INSTALLATION MANUAL SPLIT-SYSTEM CONDENSING UNITS (AIR COOLED) HB Ton HB Ton HB Ton NOTES, CAUTIONS AND WARNINGS

Transcription

1 INSTALLATION MANUAL SPLIT-SYSTEM CONDENSING UNITS (AIR COOLED) CONTENTS GENERAL SAFETY CONSIDERATIONS AGENCY APPROVALS INSPECTION INSTALLATION MAINTENANCE MODELS: HA Ton HB Ton HB Ton HB Ton See the following page for a complete Table of Contents. NOTES, CAUTIONS AND WARNINGS Installer should pay particular attention to the words: NOTE, CAUTION, and WARNING. Notes 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. CAUTION: READ ALL SAFETY GUIDES BEFORE YOU BEGIN TO INSTALL UNIT. SAVE THIS MANUAL YIM-A-0105

2 TABLE OF CONTENTS NOMENCLATURE GENERAL SAFETY CONSIDERATIONS REFERENCE AGENCY APPROVALS INSPECTION INSTALLATION LIMITATIONS LOCATION ROOFTOP LOCATIONS GROUND LEVEL LOCATIONS CLEARANCES RIGGING POWER WIRING START-UP PHASING CONTROL WIRING COMPRESSOR CRANKCASE HEATERS REFRIGERANT MAINS LINE SIZING SERVICE VALVES EVACUATION AND CHARGING PIPING AND ELECTRICAL CONNECTIONS PIPING AND ELECTRICAL CONNECTION SIZES START-UP CRANKCASE HEATER PRE-START CHECK INITIAL START-UP OPERATION SEQUENCE OF OPERATION OVERVIEW SAFETY CONTROLS PUMP OUT CONTINUOUS BLOWER INTERMITTENT BLOWER COOLING SEQUENCE OF OPERATION FLASH TIMES CONDENSER FAN OPERATION OPERATION WITH A TWO-STAGE THERMOSTAT OPERATION WITH A FOUR-STAGE THERMOSTAT.. 24 SECURE OWNER'S APPROVAL MAINTENANCE CLEANING CONDENSER SURFACE LUBRICATION COMPRESSOR REPLACEMENT LIST OF FIGURES Fig. # Pg. # 1 CORNER WEIGHTS & CENTER OF GRAVITY TYPICAL RIGGING FIELD WIRING DIAGRAM - HA 300 UNIT FIELD WIRING DIAGRAM - HB 360, 480, 600 UNITS HA/HB UNIT DIMENSIONS , 30 & 40 TON POWER AND CONTROL WIRING CONNECTIONS TON POWER AND CONTROL WIRING CONNECTIONS TON PIPING CONNECTIONS & 40 TON PIPING CONNECTIONS TON PIPING CONNECTIONS FAN ORIENTATION CONTROL BOX END TON CHARGING CHART TON CHARGING CHART TON CHARGING CHART TON CHARGING CHART TON CONDENSER UNIT WIRING DIAGRAM - 208/ TON CONDENSER UNIT WIRING DIAGRAM , OR 40 TON CONDENSING UNIT WIRING DIAGRAM - 208/ OR 40 TON CONDENSING UNIT WIRING DIAGRAM , TON CONDENSER UNIT WIRING DIAGRAM - 208/ TON CONDENSER UNIT WIRING DIAGRAM , Unitary Products Group

3 TABLE OF CONTENTS - Con t. LIST OF TABLES Tbl. # Pg. # 1 PHYSICAL DATA UNIT APPLICATION DATA CORNER WEIGHTS & CENTER OF GRAVITY (INCHES) MINIMUM CLEARANCES ELECTRICAL DATA SUCTION LINES LIQUID LINES Tbl. # Pg. # 8 R-22 LINE CHARGE UNIT DIMENSIONS (INCHES) PIPING AND ELECTRICAL CONNECTION SIZES (25T) (INCHES) PIPING AND ELECTRICAL CONNECTION SIZES (30/ 40/50T) (INCHES) ELECTRICAL POWER KNOCKOUT SIZES (INCHES) STATUS LED FLASH RATE CHART Unitary Products Group 3

4 NOMENCLATURE PRODUCT NOMENCLATURE YORK OUTDOOR SPLIT CONDENSING UNITS H A 300 C 00 A 2 A AA 2 Model # Model Number Description Options H Product Category H = Air Conditioner Split System A 300 Product Identifier Nominal Cooling Capacity MBH A = R-22 Standard Efficiency 2-Pipe B = R-22 Standard Efficiency 4-Pipe 300 = 25 Ton 360 = 30 Ton 480 = 40 Ton 600 = 50 Ton C Heat Type C = Cooling Only 00 Nominal Heating Capacity 00 = No Heat Installed A Airflow Options A = Standard Motor 2 Voltage A Installation Options 2 = 208/ = A = None B = Disconnect 5 = C = Service Valves D = Service Valves + Disconnect AA Additional Options AA = None AC = Technicoated Coil 2 Product Generation 1 = 1st Generation 2 = 2nd Generation NOTE: HB models are designed for 4-Pipe (dual) applications only. 4-Pipe condensing units cannot be matched with one single 2-Pipe air handler. 4 Unitary Products Group

5 GENERAL 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, the filter drier, the control wiring and the main power wiring are required to complete the installation. Each unit is dehydrated, evacuated, leak tested and pressure tested at 450 psig before being pressurized with a holding charge of refrigerant-22 for shipment and/or storage. All controls are located in the front of the unit and are readily accessible for maintenance, adjustment and service. All wiring (power and control) can be made through the front of the unit. SAFETY CONSIDERATIONS Installer should pay particular attention to the words: NOTE, CAUTION, and WARNING. Notes 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 additional information, consult a qualified installer or service agency. 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. REFERENCE This instruction covers the installation and operation of the basic condensing unit. For information on the installation and operation of the evaporator blower units, refer to instruction Form No All accessories come with a separate Installation Manual. Refer to Parts Manual for complete listing of replacement parts on this equipment. AGENCY APPROVALS Design certified by ETL as follows: 1. For use as a cooling unit. 2. For outdoor 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. Unitary Products Group 5

6 TABLE 1: PHYSICAL DATA Model HA/HB Compressor * Nominal Capacity Capacity Stages Qty. Dia. Pitch Deg. (tons) Condenser Fan (Propeller) Fan Motor Coil (Copper Tube-Aluminum Fin) Nom. CFM RPM HP Face Area (Ft. ) Rows Deep Coil Width (In.) Tube OD (In.) Fins per inch Unit Weight (Lbs.) Shipping Operation Charge, R-22 Operation (Lbs.-Oz.) Holding (Lbs.) System System /8 16 System System System System *. All compressors are Copeland Scrolls.. One of the fan motors is controlled by a pressure switch and will not operate until system pressure reaches 280 psig and drops below 180 psig.. The total operating charge of the condensing unit, matching indoor unit and 25 feet of interconnecting piping. TABLE 2: UNIT APPLICATION DATA Voltage Variation * Min. / Max. Ambient Air on Condenser Coil Min. /Max. Suction Pressure at Compressor and Corresponding Temp. at Saturation Min. / Max. 208/ / / / F/125 F 57.5 psig / 92.6 psig 32.0 ºF / 55.0 ºF *. Utilization range A in accordance with ARI Standard These units can operate in an ambient temperature of 125 F providing the wet bulb temperature of the air entering 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 condensing unit is designed for outdoor installation only. 6 Unitary Products Group

7 2. The condenser fans are the propeller type and are not suitable for use with ductwork in the condenser air stream. 3. The condensing unit and the evaporator should be positioned to minimize the number of bends in the refrigerant piping. 4. The condensing unit should be as close to the evaporator as practical. 5. The condensing unit 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. 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. See Figure 1. 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. The condensing unit must be mounted on level supports. The supports can be channel iron beams or wooden beams treated to reduce deterioration. TABLE 3: CORNER WEIGHTS & CENTER OF GRAVITY (INCHES) Unit Model Unit Weight (Lbs.) Unit Dimensions (Inches) A B C D Dim X Dim Y Weight A to D Weight B to C Shipping Operation Length Width HA HB HB HB FIGURE 1 - CORNER WEIGHTS & CENTER OF GRAVITY Unitary Products Group 7

8 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. 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. Do not permit overhanging structures or shrubs to obstruct condenser air discharge. RIGGING Exercise care when moving the unit. Do not remove any crating until the unit is near the place of installation. 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. When preparing to move the unit, always determine the center of gravity (see Table 3 and Figure 1) of the unit in order to equally distribute the weight. Slings connected to the compressor end of a unit will usually have to be made shorter, so the unit will lift evenly (see Figure 2). CLEARANCES The units must be installed with sufficient clearance for air to enter the condenser coil, for air discharge and for servicing access. See Table 4 for clearances. NOTE: Additional clearance is required to remove the compressors out the side of the unit, unless a means is available to lift the compressor out through the top of the unit. TABLE 4: MINIMUM CLEARANCES Clearance Description Distance in Inches Overhead (Top) 120 Front (Access Cover) 36 Rear (piping connections) 36 Left Side 30 Right Side 30 Bottom * 0 *. In all installations where snow accumulates and winter operation is expected, additional height must be provided to insure normal condenser airflow. FIGURE 2 - TYPICAL RIGGING Rig units by attaching chain or cable hooks to the holes provided on the base rail. See Figure 6 for details on rigging holes. The length of the spreader bars must exceed the width of the unit. Refer to Table 3 for unit weights. 8 Unitary Products Group

9 NOTE: If planning to handle the ton split with a fork truck, 1WS0407 skid for HA300/HB360 and 1WS0408 skid for HB480/600 units will be required. If handling a unit equipped with a 1WS skid, length of forks must be a minimum of 96. Fork lengths less than 96 will not span the required width of the skid and can cause damage to the unit s base rails or condenser coils. POWER WIRING Check the available power and the unit nameplate for like 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. Route the conduit through the large knockout located on the front of 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; this 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. START-UP PHASING The units are properly phased at the factory. Check for proper compressor rotation. If the fans or compressors rotate in the wrong direction at start-up, the electrical connection to the unit is misphased. Change the incoming line connection phasing to obtain proper rotation. (Scroll compressors operate in only one direction. If the scroll is drawing low amperage, has similar suction and discharge pressures, or producing a high noise level, the scroll is misphased.) Scroll compressors require proper rotation to operate correctly. Units are properly phased at the factory. Do not change the internal wiring to make the blower condenser fans or compressor rotate correctly. CONTROL WIRING Route the necessary low voltage control wires from the Simplicity control board to the thermostat and also from the low voltage condensing section control box or the terminal block inside the evaporator unit and to the evaporator fan motor controller. Refer to Figures 3 and 4 for field wiring diagrams. A terminal block is provided in the evaporator control box to accommodate the wiring from the evaporator solenoid valves. COMPRESSOR CRANKCASE HEATERS The compressors are equipped with crankcase heaters to prevent the migration of refrigerant to the compressors. The heaters are energized only when the unit is not running. If the main switch is disconnected for long periods of shut down, do not attempt to start the unit for 8 hours after the switch has been re-connected. This will allow sufficient time for all liquid refrigerant to be driven out of the compressor. Unitary Products Group 9

10 TABLE 5: ELECTRICAL DATA Unit Model Designation HA300 HB360 HB480 HB600 Power Supply Compressor Fan Motor Unit Qty. RLA (each) LRA (each) Power Supply HP Qty. FLA (each) Ampacity (Amps) Max. Fuse Size (Amps) Min. Disconnect Size 2 208/ / / / / / / / / / REFRIGERANT MAINS 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" ARMA- FLEX or equal. 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 must be completely insulated from each other. The liquid and suction connections permit leak testing, evacuation, and partial charging of the field piping and the evaporator without disturbing the condenser coils during initial installation. Before beginning installation of the mains, be sure that the unit has not developed a leak in transit. If pressure still exists in the system, it can be assumed to be leak free. DO NOT release the holding charge. A 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 sightglass can be used to check for excess moisture in the system or used as a visual means to verify refrigerant charge. All lines have a copper disc brazed over the end. Also, if the unit does not have service valves, the holding charge must be reclaimed to allow the installer to connect piping. The temperature required to make or break a brazed joint is sufficiently high to cause oxidation of the copper unless an inert atmosphere is provided. NOTE: Dry Nitrogen should flow through the system at all times when heat is being applied and until the joint has cooled. 10 Unitary Products Group

11 Remove the evaporator holding charge and any caps or discs on the liquid and suction connections that will not permit a free flow of nitrogen. NOTE: Always drill a small hole in sealing caps and discs before unbrazing to prevent the pressure in the line from blowing them off. NOTE: Solenoid and hot gas bypass valves (if used) should be opened manually or electrically during brazing or evacuating. The evaporator coil section is shipped with the side panels suitable for right end piping connections when viewed from the return air ends of the section. Begin the refrigerant mains by installing the liquid line from the condensing unit to the evaporator liquid connection, maintaining a flow of nitrogen during all brazing operations. The filter-drier and sight glass must be located in this line, close to the evaporator. Make the suction line connection at the evaporator and run the line to the condensing unit. For Units Without Service Valves - Reclaim the refrigerant holding charge prior to opening any portion of the system. Connect a low pressure Nitrogen source to the suction and liquid line service ports on the condensing unit. Drill a small hole in the sealing disk; the flow of Nitrogen will prevent any debris from entering the system. Unbraze the sealing disk and prepare the joint for connections of the main lines. Connect the lines while maintaining a flow of Nitrogen from the liquid line service port through the evaporator, back to the condensing unit and out the suction service port. For Units Equipped With Service Valves - Verify the service valves are fully seated by screwing the stem down into the valve body until it stops. Connect a lowpressure nitrogen source to the service port on the valve body. The flow of Nitrogen will prevent oxidation of the copper lines during installation. Drill 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 the valve body from overheating during the brazing process. Overheating the valve will damage the valve seals. Ensure the valve is adequately protected prior to any brazing on the valve body. Unbraze the sealing disk and prepare the joint for connections of the main lines. Connect the lines while maintaining a flow of Nitrogen from the liquid line valve service port through the evaporator, back to the condensing unit and out the suction valve service port. Once the brazing process is complete, leak testing should be done on all interconnecting piping and the evaporator before proper evacuation to 500 microns is performed. Once the line set and evaporator section is properly evacuated the service valves can be opened and the condensing unit is now ready to charge with the appropriate weight of refrigerant. 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. Tables 6 and 7 list friction losses for both the suction and liquid lines on the condensing section. 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. Evaporator Below Condensing Section - On a split system where the evaporator blower is located below the condensing section, the suction line must be sized for both pressure drop and for oil return. See Table 6. Condensing Section Below Evaporator - When the condensing section is located below the evaporator blower, the liquid line must be designed for the pressure drop due to both friction loss and vertical rise. See Table 10. If the pressure drop due to vertical rise and friction exceeds 40 psi, some refrigerant will flash before it reaches the 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 that starves the evaporator. 3. Erodes the seat of the refrigerant control device. 4. Causes erratic control of the refrigerant entering the evaporator. SERVICE VALVES These condensing units may have service valves on the compressor suction line and on the liquid line Unitary Products Group 11

12 leaving the condenser coil or if so equipped from the factory, if chosen as an option. The liquid and suction line service valves have an access port for evacuating, charging and pressurechecking the system. 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. EVACUATION AND CHARGING Determine the required weight of refrigerant using Table 1, Physical Data and Table 8, Refrigerant Line Charge. Table 1 includes operating charge based on the unit plus 25 feet of refrigerant lines. Table 8 includes data required to adjust the charge for line lengths other than 25 feet. Connect a vacuum pump through a charging manifold to both the liquid service port connection on the liquid line and the suction service port connection on the suction line. Vacuum pump connection lines should be short and no smaller than 3/8" OD. The refrigerant mains and the evaporator may now be evacuated. After proper evacuation and dehydration, charge the required weight of liquid refrigerant into the liquid access connection. After refrigerant flow slows, start the compressor and continue to charge refrigerant gas through the suction service port connection. If proper equipment is not available for weighing in the refrigerant charge, moisture indicating sight glass may be used to aid in charging the unit. After proper evacuation and dehydrating of the unit, charge the unit as described above until the moisture indicating sight glass is clear. The correct refrigerant pressures are indicated as shown in Figures 12 through 15. Operating compressor with suction pressure below 23 psi will result in overheating of the scrolls and permanent damage to the compressor drive bearing. 12 Unitary Products Group

13 TABLE 6: SUCTION LINES Model Designation HA300 System #1 HB360 HB480 HB600 System #1 System #2 System #1 System #2 System #1 System #2 Nominal Capacity (Tons) Refrigerant Flow Rate (Lbs./Min.) Full Capacity Half Capacity Full Capacity Half Capacity Full Capacity Half Capacity Full Capacity Half Capacity Full Capacity Half Capacity Full Capacity Half Capacity Full Capacity Half Capacity Copper Tubing (Inches, O.D.) Refrigerant Gas Velocity (Ft./Min.) Friction Loss (PSI/100 Ft.) 2 1/ / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / / Unitary Products Group 13

14 TABLE 7: LIQUID LINES Model Designation Nominal Capacity (Tons) Refrigerant Flow Rate (Lbs./Min.) HA300 System #1 Full Capacity HB360 HB480 HB600 System #1 Full Capacity System #2 Full Capacity System #1 Full Capacity System #2 Full Capacity System #1 Full Capacity System #2 Full Capacity Copper Tubing (Inches, O.D.) Refrigerant Liquid Velocity (Ft./Min.) Friction Loss (PSI/100 Ft.) 5/ / / / / / / / / / / / / / / / / / / / / TABLE 8: R-22 LINE CHARGE * LINE SET, O.D. O.D., (INCHES) REFRIGERANT, LB/FT LIQUID 7/ SUCTION 1 5/ / *. Charges based on 40ºF suction temperature and 105ºF liquid temperature.. Type L copper tubing. NOTE: Add the operating charge of the condensing unit, evaporator coil and 25 feet of interconnecting piping to any additional piping refrigerant charge required (determined from Table 8) for total system charge. 14 Unitary Products Group

15 Note 1 Note 1. See page 16 and 22 for details on wiring HA/HB models to non LA/LB indoor models. FIGURE 3 - FIELD WIRING DIAGRAM - HA 300 UNIT Unitary Products Group 15

16 FIGURE 4 - FIELD WIRING DIAGRAM - HB 360, 480, 600 UNITS 16 Unitary Products Group

17 REAR LEFT B A C G H D E FRONT F RIGHT FIGURE 5 - HA/HB UNIT DIMENSIONS TABLE 9: UNIT DIMENSIONS (INCHES) MODEL A B C D E F G H HA HB HB HB PIPING AND ELECTRICAL CONNECTIONS Piping connections are made from the rear of the unit. Connections can be made directly to the suction and liquid piping or if so equipped to the optional suction and liquid line service valves. With the piping connections being made at the rear of the unit, piping can be routed to the unit from the left or right side. Electrical connections for power and control wiring is made from the front of the unit, left of the electrical control box access. See Tables 10, 11 and 12 and Figures 6 thru 10 for piping sizes and electrical knockout details. Unitary Products Group 17

18 Control Wiring Power Wiring FIGURE 6-25, 30 & 40 TON POWER AND CONTROL WIRING CONNECTIONS Control Wiring Power Wiring FIGURE 7-50 TON POWER AND CONTROL WIRING CONNECTIONS 18 Unitary Products Group

19 PIPING AND ELECTRICAL CONNECTION SIZES TABLE 10: PIPING AND ELECTRICAL CONNECTION SIZES (25T) (INCHES) CONNECTION ENTRY SUCTION LINE SYS #1 LIQUID LINE SYS #1 SIZE 1-5/8 OD 7/8 OD POWER WIRING KNOCKOUT SEE TABLE 12 CONTROL WIRING 7/8 HOLE TABLE 11: PIPING AND ELECTRICAL CONNECTION SIZES (30/40/50T) (INCHES) CONNECTION ENTRY SUCTION LINE SYS #1 LIQUID LINE SYS #1 SUCTION LINE SYS #2 LIQUID LINE SYS #2 SIZE 1-5/8 OD 7/8 OD 1-5/8 OD 7/8 OD POWER WIRING KNOCKOUT SEE TABLE 12 CONTROL WIRING 7/8 HOLE TABLE 12: ELECTRICAL POWER KNOCKOUT SIZES (INCHES) CONNECTION ENTRY 25T/230V 25T/ V T/230V T/ V E POWER WIRING 2 1-1/2 2-1/2 1-1/2 Liquid Suction FIGURE 8-25 TON PIPING CONNECTIONS Unitary Products Group 19

20 Liquid (Sys 2) Liquid (Sys 1) Suction (Sys 1) Suction (Sys 2) FIGURE 9-30 & 40 TON PIPING CONNECTIONS FIGURE TON PIPING CONNECTIONS 20 Unitary Products Group

21 START-UP CRANKCASE HEATER The crankcase heater must be energized at least 8 hours before starting the compressor. To energize the crankcase heater, 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. 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? 5. Does the available power supply agree with the nameplate data on the unit? 6. Is the control circuit transformer set for the proper voltage? 7. Have the fuses, disconnect switch and power wire been sized properly? 8. Are all compressor hold-down nuts 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 oil residue? 11. 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. 6. Check for refrigerant leaks. 7. 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. OPERATION NOTE: The timing intervals described in the following procedures are nominal. Some variations will naturally occur due to differences in individual components, or due to variations in ambient temperature or line/control voltage. Refer to the wiring labels inside of the unit control access panel for additional information. SEQUENCE OF OPERATION OVERVIEW These series of condensing units, come factory equipped with Simplicity controls to monitor all unit functionality and safety controls. Unitary Products Group 21

22 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. Additionally, a minimum run time is imposed anytime a compressor is energized to allow proper oil return to the compressor. 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 12). 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 low-pressure switch opens, the Simplicity 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 control board will lock-out the associated compressor and flash an error code (see Table 12). An ambient air switch will lock out mechanical cooling at 40 F. In order to operate the unit in ambient temperatures below 40 F, the optional low ambient kit must be field installed which will allow the unit to operate during conditions down to 0 F. 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. PUMP OUT The pump out function is a standard feature on the 25 to 50 ton systems. The pump out circuit is activated each time the first and third compressor stage is called for by the thermostat. As such, it s a Pump Out On Start Up design. A normally closed solenoid valve (POS1, 2, 3 or 4) is placed in the liquid line, just prior to expansion valve. When cooling is not being called for by the thermostat, the pump out solenoid (POS) is not energized, so it s in the closed position. When the Simplicity control receives a call for cooling, it energizes a compressor. With the POS being closed, it causes the pressure on the low side of the system to begin falling. When the low pressure switch (LPS) opens, the control board energizes its on-board pump out relay, providing a 24vac output to an external relay used to energized the pump out solenoid. The refrigeration circuit being controlled is not in normal operating mode. If the low pressure switch is already open on a call for cooling, the pump out relay is energized immediately. If the LPS does not open after 5 minutes, the pump out relay is energized. CONTINUOUS BLOWER By setting the room thermostat to ON, 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. 22 Unitary Products Group

23 COOLING SEQUENCE OF OPERATION When the thermostat calls for the first stage of cooling, the low-voltage control circuit from the R to Y1 and G is completed. The Simplicity control board activates the first stage of cooling by energizing compressor one and both condenser fans of system one. After completing the specified fan on delay for cooling, the Simplicity control board will energize the indoor blower motor. When the thermostat calls for the second stage of cooling, the low-voltage control circuit from R to Y2 is completed. The control board will energize compressor two. If there is an initial call for both stages of cooling, the Simplicity control board will delay energizing compressor two by 30 seconds in order to avoid an excessive power rush. When the thermostat calls for the third stage of cooling, the low-voltage control circuit from the R to Y3 is completed. The Simplicity control board activates the third stage of cooling by energizing compressor three and both condenser fans of system two. When the thermostat calls for the fourth stage of cooling, the low-voltage control circuit from R to Y4 is completed. The control board will energize compressor four. Once the thermostat has been satisfied, the Simplicity control board will de-energize Y1, Y2, Y3 and Y4. If the compressors have satisfied their minimum run times, the compressors and condenser fans are de-energized. Otherwise, the unit operates each cooling stage until the ASCD has elapsed. Upon the completion of first stage cooling, the blower is stopped following the completion of the fan off delay cycle. FLASH TIMES The control will flash 1/4 second on and 1/4 second off for error codes. Only the active alarms will be flashed. The control will separate the flash codes with a 2-second off delay between flash codes. Under normal operation, the control will flash the LED at a rate of 1 second on and 1 second off. This will be the Heart Beat. Flash rates marked with an asterisk (*) are NOT alarms. TABLE 13: STATUS LED FLASH RATE CHART Flash Codes Description On Steady This is a Control Failure 1 Flash Not Applicable 2 Flash Control Waiting ASCD* 3 Flash HPS1 Compressor Lockout 4 Flash HPS2 Compressor Lockout 5 Flash LPS1 Compressor Lockout 6 Flash LPS2 Compressor Lockout 7 Flash FS1 Compressor Lockout 8 Flash FS2 Compressor Lockout 9 Flash 24 Volts not present at limit Terminal 10 Flash Compressor locked out on low outdoor temperature* 11 Flash Not applicable on split systems. 12 Flash Unit Locked out due to Fan Overload Switch Failure 13 Flash Compressor Held Off due to low voltage 14 Flash EEPROM Storage Failure OFF No Power Control or Failure CONDENSER FAN OPERATION These condensing units are factory equipped with fan cycling switches to regulate system head pressure. When outdoor ambient conditions are cool, the head pressure of any air conditioning system may drop too low for optimal performance. These condensing units maximize system performance in a variety of ambient conditions by incorporating fan cycling switches to maintain proper system head pressure. On these condensing units, the condenser fans of a given system are powered when compressor one is energized. Fan one will start immediately upon a call for first stage cooling. However, fan two is equipped with a fan cycling switch and will not start until the system head pressure reaches 280 psig. Condenser fan two will operate until the system head pressure drops below 180 psig where the fan cycling switch will shut the fan down. The unit will continue to operate condenser fan one until the system head pressure reaches 280 psig at which time condenser fan two will restart. See Fan Orientation on page 24 Figure 11. Unitary Products Group 23

24 1. Terminals Y1 and Y2 of the Simplicity control board controlling system one, should be connected to stage one and two of the thermostat. 2. Terminals Y3 and Y4 of the Simplicity control board controlling system two, should be connected to stage three and four of the thermostat. SECURE OWNER'S APPROVAL FIGURE 11 - FAN ORIENTATION CONTROL BOX END These 4-pipe condensing units can also be used with two appropriately sized indoor units. In this case, each indoor unit will have it s own thermostat. One thermostat will connect to Y1 and Y2 on the Simplicity control board and the other will connect to Y3 and Y4. OPERATION WITH A TWO-STAGE THERMOSTAT If the total system is to be controlled with a 2-stage thermostat (HA300): 1. Terminals Y1 and Y2 of the Simplicity control board controlling system one, should be connected to stage one and two of the thermostat. OPERATION WITH A FOUR-STAGE THERMOSTAT If the total system is to be controlled with a 4-stage thermostat (HB360, HB480 and HB600): When the system is functioning properly, secure the owner's approval. Show him the location of all disconnect switches and the thermostat. Teach him how to start and stop the unit and how to adjust temperature settings within the limitations of the system. MAINTENANCE CLEANING CONDENSER SURFACE Dirt should not be allowed to accumulate on the condenser coils or other parts in the condenser air circuit. Clean as often as necessary with a brush, vacuum cleaner attachment or other suitable means. LUBRICATION These fan motors are equipped with factory lubricated and sealed ball bearings. They do not require any maintenance. COMPRESSOR REPLACEMENT Obtain replacement compressor or parts from your local Distributor. 24 Unitary Products Group

25 25-ton Charging Chart Discharge Pressure (PSI) Outdoor Temperature 115º 105º 95º 85º 75º 65º Suction Pressure (PSI) 1. Ensure all condenser fans are running when charging unit. One fan may shut down at lower ambient temperatures making the chart above inaccurate. 2. This chart is applicable to the unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, the chart above may no longer apply. FIGURE TON CHARGING CHART Discharge Pressure (PSI) ton Charging Chart Outdoor Temperature 115º 105º 95º 85º 75º 65º Suction Pressure (PSI) 1. Ensure all condenser fans are running when charging unit. One fan may shut down at lower ambient temperatures making the chart above inaccurate. 2. This chart is applicable to the unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, the chart above may no longer apply. FIGURE TON CHARGING CHART Unitary Products Group 25

26 Discharge Pressure (PSI) ton Charging Chart Outdoor Temperature 115º 105º 95º 85º 75º 65º Suction Pressure (PSI) 1. Ensure all condenser fans are running when charging unit. One fan may shut down at lower ambient temperatures making the chart above inaccurate. 2. This chart is applicable to the unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, the chart above may no longer apply. FIGURE TON CHARGING CHART Discharge Pressure (PSI) ton Charging Chart Outdoor Temperature 115º 105º 95º 85º 75º 65º Suction Pressure (PSI) 1. Ensure all condenser fans are running when charging unit. One fan may shut down at lower ambient temperatures making the chart above inaccurate. 2. This chart is applicable to the unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, the chart above may no longer apply. FIGURE TON CHARGING CHART 26 Unitary Products Group

27 FIGURE TON CONDENSER UNIT WIRING DIAGRAM - 208/ Unitary Products Group 27

28 FIGURE TON CONDENSER UNIT WIRING DIAGRAM , Unitary Products Group

29 FIGURE or 40 TON CONDENSING UNIT WIRING DIAGRAM - 208/ Unitary Products Group 29

30 FIGURE or 40 TON CONDENSING UNIT WIRING DIAGRAM , Unitary Products Group

31 FIGURE TON CONDENSER UNIT WIRING DIAGRAM - 208/ Unitary Products Group 31

32 FIGURE TON CONDENSER UNIT WIRING DIAGRAM , Subject to change without notice. Printed in U.S.A. Copyright 2005 by Unitary Products Group. All rights reserved YIM-A-0105 Supersedes: YIM-C-0404/ C-0404 Unitary 5005 Norman Products York OK Group Drive 73069