ZenAire 18 Installation And Operation Manual

Heat pump & cooling only 1.5-5 tons r454b up to 14.3 seer2

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INSTALLATION AND OPERATION MANUAL

Heat Pump ＆ Cooling Only

1.5-5 Tons R454B

UP TO 14.3 SEER2

Please read this manual carefully and keep it for future reference.

All the pictures in this manual are for illustrations purpose only.

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Page 1 INSTALLATION AND OPERATION MANUAL Heat Pump ＆ Cooling Only 1.5-5 Tons R454B UP TO 14.3 SEER2 Please read this manual carefully and keep it for future reference. All the pictures in this manual are for illustrations purpose only.
Page 2 RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION WARNING WARNING These instructions are intended as an aid to qualified licensed service personnel for proper installation, adjust- ment and operation of this unit. Read these instructions thoroughly before attempting installation or operation. Failure to follow these instructions may result in improper installation, adjustment, service or maintenance possibly resulting in fire, electrical shock, property damage, personal injury or death.
Page 3: Table Of Contents
CONTENTS 1 SAFETY Safety Signs Safety Precautions UNIT LOCATION CONSIDERATIONS Unit Dimensions Refrigerant Line Sizes Required Refrigerant Line Length Location Restrictions Refrigerant Charge and Room Area Limitations 3 UNIT PREPARATION Pre-installation 4 SETTING UP THE UNIT Pad Installation 5 REFRIGERANT LINE CONSIDERATIONS Service Valve Connection Sizes Refrigerant Line Insulation Reuse Existing Refrigerant Lines...
Page 4 16 SYSTEM OPERATION AND TROUBLESHOOTING 16.1 Compressor Crankcase Heater(CCH) 16.2 Reversing Valve 16.3 Protection Function 16.4 LED Status Defrost Mode 16.5 16.6 Electric Wiring Gauge 16.7 Trouble Code Table 17 SERVICE Maintenance 17.1 17.2 Changing Motor 18 CHECKLIST 19 DISPOSAL...
Page 5: Safety
1 SAFETY 1.1 Safety Signs This is the general warning sign. It is used to alert the user to potential hazards. All safety messages that follow this sign shall be obeyed to avoid possible harm. DANGER Indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury. WARNING Indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury.
Page 6: Safety Precautions
1.2 Safety Precautions Please read before proceeding DANGER ELECTRICAL HAZARD Failure to follow this warning could result in property damage, severe personal injury, or death. Wait five (5) minutes after disconnecting power prior to touching electrical components. NOTE This document is customer property and is to remain with this unit. Please return to service information pack upon completion of work.
Page 7 CAUTION CONTAINS REFRIGERANT Failure to follow proper procedures can result in personal illness or injury or severe equipment damage. System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening system. Flammable refrigerant used. WARNING This product can expose you to chemicals including Lead and Lead components, which are known to the State of Califor- nia to cause cancer and birth defects or other reproductive harm.
Page 8 WARNING Risk of electric shock. Can cause injury or death. Disconnect all remote electric power supplies before servicing. Risk of fire mild. Flammable refrigerant used. To be repaired only by trained service personnel. Do not puncture refrigerant tubing. Risk of fire. Dispose of properly in accordance with federal or local regulations. Risk of fire.
Page 9 Where electrical components are being changed, they shall be fit according to their purpose and to the correct specifi- cation. At all times the manufacturer’s maintenance and service guidelines shall be followed. If in doubt, consult the manufacturer’s technical department for assistance. The following checks shall be applied to installations using flammable refrigerants: –...
Page 10 WARNING Sealed electrical components shall be replaced. Intrinsically safe components must be replaced. Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.
Page 11 c) Before attempting the procedure ensure that: – mechanical handling equipment is available, if required, for handling refrigerant cylinders; – all personal protective equipment is available and being used correctly; – the recovery process is supervised at all times by a competent person; –...
Page 12 The refrigerant in the air conditioner is safe and normally does not leak. If the refrigerant leaks into the room and comes into contact with the fire of a burner, a heater or a cooker, a harmful gas could be released. Turn off any combustible heating devices, ventilate the room, and contact the dealer where you purchased the unit.
Page 13 WARNING This outdoor unit must combine the indoor unit with a refrigerant leak detection device. These instructions are exclusively intended for qualified contractors and authorized installers. Work on the refrigerant circuit with mild flammable refrigerant in safety group A2L may only be carried out by authorized heating contractors.
Page 14: Unit Location Considerations
2 UNIT LOCATION CONSIDERATIONS WARNING Ensure that apparatus is mounted securely. 2.1 Unit Dimensions Unit Dimensions Model H(inches) L(inches) W(inches) 18/24/30 23-3/5 23-3/5 29-1/7 29-1/7 42/48/60 32-7/8 29-1/7 29-1/7 Table 2-1 The unit’s weight value is on the cardboard box.
Page 15: Location Restrictions
Figure 2-2 NOTE Total Line Length _ Feet = Total Horizontal Line Length_ Feet + Total Vertical Change(Lift) _ Feet. 2.4 Location Restrictions WARNING The outdoor unit shall be located in a well-ventilated location other than the occupied space, such as in the open air. For installation of the indoor unit, refer to the corresponding installation and operation manual.
Page 16: Refrigerant Charge And Room Area Limitations
Min.12″ Snow barrier Snow legs 3-12″ Elevation Figure 2-5 2.5 Refrigerant Charge and Room Area Limitations In UL/CSA 60335-2-40, R454B refrigerant is classified as class A2L, which is mildly flammable. Therefore, R454B refrigerant will limit the area of the rooms being served by the system. Similarly, the total amount of refrigerant in the system shall be less than or equal to the allowable maximum refrigerant charge.
Page 17 14.9 7.48 15.8 16-8 7.48 11-5 0.62 0.06 16.7 16-8 7.48 11-15 0.55 0.05 17.7 16-8 7.48 12-11 0.46 0.04 18.6 16-8 7.48 13-5 0.38 0.04 0.30 19.5 16-8 7.48 13-15 0.03 20.4 16-8 7.48 14-10 0.22 0.02 21.4 16-8 7.48...
Page 18 The allowable maximum refrigerant charge A/TA Mmax Mmax M/TA lb-oz lb-oz 13.9 9-15 14.9 10-11 2-10 15.8 11-5 16.7 11-15 17.7 12-11 4-10 18.6 13-5 19.5 13-15 20.4 14-10 6-11 10.2 21.4 15-5 11.1 22.3 15-16 7-15 12.1 23.2 16-10 8-11 13.0 24.2...
Page 19 The minimum circulation airflow Qmin Qmin lb-oz lb-oz 10-2 10-9 11-0 11-8 3-15 11-14 12 -5 12-12 4-13 13-3 5-11 13-10 14-1 14-8 15-0 15-6 15-14 16-5 8-13 16-12 17-3 9-11 Table 2-7 If the altitude of installation is higher than 2000 ft，the required minimum room area follow as Table 2-8. Altitude(ft) 2001- 4001-...
Page 20 CAUTION The allowable maximum refrigerant charge of the Table 2-5 or the required minimum room area of the Table 2-6 is available only if the following conditions are met: Minimum velocity of 3.28ft/s, which is calculated as the indoor unit airflow divided by the nominal face area of the outlet. And the grill area shall not be deducted.
Page 21: Unit Preparation
3 UNIT PREPARATION 3.1 Pre-installation STEP 1 - Check for damage and report promptly to the carrier any damage found to the unit (Fig.3-1). STEP 2 - Instruments must be designed to install/serve R454B equipmens. Gauge sets, hoses, refrigerant containers and recovery system must be designed to handle the POE type oils.
Page 22: Refrigerant Line Considerations
5 REFRIGERANT LINE CONSIDERATIONS 5.1 Service Valve Connection Sizes Vapor line Liquid line Models connection connection 18/24/30/36/42 48/60 Table 5-1 Vapor line Figure 5-1 5.2 Refrigerant Line Insulation NOTE The vapor line must always be insulated. DO NOT allow the Liquid Line and Vapor Line to come in direct (metal to metal) contact.
Page 23: Reuse Existing Refrigerant Lines
5.3 Reuse Existing Refrigerant Lines CAUTION If using existing refrigerant lines make certain that all joints are brazed, not soldered. For retrofit applications, where the existing refrigerant lines will be used, the following precautions should be taken: Ensure that the size of the refrigerant lines is correct. Refer to Section 2.2 and Table 2-2. Ensure that the refrigerant pipe length is in the recommended range.
Page 24 8 Feet Maximum Jo ist/Raft er Bracket Side View 8 Feet Maximum Line Set Secure Vapor line from joists using isolators every 8 feet. Secure Liquid Line directly to Vapor line using tape, wire, or other appropriate method every 8 feet. Jo ist/Raft er Isolation In Spaces...
Page 25: Refrigerant Line Connection
7 REFRIGERANT LINE CONNECTION 7.1 Connecting to Refrigerant Lines WARNING Pipe work and installation shall be in compliance with national codes ASHRAE15. The installation of pipe-work shall be kept to a minimum. It is recommended to install a filter dryer，the filter drier should be installed in the liquid line between the outdoor unit's liquid line service valve and the indoor coil's metering device.
Page 26 3. Purge the refrigerant lines and indoor coil with dry nitrogen. This pipe must have a thimble Figure 8-3 4. Wrap a wet rag around the valve body to avoid heat damage and continue the dry nitrogen purge (Fig. 8-4). Braze the refrigerant lines to the service valves.
Page 27: Refrigerant Line Leak Check
9 REFRIGERANT LINE LEAK CHECK 9.1 Check for Leaks 1. Pressurize the refrigerant lines and evaporator coil to 600 psig and hold the pressure for 1 hour using dry nitrogen. 600 psig Figure 9-1 2. Check for leaks by using bubbles or refrigerant leak detector at each brazed location. Figure 9-2 Remove nitrogen pressure and repair any leaks before continuing.
Page 28: Evacuation
10 EVACUATION 10.1 Evacuate the Refrigerant Lines and Indoor Coil NOTE Do not open the service valves until the refrigerant lines and indoor coil leak check and evacuation are complete. 1. Evacuate until the micron gauge reads no higher than 350 microns, then close off the valve to the vacuum pump. 0350 Microns Figure 10-1...
Page 29: Electrical - Low Voltage
5/16” Hex Wrench for Vapor Service Valve 3/16” Hex Wrench Unit S ide for Liqu id Service Valve of Service Valve Roll ed Edge to Capti vate Stem Hex Headed Valve System Service Port Figure 11-1 12 ELECTRICAL - LOW VOLTAGE In the U.S.A., wiring must conform with current local, codes and the current National Electric Code (NEC).
Page 30: Low Voltage Wiring
12.1 Low Voltage Wiring electrical control box panel Power wiring electrical control box panel Control wiring Figure 12-1 Figure 12-2 WARNING Low Voltage line must be connected inside the outdoor unit case through control wiring channel on the right. High Voltage line must be connected through power wiring channel on the left.
Page 31: Electrical - High Voltage
13 ELECTRICAL - HIGH VOLTAGE In the U.S.A., wiring must conform with current local codes and the current National Electric Code (NEC). In Canada, wiring must conform with current local codes and the current Canadian Electrical Code (CEC). WARNING Installation and servicing of air conditioning equipment can be hazardous due to internal refrigerant pressure and live electrical components.
Page 32: High Voltage Power Supply
13.1 High Voltage Power Supply The high voltage power supply must match the equipment nameplate (208/230V~, 1PH, 60Hz). 13.2 High Voltage Disconnect Switch and Breaker Refer to the unit nameplate for minimum circuit ampacity, and maximum fuse or circuit breaker (HACR TYPE per NEC). Install power cords and properly sized disconnect switch and breaker.
Page 33: Start Up
2. Firstly thread the power cords (L1, L2) and ground wire through the power cords hole. Secondly connect L1, L2 and ground wire to terminals of the AC contactor properly one by one. Finally fasten the pipe of the power cords and ground wire. Refer to Figure 13-3.
Page 34: System Charge Adjustment
4. Wait one (1) hour before starting the unit if compressor crankcase heater is used and the outdoor ambient temperature is below 70 ºF. 60 MIN. Figure 14-3 5. Set system thermostat to ON. Figure 14-4 15 SYSTEM CHARGE ADJUSTMENT 15.1 Charging: Superheating Charging in Cooling for Piston Match-Ups(above 55 ºF outdoor temp) 1.Check the outdoor ambient temperatures.
Page 35 For best results the indoor temperature should be kept between 70 ºF to 80 ºF during the install. 80 ºF 70 ºF Indoor Temp. Figure 15-2 2. Ensure Sections 7,8,9,10,11,12,13,14 have been completed. 3. Stabilize the system by operating for a minimum of 20 minutes. NOTE At startup, or whenever charge is removed or added, the system must be operated for a minimum of 20 minutes to stabilize before accurate measurements can be made.
Page 36 Add 4° of Superheat Add 2° of Superheat Add 2° of Superheat Add 4° of Superheat Use Design Superheat Value Add 2° of Superheat Total Refrigerant Line Length-feet Table 15-2 Add 2° of Superheat Add 4° of Superheat Add 6° of Superheat Use Design Superheat Value Add 2°...
Page 37 Add 4° of Superheat Add 2° of Superheat Add 4° of Superheat Add 6° of Superheat Add 2° of Superheat Use Design Superheat Value Add 4° of Superheat Total Refrigerant Line Length-feet Table 15-6 Add 4° of Superheat Add 2° of Superheat Add 6°...
Page 38 R454B Refrigerant Superheat chart Final Superheat (°F) Suction Temp (°F) Suction Gauge Pressure (PSI) Table 15-9 Insulation Figure 15-4 6. Adjust refrigerant level to attain proper final superheat. NOTE Add refrigerant if the measured superheat is higher than the final superheat value. Connect gauges to refrigerant bottle and unit as illustrated (Fig.
Page 39 Figure 15-5 7. Stabilize the system. Wait 20 minutes for the system condition to stabilize between adjustments. NOTE When the vapor line pressure match the chart, the system is properly charged. Remove gauges. Replace service port caps to prevent leaks. Tighten finger tight plus an additional 1/6 turn. 20 MIN.
Page 40: Charging: Weigh-In Method
15.2 Charging: Weigh-In Method Weigh-In method can be used for the initial installation, or anytime a system charge is being replaced. Factory Charge multiplier for Model liquid line length Charge 3/8'' 1/2'' The data on All models nameplate 0.38 oz/ft 0.60 oz/ft Table 15-11 NOTE...
Page 41: System Operation And Troubleshooting
16 SYSTEM OPERATION AND TROUBLESHOOTING 16.1 Compressor Crankcase Heater (CCH) Refrigerant migration during the OFF cycle can result in noisy start-ups, therefore a Crankcase Heater (CCH) is used to minimize refrigerant migration thereby minimizing start-up noise and/or bearing “wash out”. All CCHs must be installed on the lower half of the compressor shell.
Page 42: Defrost Mode
16.5 Defrost Mode Manual defrost mode Enter manual defrost mode by dialing. The defrost mode exits by the logic of shut-down conditions of defrost mode. 16.6 Electric Wiring Gauge Model ( cooling only type ) Line Quantity Indoor Unit Power Line Line Diameter(AWG) Line Quantity Outdoor Unit...
Page 43: Service
Display content State description (T3) Temperature sensor fault Green light flashes 2 times every 8 seconds (T4) Temperature sensor fault Green light flashes 9 times every 8 seconds (T5) Temperature sensor fault Green light flashes 8 times every 8 seconds Low pressure alarm Green light flashes 6 times every 8 seconds System...
Page 44: Checklist
" Figure 17-1 18 CHECKLIST Operational and Checkout Procedures Final phases of this installation are the unit Operational and Checkout Procedures. To obtain proper performance, all units must be operated and charge adjustments made in accordance with procedures found in the Service Facts of the Outdoor Unit.

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