refer to Instruction Manual No 508526 All accessories come with a separate Installation Manual Renewal Parts Contact your local Source 1 Center for authorized replacement parts Agency Approvals Design certified by CSA as follows 1 Foruse as a cooling heating unit 2 Foroutdoor installation only Inspection As soon as a unit is received it should be inspected for possible damage during transit If damage is evident the extent of the damage should be noted on the carrier s freight bill A separate request for inspection by the carrier s agent should be made in writing CAUTION This product must be installed in strict compliance with the enclosed installation instructions and any applicable local state and national codes including but not limited to building electrical and mechanical codes 430645 YIM D 0610 Physical Data Table 1 9 240 and PD180 240 Physical Data Component pote PD240 Nominal Tonnage __75 5 15 29 REFRIGERANT Refrigerant type RATOA Holding charge ib 15
20. NOTE Liquid line solenoid is only activated during LIQUID LINE second stage cooling operation SOLENOID VALVE POWER SUPPLY 208 230 460 OR 575 3 60 EVAPORATOR BLOWER MOTOR CONTACTOR EVAPORATOR CONTROL BOX Figure 4 Typical Field Wiring Diagram NC120 thru 240 Evaporator Unit with PC120 thru 240 Heat Pump VALVE SYS 2 1LLS BLK O 218 BR BLK O 2197 Y Figure 5 NC120 240 Liquid Line Solenoid Wiring Johnson Controls Unitary Products 13 430645 YIM D 0610 POWER SUPPLY 208 230 460 OR 575 3 60 14 POWER SUPPLY 208 230 460 OR 575 3 60 CONDENSER CONTROL BOX SYSTEM ONE CONTROL BOARD TB2 516152 c 66 60 x NOTE Do not use a heat pump thermostat REP THERMOSTAT TWO STAGE COOLING TWO STAGE HEATING 11e 1 s2 e2 c NOTE Liquid line solenoid is not included or required on any 4 pipe units EVAPORATOR BLOWER MOTOR CONTACTOR EVAPORATOR CONTROL BOX Figure 6 Typical Field Wiring Diagram ND180 thru 240 Evaporator Unit with PD180 thru 240 Heat Pump Johnson Controls Unitary Products 430645 YIM D 0610 RIGHT iil WT p m HIS d M OUTLET 7 2 1 375 30 994 KNOCKOUT 2X 0 875 KNOCKOUT
21. Products Table 2 Unit Application Data 208 230 3 60 187 252 er Voltage Variation 460 3 60 432 504 Min Max 575 3 60 540 630 Ambient Ai il mbient Air on Condenser Coi 0 F 125 F Min Suction Pressure at Compressor and Corresponding Temp at Saturation Min Max 101 6 psig 156 6 psig 32 0 F 55 0 F 1 Utilization range A in accordance with ARI Standard 110 2 These units can operate in an ambient temperature of 125 F providing the wet bulb temperature of the air enter ing the evaporator coil does not exceed 67 F Unit can operate to 0 F if equipped with a low ambient kit Installation Limitations These units must be installed in accordance with all national and local safety codes If no local codes apply installation must conform to the appropriate national codes Units are designed to meet National Safety Code Standards If components are to be added to a unit to meet local codes they are to be installed at the dealer s and or the customer s expense Location Use the following guidelines to select a suitable location for both the condensing unit and the evaporator 1 The heat pump is designed for outdoor installation only 2 condenser fans are the propeller type and are not suitable for use with ductwork in the condenser air stream Johnson Controls Unitary Products 430645 YIM D 0610 heat pump and the evaporator should be positioned to
22. compressor 1 are operating but compressor 2 is not the room thermostat fan switch is in the AUTO position 1 Compressor 2 will not energize simultaneously with compressor 1 if a call for both stages of cooling is received The UCB delays compressor 2 by 30 seconds to prevent a power surge If after the delay compressor 2 does not energize on a second stage call for cooling check for line voltage at the compressor contactor M2 and that the contactor is pulled in Check for loose wiring between the contactor and the compressor If M2 is pulled in and voltage is supplied at M2 lightly touch the compressor housing If it is hot the compressor may be off on inherent protection Cancel any calls for cooling and wait for the internal overload to reset Test again when cool If M2 is not pulled in check for 24 volts at the M2 coil If 24 volts is present and M2 is not pulled in replace the contactor Failing the above if voltage is supplied at M2 M2 is pulled in and the compressor still does not operate replace the compressor If 24 volts is not present at M2 check for 24 volts at the UCB terminal C2 If 24 volts are present check for loose wiring between C2 and the compressor contactor If 24 volts is not present at the C2 terminal check for 24 volts from the room thermostat at the UCB Y2 terminal 24 volts is not present from the room thermostat check for the following a 24 volts at the thermostat
23. compressor still does not operate replace the compressor If 24 volts is not present at M1 check for 24 volts at the UCB terminal C1 If 24 volts is present check for loose wiring between C1 and the compressor contactor If 24 volts is not present at the C1 terminal check for 24 volts from the room thermostat at the UCB Y1 terminal 24 volts is not present from the room thermostat check for the following a 24 volts at the thermostat Y1 terminal b Proper wiring between the room thermostat and the UCB i e Y1 to Y1 Y2 to Y2 and c Loose wiring from the room thermostat to the UCB If 24 volts is present at the UCB Y1 terminal the compressor may be out due to an open high pressure switch or low pressure switch Check for 24 volts at the HPS1 and LPS1 terminals of the UCB If a switch has opened there should be a voltage potential between the UCB terminals e g if LPS1 has opened there will be a 24 volt potential between the LPS1 terminals If 24 volts is present at the UCB Y1 terminal and none of the protection switches have opened the UCB may have locked out the compressor for repeat trips The UCB should be flashing an alarm code If not press and release the ALARMS button on the UCB The UCB will flash the last five alarms on the LED If the compressor is locked out cancel any call for cooling This will reset any compressor lock outs NOTE While the above step will reset any lockouts compressor 1 may b
24. low pressure switch opens the Simplicity M control board will monitor the low pressure switch to make sure it closes within one minute If it fails to close the unit will shut down the associated compressor and begin an ASCD If the call for cool is still present at the end of the anti short cycle time delay the control board will re energize the halted compressor If a low pressure switch opens three times within one hour of operation the Simplicity M control board will lock out the associated compressor and flash an error code see Table 11 An ambient air switch will lock out mechanical cooling at 40 F If the product was equipped from the factory with the low ambient option the unit will operate down to O F If the unit was not ordered with the factory low ambient option a field installed low ambient kit is available The refrigerant systems are independently monitored and controlled On any fault only the associated system will be affected by any safety preventive action The other refrigerant system will continue to operate unless it is affected by the fault as well 18 Compressor Protection In addition to the external pressure switches the compressors also have inherent internal protection If there is an abnormal temperature rise in a compressor the protector will open to shut down the compressor The UCB incorporates features to minimize compressor wear and damage An Anti Short Cycle Delay ASCD is utilized to preve
25. to the heat pump Connect the main suction line to the suction line service valve connection while maintaining a flow of nitrogen Cool the valve body and replace the Schrader valve stem in the service port Once the brazing process is complete leak testing should be done on all interconnecting piping and the evaporator before proper evacuation to below 500 microns is performed Verify evacuation with micron guage or thermocouple Once the line set and evaporator section is properly evacuated the service valves can be opened and the heat pump is now ready to charge with the appropriate weight of refrigerant Calculate the correct system charge for the outdoor unit the indoor unit and the field line set Charge the system by introducing liquid refrigerant into the liquid line through the liquid port connection Complete adding the refrigerant in vapor form into the suction port when the compressor is started The correct refrigerant pressures are indicated as shown in Figures 11 thru 16 A CAUTION This system uses R 410A Refrigerant which operates at higher pressures than R 22 No other refrigerant may be used in this system Gage sets hoses refrigerant containers and recovery systems must be designed to handle R 410A If you are unsure consult the equipment manufacturer Failure to use R 410A compatible servicing equipment may result in property damage or injury Wear safety glasses and gloves when hand
26. unless an inert atmosphere 5 provided NOTE Dry nitrogen should flow through the system at all times when heat is being applied and until the joint has cooled The flow of nitrogen will prevent oxidation of the copper lines during installation Johnson Controls Unitary Products Always punch a small hole sealing disks before unbrazing to prevent the pressure in the line from blowing them off Do not use a drill as copper shavings can enter system NOTE Solenoid and hot gas bypass valves if used should be opened manually or electrically during brazing or evacuating NOTE Schrader valves located on unit service valves should have their stems removed during brazing to prevent damage to the valve and reduce system evacuation time Start Installation Start the installation of main lines at the heat pump Verify holding charge in unit by cracking open valve If pressure is present close valve and proceed with installation If no pressure Is present check system for leaks Verify all service valves are fully seated by screwing the stems of both valves down into the valve bodies until they stop Remove the Schrader valve stem and connect a low pressure nitrogen source to the service port on the suction line valve body Punch a small hole in the sealing disk the flow of nitrogen will prevent any debris from entering the system Wrap the valve body with a wet rag to prevent overheating during the brazing process Overheating t
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28. 140 150 160 170 Suction Pressure psi 1 Make sure that all condenser fans are running when charging 2 This chart is applicable to unit with the 5 left to the factory setting If the 5 have been adjusted in the field the charging chart may no longer apply Figure 16 PD240 Charging Chart Johnson Controls Unitary Products 29 430645 YIM D 0610 Typical Wiring Diagrams V A 4 Q 6 G G 0V01 2V1 OL 2 128 A GII 123 02 1051 02 1N3IGNY 403 7 005 QuvOB lONINOD Ol 21A30 ONIYIM AHOLOV3 03123NNOO S 122 Q311V1SNI LON 51 YOLINOW 5501 3SVHd N3HM 9 LAIM 30 ONIYIM 1VNOILdO JINA SIHL 9NI2IAHJS 380439 ALIOVdMY 1102812 WAWININ ONY A gud 3215 4u34v388 1102812 3Snj W hWIXVN 803 JLVId3WVN LINN 33S SLOANNODSIG 11 N3JdO NOILNYO I1 LIOA 802 OL JYIM O 121 110A 802 403 NOILYYJJO LIOA 062 0381 AHOlOV3 v SNOILIGNOD 3SVHd 319NIS AUWNIYd YIONN 031231084 A11N3H3HNI SYOLOW 3SVHd 33YHL 8 11v13Q v 11V13Q 98NI21A83S YILIV 4 YJdOYd VA SL VA SL SWuv1v 13533933 LON 00 3002 HSV1j 353 1 NO 1V213 1N30 803 GIYIGWNNGY ATYVITD YO 3UIM LIOA 009 8 192 23S Ape 936 Ave Janiva 1ONINO2 80 H3MOd ON 130 338930 SOI 3441 03971939 38 9 11 Q3A0W3H 38 L
29. 2 803 340 110A O2 403 0341 ASLS Smuv1v 1N3S3ud3U LON OO 53002 14 3S3Hl AUVWNIYd YIGNN 031931098 ATLNIYIHNI JYV SYOLON 3SVHd v1 3unliv4 1081 0 U3NOd ON 340 NO11Y21311N30 418v319 0 603 40 JAIR LIOR 009 Jg MOM oi 19 982 S3uSvii vi 11921311 JOWYOLS 53 5 13 vi 2 338930 01 3941 032 143 38 1 11 38 LSNW foes wr 39V1 0A MO OL JNA 330 013 YOSSIYdNOD S3HSV13 LINA HLIM 03119915 SV ONINIM JHI 30 ANY 3 NOllVH3dO 16 6 m Jata 4181 AV138 QvOT83AO 8 3 13 21 SNOYIONVG YIdOYdNI JSNVD SHONN3 ONIYIM IOYLINOD W186 9NI1002 3383 NISN 51 8321WONO23 35 238 LNO 034201 5805539902 3 13 9000110 MOT NO LNO 034201 5805539902 S3HSY14 01 1 11 1 JO INIL JHL 1Y 123433 NI 3003 q1YN I LYN 18 612 8 T dial LIWI1 34N1iY3 1051 02 NOIIINO 1NO 134201 10 1 2 NOILINODI SiHSY14 6 1201 ALID 9N1401104 Q3HSl 14WO22V 38 01 ONINIM 01313 11 1 154 318vollddv 1ON S3HSv1i 9 n 18 v12 T mm S Dang 1004201 80 384 2 153 3 14 L Gase 319 21 194 1ON 53 5913 9 9 l 1004201 YOSSIYdNOD 1591 _ 53 5 73 S 09 38 892
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33. Y2 terminal b Proper wiring between the room thermostat and the UCB i e Y1 to Y1 Y2 to Y2 and Loose wiring from the room thermostat to the UCB If 24 volts is present at the UCB Y2 terminal the compressor may be out due to an open high pressure switch low pressure switch or freezestat Check for 24 volts at the HPS2 LPS2 and FS2 terminals of the UCB If a switch has opened there should be a voltage potential between the UCB terminals e g if LPS2 has opened there will be 24 volts of potential between the LPS2 terminals If 24 volts is present at the UCB Y2 terminal and none of the protection switches have opened the UCB may have locked out the compressor for repeat trips The UCB should be flashing a code If not press and release the ALARMS button on the UCB The UCB will flash the last five alarms on the LED If the compressor is locked out Johnson Controls Unitary Products 430645 YIM D 0610 remove any call for cooling at the thermostat or by disconnecting the thermostat wiring at the Y2 UCB terminal This will reset any compressor lock outs NOTE While the above step will reset any lock outs 11 compressor 1 will be held off for the ASCD and compressor 2 may be held off for a portion of the ASCD See the next step If 24 volts is present at the UCB Y2 terminal and none of the switches are open and the compressor is not locked out the UCB may have the compressor in an ASCD Check the LED for an ind
34. al connections for power and control wiring are made from the right or left side of the electrical control box See Table 9 and Figures 7 and 8 for piping sizes and electrical knockout details Start Up Crankcase Heaters The crankcase heaters must be energized at least 8 hours before starting the compressors To energize the crankcase heaters the main disconnect switch must be closed During this 8 hour period the system switch on the room thermostat must be OFF to prevent the compressor from starting Make sure that the bottom of the compressor is warm to the touch to prove crankcase heater operation A CAUTION Do not attempt to start the compressor without at least 8 hours of crankcase heat or compressor damage can occur Pre Start Check Before starting the unit complete the following check list 1 Have sufficient clearances been provided 2 Has all foreign matter been removed from the interior of the unit tools construction or shipping materials etc 3 Have the condenser fans been rotated manually to check for free rotation 4 Are all wiring connections tight Johnson Controls Unitary Products 090 120 PC180 PD180 PC240 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 1 3 8 430645 YIM D 0610 PD240 8 5 8 7 8 7 5 Does the available power supply agree with the nameplate data on the unit 6 15 the control circuit transformer set for the proper voltage 7 Have the fuses disconnec
35. compressor also uses a polyolester POE oil Mobil 3MA POE This oil is extremely hydroscopic meaning it absorbs water readily POE oil can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precautions to avoid exposure of the oil to the atmosphere A CAUTION Do not leave the system open to the atmosphere Unit damage could occur due to moisture being absorbed by the POE oil in the system This type of oil is highly susceptible to moisture absorption POE polyolester compressor lubricants are known to cause long term damage to some synthetic roofing materials A CAUTION Exposure even if immediately cleaned up may cause embrittlement leading to cracking to occur in one year or more When performing any service that may risk exposure of compressor oil to the roof take precautions to protect roofing Procedures which risk oil leakage include but are not limited to compressor replacement repairing refrigerant leaks replacing refrigerant components such as filter drier pressure switch metering device or coil The unit is shipped with compressor mounting bolts which are factory adjusted and ready for operation A CAUTION Do not loosen compressor mounting bolts Phasing Three phase scroll compressors operate in only one direction If the scroll is drawing low amperage has similar suction and discharge pressures or is p
36. d to control operation of an indoor blower When the thermostat calls for second stage cooling Y2 the Simplicity control board UCB closes the coils of relay RY2 and contactor M2 while sending a signal to one of the CFAN terminals on DC2 Relay RY2 has two functions 1 control the crankcase heater CCH2 2 control the 24V output signal to S2 on terminal block TB2 Contactor M2 controls compressor COMPR2 The output signal from the remaining CFAN terminal on DC2 closes the coil of contactor M4 430645 YIM D 0610 Contactor M4 controls outdoor fans ODFANS amp 4 If the initial call for cooling requires both stages Y1 and Y2 the UCB will delay the second stage by 30 seconds to avoid an excessive power inrush When the call for cooling Y2 is satisfied the UCB disables the signal to RY2 and M2 as long as the specified minimum run time ASCD has elapsed When the call for cooling Y1 is satisfied the UCB disables the signal to RY1 and M1 as long as the specified minimum run time ASCD has elapsed Low Ambient Cooling These units are factory equipped with low ambient switches that work through the Simplicity control board to operate the compressors and condenser fans normally to 40 F ambient temperature The Electronic Low Ambient Controller 2LA04703000 Accessory is designed to assure safe operation through condenser head pressure regulation down to 0 F ambient temperature Low Ambient Control Op
37. e held off for the ASCD See the next step If 24 volts is present at the UCB Y1 terminal and none of the switches are open and the compressor is not locked out the UCB may have the compressor in an ASCD Check the LED for an indication of an ASCD cycle The ASCD should time out within 5 minutes Press and release the TEST button to reset all ASCDs If 24 volts is present at the UCB Y1 terminal and the compressor is not out due to a protective switch trip repeat trip lock out or ASCD the economizer terminals of the UCB may be improperly wired Check for 24 volts at the Y1 OUT terminal of the UCB If 24 volts is not present at the Y1 OUT terminal the UCB must be replaced If 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 Johnson Controls Unitary Products 12 13 OUT terminal to the Mate N Lock plug the jumper in the Mate N Lock plug and in the wiring from the Mate N Lock plug to the Y1 ECON terminal If none of the above corrected the error test the integrity of the UCB Disconnect the C1 terminal wire and jumper it to the Y1 terminal DO NOT jump the Y1 to C1 terminals If the compressor engages the UCB has faulted If none of the above correct the error replace the UCB For units with two stages of cooling On calls for the second stage of cooling the supply air blower motor and
38. e is energized during cooling mode A continuous 24V signal is passed through the normally closed contacts of relay RY2 to the O terminal of the Defrost Control Board DC The normally closed relay DR 2 within DC energizes the solenoid SOL of the reversing valve When the thermostat calls for cooling Y1 the Simplicity control board UCB closes the coils of relay RY1 and contactor Johnson Controls Unitary Products M1 while sending a signal to of the CFAN terminals DC Relay RY1 controls the crankcase heater CCH1 The normally closed contacts allow CCH1 to operate during unit shutdown e Contactor M1 controls compressor The output signal from the remaining CFAN terminal on DC closes the coil of contactor M3 e Contactor controls outdoor fans ODFAN1 amp 2 After completing the specified time for fan on delay UCB closes the coil of relay BR1 Relay BR1 sends a 24V signal to G1 of terminal block TB2 It may be used to control operation of an indoor blower When the call for cooling Y1 is satisfied the UCB disables the signal to RY1 M1 and DC as long as the specified minimum run time ASCD has elapsed The UCB disables the signal to BR1 after completing the fan off delay period Dual Stage Heat Pump PC120 240 A two stage thermostat is required to operate the heat pump in cooling mode The reversing valve is energized during cooling mode A continuous 24V signal is
39. e listed in Table Table 10 Unit Control Board Option Setup Option Byte Setup Enter The Option Setup Mode By Pushing The Option Setup Store Button And Holding It For At Least 2 Seconds he Green Status Led Option Byte Will Be Turned On And The Red Status Led Heat Delay Is Turned Off The 4 Led Will Then Show The Status Of The Labeled Option Low Ambient Lockout Press The Up Or Down Button To Change The Led Status To Correspond To The Desired Option Setup To Save The Current Displayed Value Push The Option Setup Store Button And Hold It For At Least 2 Seconds When The Value Is Saved The Green Led Will Flash A Few Times And Then Normal Display Will Resume NOTE While in either Setup mode if no buttons are pushed for 60 seconds the display will revert to its normal display exiting the Option Setup mode When saving the control board only saves the parameters for the currently displayed mode Option Byte or Heat Delay Heat Delay not applicable on these units Johnson Controls Unitary Products 430645 YIM D 0610 Normal Maintenance A WARNING Prior to any of the following maintenance procedures shut off all power to the unit to avoid personal injury Periodic maintenance consists of changing or cleaning filters and general cleaning of the outdoor coil FILTERS Inspect once a month Replace Disposable or clean Permanent Type as necessary DO NOT replace Permanent Typ
40. e with Disposable MOTORS Outdoor fan motors are permanently lubricated and require no maintenance OUTDOOR COIL Dirt should not be allowed to accumulate on the outdoor coil surface or other parts in the air circuit Cleaning should be as often as necessary to keep the coil clean Use a brush vacuum cleaner attachment or other suitable means Be sure that the power to the unit is shut off prior to cleaning CAUTION Exercise care when cleaning the coil so that the coil fins are not damaged Do not permit the hot condenser air discharge to be obstructed by overhanging structures or shrubs Troubleshooting Troubleshooting of components necessarily requires opening the electrical control box with the power connected to the unit Use extreme care when working with live circuit Check the unit nameplate for the correct range before making any connections with line terminals CAUTION The wire number or color and terminal designations referred to may vary Check the wiring label inside the control box access panel for the correct wiring 23 430645 YIM D 0610 Cooling Troubleshooting Guide On calls for cooling if the compressors are operating but the supply air blower motor does not energize after a short delay the room thermostat fan switch is in the AUTO position 1 10 Turn the thermostat fan switch to the ON position If the Supply air blower motor does not e
41. ent from the room thermostat check for the following a Proper operation of the room thermostat contact between R and G with the fan switch in the ON position and in the AUTO position during operation calls b Proper wiring between the room thermostat and the UCB and c Loose wiring from the room thermostat to the UCB If 24 volts is present at the room thermostat but not at the UCB check for proper wiring between the thermostat and the UCB i e that the thermostat G terminal is connected to the G terminal of the UCB and for loose wiring If the thermostat and UCB are properly wired replace the UCB On calls for cooling the supply air blower motor is operating but compressor 1 is not the room thermostat fan switch is in the AUTO position 1 24 If compressor 1 does not energize on a call for cooling check for line voltage at the compressor contactor M1 and that the contactor is pulled in Check for loose wiring between the contactor and the compressor If M1 is pulled in and voltage is supplied at M1 lightly touch the compressor housing If it is hot the compressor may be off on inherent protection Cancel any calls for cooling and wait for the internal overload to reset Test again when cool If M1 is not pulled in check for 24 volts at the M1 coil If 24 volts are present and M1 is not pulled in replace the contactor Failing the above if voltage is supplied at M1 M1 is pulled in and the
42. eration A call for cooling closes contactor which energizes all condenser fans The Low Ambient Control starts all fans at full speed then adjusts according to the liquid line temperature Refer to the appropriate 2LA low ambient kit instructions for additional detail on the factory or field installed low ambient kit and its operation Heating Sequence of Operation General Heat pump models are to be matched with air handlers of equivalent tonnage ratings Twinning of heat pumps and air handlers is not recommended A two stage thermostat is required to operate the heat pump in heating mode All reversing valves are de energized during normal heating mode They are energized only during cooling and defrost modes The heat pump operates all compressors during a first stage call for heating unless locked out by the Unit Control Board UCB First Stage Heating Operation When the thermostat calls for first stage heating W1 e The Simplicity control board UCB goes into a five minute ASCD timer delay When the ASCD time delay is satisfied the UCB closes its internal compressor relay contact thus energizing the contacts of relay RY1 and contactor M1 20 Relay RY1 has two functions 1 control the operation of crankcase heater CCH1 and 2 control the 24V output signal to 51 on terminal block TB2 Contactor M1 controls compressor COMPH1 Relay RY3 RY2 for 9 model toggles the 24V signal f
43. gging 7 10 Unit Control 22 3 Typical Field Wiring Diagram NC090 Air Handling Unit 11 90 Charging 27 With PC090 Heat 12 12 PC120Charging 27 4 Typical Field Wiring Diagram NC120 thru 240 Evaporator 13 PC180 Charging 28 Unit with PC120 thru 240 Heat Pump 9 44 PD180 Charging 28 E SE PM 13 15 PC240 Charging 29 iring Diagram Unit with PDI 80 thru 240 eel Pump 14 b pecie CHEM sss E 7 090 PC120 Unit Dimensions 15 Lr dpa Un cun M 18 Typical PC120 Heat Pump Wiring Diagram 31 8 PC PD180 amp PC PD240 Unit Dimensions and Piping p amp Electrical 19 Typical PC180 240 Heat Pump Wiring Diagram 32 20 Typical PD180 240 Heat Pump Wiring Diagram 33 430645 YIM D 0610 430645 YIM D 0610 Nomenclature Configured Split Condenser Model Number Nomenclature 240 00 2 2 Product Style Product Category A Style A P Split System Condenser HP R 410A Product Generation 1 First Generation Product Identifier
44. he thermal expansion valve Flash gas 1 Increases the liquid line pressure loss due to friction that in turn causes further flashing 2 Reduces the capacity of the refrigerant control device which starves the evaporator Erodes the seat of the refrigerant control device 4 Causes erratic control of the refrigerant entering the evaporator 10 Take Adequate Precautions Many service problems can be avoided by taking adequate precautions to provide an internally clean and dry system and by using procedures and materials that conform to established standards Use hard drawn copper tubing where no appreciable amount of bending around pipes or other obstructions is necessary If soft copper is used care should be taken to avoid sharp bends that may cause a restriction Pack fiberglass insulation and a sealing material such as permagum around refrigerant lines where they penetrate a wall to reduce vibrations and to retain some flexibility Support all tubing at minimum intervals with suitable hangers brackets or clamps Braze all copper to copper joints with Silfos 5 or equivalent brazing material Do not use soft solder Insulate all suction lines with a minimum of 1 2 ARMAFLEX or equivalent that meets local codes Liquid lines exposed to direct sunlight and or high temperatures must also be insulated Never solder suction and liquid lines together They can be taped together for convenience and support purposes but they m
45. he valve will damage the valve seals Unbraze the sealing disk cool the valve body and prepare the joint for connections of the main lines Repeat for the liquid line valve body Never remove a cap from an access port unless the valve is fully back seated with its valve stem in the maximum counter clockwise position because the refrigerant charge will be lost Always use a refrigeration valve wrench to open and close these service valves Connect the main liquid line to the liquid line service valve connection while maintaining a flow of nitrogen Cool the valve body and replace the Schrader valve stem in the service port Install the liquid line from the heat pump to the evaporator liquid connection maintaining a flow of nitrogen during all brazing operations The filter drier and sight glass must be located in the liquid line leaving the O D unit Connect a low pressure nitrogen source to the Schrader valve located on the evaporator section coil headers Punch a small hole in the sealing disks the flow of nitrogen will prevent any debris from entering the system Unbraze both liquid and Johnson Controls Unitary Products 430645 YIM D 0610 suction sealing disks and prepare the joints for connections of the main lines Connect the main liquid line to the liquid line connection on the evaporator section while maintaining a flow of nitrogen Make the suction line connection at the evaporator and run the line
46. his chart is applicable to unit with the 5 left to the factory setting If the 5 have been adjusted in the field the charging chart may no longer apply Figure 13 PC180 Charging Chart Discharge Pressure psi Outdoor Air Entering Condenser F 600 900 400 300 200 Cooling Charging Curves PD180 120 130 140 150 160 Suction Pressure psi 1 Make sure that all condenser fans are running when charging 170 180 2 This chart is applicable to unit with the 5 left to the factory setting If the TXV s have been adjusted in the field the charging chart may no longer apply Figure 14 PD180 Charging Chart 28 Johnson Controls Unitary Products 430645 YIM D 0610 Cooling Charging Curves PC240 600 amp 500 9 o 2 5 5 m 300 lt A 9 200 120 130 140 150 160 170 Suction Pressure psi 1 Make sure that all condenser fans are running when charging 2 This chart is applicable to unit with the to the factory setting If the TXV s have been adjusted in the field the charging chart may no longer apply Figure 15 PC240 Charging Chart Cooling Charging Curves PD240 600 T 5 500 5 0 9 400 3 D Q 5 200 120 130
47. ication of an ASCD cycle The ASCD should time out within 5 minutes Press and release the TEST button to reset all ASCDs If none of the above corrected the error test the integrity of the UCB Disconnect the C2 terminal wire and jumper it to the Y2 terminal DO NOT jump the Y2 to C2 terminals If the compressor engages the UCB has faulted If none of the above correct the error replace the UCB On a call for cooling the supply air blower motor and compressor 2 are operating but compressor 1 is not the room thermostat fan switch is in the AUTO position 1 Compressor 2 is energized in place of compressor 1 when compressor 1 is unavailable for cooling calls Check the UCB for alarms indicating that compressor 1 is locked out Press and release the ALARMS button if the LED is not flashing an alarm Check for line voltage at the compressor contactor M1 and that the contactor is pulled in Check for loose wiring between the contactor and the compressor If M1 is pulled in and voltage is supplied at M1 lightly touch the compressor housing If it is hot the compressor may be off on inherent protection Cancel any calls for cooling and wait for the internal overload to reset Test again when cool If M1 is not pulled in check for 24 volts at the M1 coil If 24 volts is present and M1 is not pulled in replace the contactor Failing the above if voltage is supplied at M1 M1 is pulled in and the compressor still doe
48. ling refrigerants Failure to follow this warning can cause serious personal injury NOTE This instruction covers the installation and operation of the basic heat pump For refrigerant piping installation instructions refer to document 247077 Application Data General Piping Recommendations for Split System Air Conditioning and Heat Pumps 430645 YIM D 0610 POWER SUPPLY 208 230 460 OR 575 3 60 POWER SUPPLY 208 230 460 OR 575 3 60 CONDENSER CONTROL BOX SYSTEM ONE CONTROL BOARD TB2 2 6 60 X xX RSQ NOTE Do not use a heat pump thermostat RCP Te THERMOSTAT SINGLE STAGE COOLING TWO STAGE HEATING NOTE Liquid line solenoid is not included or required on 7 5 Ton Single Stage Units EVAPORATOR BLOWER MOTOR CONTACTOR EVAPORATOR CONTROL BOX Figure 3 Typical Field Wiring Diagram NC090 Air Handling Unit With PC090 Heat Pump 12 Johnson Controls Unitary Products 430645 YIM D 0610 POWER SUPPLY 208 230 460 OR 575 3 60 7 CONTROL BOARD TB2 516152 66 60 x CONDENSER CONTROL BOX SYSTEM ONE NOTE Do not use a heat pump thermostat THERMOSTAT TWO STAGE COOLING TWO STAGE HEATING 5115115252 66 60
49. load Switch Failure Off Off 13 Flashes Compressor Held Off due to Low Voltage Flashing On 14 Flashes EEPROM Storage Failure On Off OFF No Power or Control Failure Off 1 Non alarm condition 2 Freeze stat not applicable Johnson Controls Unitary Products 21 430645 YIM D 0610 Table 11 PD180 thru 240 Unit Control Board Flash Codes GREEN RED RED RED RED FLASH CODE DESCRIPTION p P x p LED 1 On Steady a RE ERE ERR 1 Flash Applicable ee es 3 Flashes On 4 Flashes of 5 Flashes On 6 Flashes of 8 Flashes FS2 Compressor Lockout on 10 Flashes Compressors Locked Out on Low Outdoor Air Temperature Flashing Off 12 Flashes Of 14 Flashes OFF 1 Non alarm condition 2 Freeze stat not applicable Y ST OPTION RESET SETUP LIS 4 Atl amp EJ _ RE a aar Alarm Os Di History EE 2s B lt i i a Macr 2 i h po Ammo 73 U ra Reset All ASCDs for SELECT UP DOWN pio STQRE One Cycle a Iz 8 M FAN OFF 8 Eh HET EAT START y MEAT X LOW A Condition Green A 2 022 5 ROSIER o 1HR LEAD LAG BE e Te Current Alarm R5 le e Flashed Ri6e Tt x WU Red LED Ri2e
50. mation on minimum disconnect sizing Table 6 Electrical Data Outdoor Unit HP With Powered Convenience Outlet Compressors Outdoor Fan Motor Pwr Pwr Conv Outlet Outlet Minimum Maximum Compressors Supply each a each Supply EIE mpacity A 208 230 3 60 208 230 3 60 1 250 250 73 2 100 60 wr zi m 35 5s H poizo a so wo amp sm so sae 16 s sme ua 2 220 208230390 2 250 els 100 wo tea sw we worm eo w sre vals o 545 2 4 2 4 2 rwr m m mem sea 1 Based on three 75 C insulated copper conductors in conduit and ambient of 30 C 2 Maximum fuse or maximum circuit breaker HACR type per NEC Refer to NEC NFPA No 70 Articles 440 11 12 for information on minimum disconnect sizing Johnson Controls Unitary Products 9 430645 YIM D 0610 Refrigerant Mains A CAUTION This Split System Air Condensing Heat Pump Air Handling unit is one component of an entire system As such it requires specific application considerations with regard to the rest of the system air handling unit duct design condensing unit refrigerant piping and control scheme Failure to properly apply this equipment with the re
51. minimize the number of bends in the refrigerant piping 4 The heat pump should be as close to the evaporator as practical 5 The heat pump should not be installed where normal operating sounds may be objectionable 6 The evaporator should be located within the building either outside or inside the conditioned space Rooftop Locations Be careful not to damage the roof Consult the building contractor or architect if the roof is bonded Choose a location with adequate structural strength to support the unit The heat pump must be mounted on level supports The supports can be channel iron beams or wooden beams treated to reduce deterioration Minimums of two 2 beams are required to support each unit The beams should 1 be positioned perpendicular to the roof joists 2 Extend beyond the dimensions of the section to distribute the load on the roof 3 Be capable of adequately supporting the concentrated loads at the corners These beams can usually be set directly on the roof Flashing is not required NOTE On bonded roofs check for special installation requirements Ground Level Locations It is important that the units be installed on a substantial base that will not settle causing strain on the refrigerant lines and possible leaks A one piece concrete slab with footers that extend below the frost line is recommended The slab should not be tied to the building foundation as noise will telegraph through the slab
52. nergize go to Step 3 If the blower motor runs with the fan switch in the ON position but will not run after the first compressor has energized when the fan switch is in the AUTO position check the room thermostat for contact between R and G in the AUTO position during calls for cooling If the supply air blower motor does not energize when the fan switch is set to ON check that line voltage is being supplied to the contacts of the M3 contactor and that the contactor is pulled in Check for loose wiring between the contactor and the supply air blower motor If M3 is pulled in and voltage is supplied to M3 lightly touch the supply air blower motor housing If it is hot the motor may be off on internal protection Cancel any thermostat calls and set the fan switch to AUTO Wait for the internal overload to reset Test again when cool If M3 is not pulled in check for 24 volts at the M3 coil If 24 volts are present at M3 but M3 is not pulled in replace the contactor Failing the above if there is line voltage supplied at M3 M3 is pulled in and the supply air blower motor still does not operate replace the motor If 24 volts is not present at M3 check that 24 volts is present at the UCB supply air blower motor terminal FAN If 24 volts is present at the FAN check for loose wiring between the UCB and M3 If 24 volts is not present at the FAN terminal check for 24 volts from the room thermostat If 24 volts are not pres
53. nt operation of a compressor too soon after its previous run Additionally a minimum run time is imposed any time a compressor is energized The ASCD is initiated on unit start up and on any compressor reset or lock out Flash Codes The UCB will initiate a flash code associated with errors within the system Refer to UNIT CONTROL BOARD FLASH CODES Table 11 Reset Remove the call for cooling by raising thermostat setting higher than the conditioned space temperature This resets any pressure or freezestat flash codes Simplicity only has minimum run time in cool Heat pump mode shuts off immediately Sequence of Operation Continuous Blower By setting the room thermostat to ON the low voltage control circuit from the to is completed and the supply air blower will operate continuously Intermittent Blower With the room thermostat fan switch set to AUTO and the system switch set to either the AUTO or HEAT settings the blower is energized whenever a cooling or heating operation is requested The blower is energized after any specified delay associated with the operation When energized the indoor blower has a minimum run time of 30 seconds Additionally the indoor blower has a delay of 10 seconds between operations Cooling Sequence Of Operation Single Stage Heat Pump PC090 A single stage thermostat is required to operate the heat pump in cooling mode The reversing valv
54. oducts 430645 YIM D 0610 Cooling Charging Curves 090 600 pu D 0 un c g 5 500 gt N 400 5 O T 200 6 120 130 140 150 160 170 180 Suction Pressure psi 1 Make sure that both condenser fans are running when charging 2 This chart is applicable to unit with the 5 left to the factory setting If the TXV s have been adjusted in the field the charging chart may no longer apply Figure 11 PC090 Charging Chart Cooling Charging Curves PC120 600 Th 2 500 5 t 4 e 9 5 5 200 120 130 140 150 160 170 180 Suction Pressure psi 1 Make sure that both condenser fans are running when charging 2 This chart is applicable to unit with the 5 left to the factory setting If the TXV s have been adjusted in the field the charging chart may no longer apply Figure 12 PC120 Charging Chart Johnson Controls Unitary Products 27 430645 YIM D 0610 Discharge Pressure psi 600 500 400 300 200 Cooling Charging Curves PC180 TN D c 1159 E c 105 95 o 85 E lt 65 5 5 120 130 140 150 160 170 180 Suction Pressure psi 1 Make sure that all condenser fans are running when charging 2 T
55. passed through the normally closed contacts of relay RY2 to the O terminal of the Defrost Control Board DC The normally closed relay DR 2 within DC energizes the solenoid SOL of the reversing valve When the thermostat calls for first stage cooling Y1 the Simplicity control board UCB closes the coils of relay RY1 and contactor M1 while sending a signal to one of the CFAN terminals on DC Relay RY1 has two functions 1 control the crankcase heater CCH1 2 control the 24V output signal to S1 on terminal block TB2 Contactor M1 controls compressor COMPH1 The output signal from the remaining CFAN terminal on DC closes the coil of contactor M3 Contactor controls all outdoor fans After completing the specified time for fan on delay UCB closes the coil of relay BR1 Relay BR1 sends a 24V signal to G1 of terminal block TB2 It may be used to control operation of an indoor blower When the thermostat calls for second stage cooling Y2 the Simplicity control board UCB closes the coil of relay RY2 and contactor M2 Johnson Controls Unitary Products 430645 YIM D 0610 Relay RY2 has two functions 1 control the crankcase heater CCH2 2 control the 24V output signal to S2 on terminal block TB2 Contactor M2 controls compressor COMPR2 If the initial call for cooling requires both stages Y1 and Y2 the UCB will delay the second stage by 30 seconds to avoid an excessive power inrush
56. roducing a high noise level the scroll is misphased Change the incoming line connection phasing to obtain the proper rotation CAUTION Scroll compressors require proper rotation to operate properly Failure to check and correct rotation may result in property damage Johnson Controls Unitary Products 430645 YIM D 0610 Electrical Data Table 5 Electrical Data Outdoor Unit HP Without Powered Convenience Outlet Compressors Outdoor Fan Motor Pwr Pwr Conv Outlet Outlet Minimum Maximum _______ Model Power RLA MCC LRA Power FLA Circuit Fuse Size 208230390 350 5 at a cos s wsss 0 ss 208220390 2 i e 9 sss 200210390 2 250 s 21 wsss e so ss 200210390 e 250 meos 21 __ ___ wsss e so ss 2 sss e i ss as 4 sex we 1 Based on three 75 C insulated copper conductors in conduit and ambient of 30 C 2 Maximum fuse or maximum circuit breaker HACR type per NEC Refer to NEC NFPA No 70 Articles 440 11 12 for infor
57. rom the O terminal of DC to the Y terminal assuring the reversing valve cannot be energized except during defrost Concurrently a 24V signal is sent to one of the CFAN terminals of DC The output signal from the remaining CFAN terminal closes the coil of contactor e Contactor controls outdoor fans ODFAN 1 amp 2 all models and ODFANS amp 4 PC180 240 PC120 240 PD180 240 models After a two second delay UCB energizes the contacts of relay RY2 and contactor M2 Relay RY2 has two functions 1 control the operation of crankcase heater CCH2 and 2 control the 24V output signal to S2 on terminal block TB2 Contactor M2 controls compressor COMPR2 PD180 240 models only Concurrently a 24V signal is sent to one of the CFAN terminals of defrost control board DC2 The output signal from the remaining CFAN terminal closes the coil of contactor Contactor M4 controls outdoor fans ODFANS amp 4 Second Stage Heating Operation When the thermostat calls for second stage heating W2 A 24V signal passes through UCB sending an input signal to the W terminal of DC This signal passes through DC as an output signal to the 66 terminal of TB2 to be used as a control signal for first stage electric heat Emergency Heating Operation When the thermostat calls for emergency heating EMER he UCB de energizes all compressor relays and contactors A 24V signal passes thro
58. s See Table Table 4 for clearances NOTE Additional clearance is required to remove the compressors out the back of the unit Table 4 Minimum Clearances Clearance Description Distance in Inches Overhead Top 120 Front 36 Rear 36 Left Side 30 Right Side 30 Bottom 0 1 In all installations where snow accumulates and winter oper ation is expected additional height must be provided to insure normal condenser airflow Do not permit overhanging structures or shrubs to obstruct condenser air discharge Rigging Exercise care when moving the unit Do not remove any packaging until the unit is near the place of installation Rig the unit by attaching chain or cable slings to the lifting holes provided in the base rails Spreader bars whose length exceeds the largest dimension across the unit MUST be used across the top of the unit The unit may be moved or lifted with a forklift Slotted openings in the base rails are provided for this purpose Johnson Controls Unitary Products 430645 YIM D 0610 LENGTH OF FORKS MUST BE A MINIMUM OF 60 INCHES CAUTION Spreaders longer than the largest dimension across the unit must be used across the top of the unit Before lifting a unit make sure that its weight is distributed equally on the cables so that it will lift evenly
59. s are intended to clarify or make the installation easier Cautions are given to prevent equipment damage Warnings are given to alert installer that personal injury and or equipment damage may result if installation procedure is not handled properly Improper installation may create a condition where the operation of the product could cause personal injury or property damage Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual for assistance or for additional information consult a qualified contractor installer or service agency Before performing service or maintenance operations on unit turn off main power switch to unit Electrical shock could cause personal injury Improper installation adjustment alteration service or maintenance can cause injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier A CAUTION This system uses R 410A Refrigerant which operates at higher pressures than R 22 No other refrigerant may be used in this system Gage sets hoses refrigerant containers and recovery systems must be designed to handle R 410A If you are unsure consult the equipment manufacturer Failure to use R 410A compatible servicing equipment may result in property damage or injury Johnson Controls Unitary Products
60. s not operate replace the compressor If 24 volts is not present at M1 check for 24 volts at the UCB terminal C1 If 24 volts is present check for loose wiring between C1 and the compressor contactor If 24 volts is not present at the C1 terminal check for 24 volts from the room thermostat at the UCB Y1 terminal 24 volts are not present at the UCB Y1 terminal the UCB may have faulted Check for 24 volts at the Y1 ECON terminal If 24 volts is not present at Y1 ECON the UCB has faulted The UCB should de energize all compressors on a loss of call for the first stage of cooling i e a loss if 24 volts at the Y1 terminal If 24 volts are present at the UCB Y1 terminal the compressor may be out due to an open high pressure switch or low pressure switch Check for 24 volts at the 25 430645 YIM D 0610 HPS1 and LPS1 terminals of the UCB If a switch has opened there should be a voltage potential between the UCB terminals e g if LPS1 has opened there will be a 24 volt potential between the LPS1 terminals If 24 volts is present at the UCB Y1 terminal and none of the protection switches have opened the UCB may have locked out the compressor for repeat trips The UCB should be flashing a code If not press and release the ALARMS button on the UCB The UCB will flash the last five alarms on the LED If the compressor is locked out remove any call for cooling This will reset any compressor lock outs NOTE While
61. st of the system may result in premature failure and or reduced performance increased costs Warranty coverage specifically excludes failures due to improper application and Unitary Products specifically disclaims any liability resulting from improper application Please refer to the equipment Technical Guide Installation Manual and the piping applications bulletin 247077 or call the applications department for Unitary Products 1 877 UPG SERV for guidance Line Sizing When sizing refrigerant pipe for a split system air conditioner check the following 1 Suction line pressure drop due to friction 2 Liquid line pressure drop due to friction 3 Suction line velocity for oil return 4 Liquid line pressure drop due to vertical rise For certain piping arrangements different sizes of suction line pipe may have to be used The velocity of the refrigerant vapor must always be great enough to carry the oil back to the compressor 5 Evaporator Located Below Condenser On a split system where the evaporator blower is located below the condenser the suction line must be sized for both pressure drop and for oil return 6 Condenser Located Below Evaporator When the condenser is located below the evaporator blower the liquid line must be designed for the pressure drop due to both friction loss and vertical rise If the pressure drop due to vertical rise and friction exceeds 60 psi some refrigerant will flash before it reaches t
62. t switch and power wire been sized properly 8 Are compressor mounting bolts properly secured 9 Are any refrigerant lines touching each other or any sheet metal surface Rubbing due to vibration could cause a refrigerant leak 10 Are there any visible signs of a refrigerant leak such as residue 11 Has the refrigeration system been leak checked evacuated and had the correctly calculated charge weighted in 12 Is any electrical wire laying against a hot refrigerant line Initial Start Up 1 Supply power to the unit through the disconnect switch at least 8 hours prior to starting the compressor 2 Move the system switch on the thermostat to the AUTO or COOL position 3 Reduce the setting of the room thermostat to energize the compressor 4 Check the operation of the evaporator unit per the manufacturer s recommendations 5 With an ammeter check the compressor amps against the unit data plate Check for refrigerant leaks Check for any abnormal noises and or vibrations and make the necessary adjustments to correct fan blade s touching shroud refrigerant lines hitting on sheet metal etc 8 After the unit has been operating for several minutes shut off the main power supply at the disconnect switch and inspect all factory wiring connections and bolted surfaces for tightness 430645 YIM D 0610 Operation Unit Control Overview This series of heat pumps come factory equipped with Simplicit
63. the above step will reset any lock outs 10 26 compressor 2 will be held off for the ASCD and compressor 1 may be held off for a portion of the ASCD See the next step If 24 volts is present at the UCB Y1 terminal and none of the switches are open and the compressor is not locked out the UCB may have the compressor in an ASCD Check the LED for an indication of an ASCD cycle The should time out within 5 minutes Press and release the TEST button to reset all ASCDs If 24 volts is present at the UCB Y1 terminal and the compressor is not out due to a protective switch trip repeat trip lock out or ASCD the economizer terminals of the UCB may be improperly wired Check for 24 volts at the Y1 OUT terminal of the UCB If 24 volts is not present at the Y1 OUT terminal the UCB must be replaced If 24 volts is present at the Y1 OUT terminal check for 24 volts at the Y1 ECON terminal If 24 volts is not present check for loose wiring from the Y1 OUT terminal to the Mate N Lock plug the jumper in the Mate N Lock plug and in the wiring from the Mate N Lock plug to the Y1 ECON terminal If none of the above corrected the error test the integrity of the UCB Disconnect the C1 terminal wire and jumper it to the Y1 terminal DO NOT jump the Y1 to C1 terminals If the compressor engages the UCB has faulted If none of the above correct the error replace the UCB Johnson Controls Unitary Pr
64. ugh UCB sending an input signal to the W terminal of DC This signal passes through DC as an output signal to the 66 terminal of TB2 to be used as a control signal for first stage electric heat e The normally closed contacts of M1 AUX and M2 AUX PC120 240 PD180 240 models only send a 24V output signal to the 60 terminal of TB2 to be used as a control signal for second stage electric heat Johnson Controls Unitary Products Defrost Operation The defrost control board DC utilizes a time temperature defrost scheme The DC repeats normal heating run cycles which must be completed until one of the following conditions is met and the DC enters defrost mode 1 The DC satisfies its accumulated minimum run time This is factory set at 60 minutes but is field adjustable to 30 60 or 90 minutes 2 The defrost switch es is closed This normally open switch is set to close at 28 F 4 3 When the DC enters defrost mode its on board defrost relays are powered This energizes the reversing valve solenoid de energizes the condenser fan motors and energizes the unit s optional electric heater The DC remains in defrost mode until either of the following two conditions are met 430645 YIM D 0610 NOTE The DC has two flash codes that only initiate if the jumper between the two pressure switch terminals is removed or broken Blower Operation After completing the specified time for fan on delay UCB closes the coil of rela
65. ust be completely insulated from each other The liquid and suction service ports on the condenser section permit leak testing evacuation and partial charging of the field piping and the evaporator without disturbing refrigerant stored in the condenser during initial installation Before beginning installation of the main lines be sure that the evaporator section has not developed a leak in transit Check pressure at the Schrader valve located on the header of each coil If pressure still exists in the system it can be assumed to be leak free If pressure DOES NOT exist the section will need to be repaired before evacuation and charging is performed A bi flow solid core filter drier MUST be field installed in the liquid line of every system to prevent dirt and moisture from damaging the system Properly sized filter driers are shipped with each condensing section NOTE Installing a filter drier does not eliminate the need for the proper evacuation of a system before it is charged A field installed moisture indicating sight glass should be installed in the liquid line s between the filter drier and the evaporator coil The moisture indicating sight glass can be used to check for excess moisture in the system Both condenser and evaporator sections have copper sealing disks brazed over the end of liquid and suction connections The temperature required to make or break a brazed joint is high enough to cause oxidation of the copper
66. y controls to monitor all unit functionality and safety controls Safety Controls The Simplicity control board incorporates features to monitor safety circuits as well as minimize compressor wear and damage An anti short cycle delay ASCD is utilized to prevent operation of a compressor too soon after its previous run The ASCD is initiated on unit start up and on any compressor reset or lockout The Simplicity control board monitors the following inputs for each cooling system A high pressure switch is factory installed to protect against excessive discharge pressure due to a blocked condenser coil or a condenser fan motor failure During cooling operation if a high pressure limit switch opens the Simplicity control board will de energize the associated compressors and initiate the 5 minute ASCD If the call for cool is still present at the end of the ASCD the control board will re energize the halted compressor If a high pressure switch opens three times within two hours of operation the Simplicity control board will lockout the associated system compressors and will flash an error code see Table 11 A low pressure switch to protect the unit against excessively low suction pressure is standard on all condensing units If the low pressure switch opens during normal operation the Simplicity control board will de energize the compressor initiate the ASCD and shut down the condenser fans On startup if the
67. y BR1 Relay BR1 sends a 24V signal to G1 of terminal block TB2 It may be used to control operation of an indoor blower The UCB disables the signal to BR1 after completing the fan off delay period 1 Both of the liquid line thermostats are open Each is set to 2 4 open at 55 degrees 3 a 2 The maximum defrost run time of 10 minutes is met The DC also contains a set of test pins Placing a jumper across these pins will result in the following actions If the ASCD timer is active it is now bypassed allowing the compressor to run If the DC is in a lockout condition the lockout is reset 1 3 If the compressor is running the DC is forced into defrost mode The control will remain in defrost mode as long as the jumper is in place When the jumper is removed the Front Front control will terminate defrost mode Figure 9 Fan Orientation Control Box End Table 10 9 thru 240 Unit Control Board Flash Codes GREEN RED RED RED RED FLASH CODE DESCRIPTION LED LED LED LED LED 16 8 4 2 1 On Steady This is a Control Failure bor bo oc 1 Flash Not Applicable _ _ _ _ __ ____ 3 Flashes HPS1 Compressor Lockout On 4 Flashes Not Applicable _ 5 Flashes LPS1 Compressor Lockout On 6 Flashes Not Applicable _ _ ___ 8 Flashes Not Applicable _ LC 10 Flashes Compressors Locked Out on Low Outdoor Air Temperature Flashing Off 12 Flashes Unit Locked Out due to Fan Over

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