Table of Contents
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CONTENTS
1.0 IMPORTANT SAFETY INFORMATION ......................................................3
2.0 GENERAL INFORMATION ....................................................................4-5
2.1 Introduction ..........................................................................................4
2.2 Agency Performance Audit Testing Notice ..........................................4
2.3 Importance of a Quality Installation ....................................................4
2.4 System Sizing and Selection .................................................................4
2.5 Importance of Proper Indoor/Outdoor Match-Ups ............................5
2.6 Checking Product Received ..................................................................5
2.7 Compressor Break-In Notice ................................................................5
3.0 UNIT SPECIFICATIONS .........................................................................5-6
3.1 Model Number Nomenclature and Available Models ........................5
3.2 Electrical and Physical Data ..................................................................6
4.0 INSTALLATION ...................................................................................7-26
4.1 Tools & Refrigerant ...............................................................................7
4.1.2 Specifications of R-410A ...........................................................7
4.1.3 Quick Reference Guide for R-410A ...........................................7
4.2 Choosing a Location .............................................................................8
4.2.1 Allowable Clearances ................................................................8
4.2.2 Operational Issues Related to Unit Location ............................8
4.2.3 Corrosive Environments ...........................................................9
4.2.4 Customer Satisfaction Issues ....................................................9
4.3 Mounting Unit ......................................................................................9
4.3.1 Unit-Mounting Methods ..........................................................9
4.3.2 High Wind and Seismic Tie-Down Methods ............................9
4.3.3 Elevating Unit ..........................................................................10
4.4 Refrigerant Line Set Selection ............................................................10
4.4.1 Replacing Existing Systems .....................................................10
4.4.2 Line Set Length and Fitting Losses ..........................................10
4.4.3 Liquid Line Selection ...............................................................11
4.4.4 Suction Line Selection .............................................................11
4.4.5 Long Line Length Considerations ............................................14
4.4.5.2 Oil Return to Compressor ..................................................14
4.4.5.3 Refrigerant Migration During Off Cycle .............................14
4.4.5.4 Maximum Liquid Pressure Drop ........................................14
4.4.5.5 Liquid Line Refrigerant Flashing .........................................14
4.4.5.6 Compressor Oil Level Adjustment .....................................15
4.4.5.7 Capacity Losses ..................................................................15
4.5 Line Set Installation ............................................................................16
4.5.1 Important Tubing Installation Practices .................................16
4.5.2 Relative Location of Indoor and Outdoor Units .....................17
4.5.2.1 Indoor and Outdoor Unit Near Same Level .......................17
4.5.2.2 Outdoor Unit Below Indoor Unit .......................................18
4.5.2.3 Outdoor Unit Above Indoor Unit .......................................19
4.5.3 Tubing Connections ................................................................20
4.6 Initial Leak Testing ..............................................................................21
4.7 Evacuation ..........................................................................................21
4.8 Final Leak Testing ................................................................................22
4.9 Control Wiring ....................................................................................22
Communications .....................................................22
Control Center or Thermostat Installation .............22
Communication Wiring Connections ......................22
4.10 Power Wiring ....................................................................................24
4.11 Grounding .........................................................................................25
2
5.0 SYSTEM START-UP AND REFRIGERANT CHARGING .........................25-28
5.1 System Start-Up Overview ..................................................................25
Control Center Set-Up .........................................................25
5.4 Initial System Start-Up ........................................................................25
5.5 Indoor Air-Flow Verification ................................................................26
5.6 Refrigerant Charging ...........................................................................27
5.6.1 Measurement Device Set-Up ..................................................27
5.6.2 Preliminary Charging by Weight .............................................27
5.6.3 Preliminary Charging by Pressures ..........................................27
5.6.4 Final Charging by Liquid Subcooling .......................................28
5.6.5 R-410A Temperature Pressure Chart ......................................28
5.7 Completing Installation ..............................................................28
6.0 SEQUENCE OF OPERATION ..................................................................29
6.1 Cooling Mode ......................................................................................29
6.2 On-Demand Cooling Dehumidification ..............................................29
7.0 COMPONENTS & CONTROLS ..........................................................29-33
7.1 Compressor .........................................................................................29
7.2 Compressor/Fan Motor Capacitor ......................................................29
7.3 Compressor Contactor ........................................................................29
7.4 Compressor Crankcase Heater ............................................................29
2-Stage Outdoor Control (TSODC) ......................................30
7.5.1 TSODC Features and Connections ..........................................30
7.5.2 Overview of TSODC Operation ................................................31
7.5.3 Control Board Replacement ....................................................32
7.6 High and Low Pressure Controls .........................................................32
7.7 Outdoor Ambient Temperature Thermistor .......................................33
7.8 Outdoor Fan Blade ..............................................................................33
7.9 Outdoor Fan Motor .............................................................................33
8.0 ACTIVE COMPRESSOR PROTECTION ....................................................33
9.0 ACCESSORIES .......................................................................................34
9.1 Low Ambient Kit ..................................................................................34
9.2 Hard Start Kit .......................................................................................34
9.3 Crankcase Heater ................................................................................34
9.4 Compressor Sound Enclosure .............................................................34
10.0 DIAGNOSTICS AND TROUBLESHOOTING ......................................35-48
10.1 Test and Fault Recall Mode ...............................................................35
10.1.1 Test Mode ..............................................................................35
10.1.2 Fault Recall Mode ..................................................................35
10.1.3 Clearing Fault History ............................................................35
10.2 Status and Diagnostic Codes .............................................................36
10.3 Electrical Checks Flowchart ...............................................................39
10.4 Cooling Mechanical Checks Flowchart .............................................40
10.5 Checking Temperature Sensors ........................................................41
10.6 General Troubleshooting Guide ........................................................42
10.7 Service Analyzer Charts .....................................................................43
10.8 Troubleshooting Tips .........................................................................48
11.0 OUTDOOR UNIT MAINTENANCE ........................................................49
11.1 Outdoor Coil Cleaning .......................................................................49
11.2 Cabinet Cleaning and Care ................................................................49
11.3 Motor Lubrication .............................................................................49
11.4 Replacement Parts ............................................................................49
12.0 WIRING DIAGRAMS ......................................................................50-51
12.1 2, 4, and 5 Ton Models - ECM Fan Motor ........................................50
12.2 3 Ton Model - PSC Fan Motor ..........................................................51
Communication Verification ......................25
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Table of Contents
Troubleshooting
