UNIT INFORMATION. Corp L7. Gauge Manifold Attachment... Page 30 Parts Arrangement... Page 8

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1 SERVICE UNIT INFORMATION Corp L7 CHA TON UNITS Litho U.S.A. CHA16 series units in the 2 5 ton sizes were introduced in the spring of The single package cooling units may be used in both residential and commercial applications. Electric heat is available in several Kw sizes. Units are designed for rooftop or side of building installation with either bottom or horizontal discharge. For commercial applications, the CHA16 is designed to accept any of several different thermostat control systems with minimum field wiring. Control options such as economizer, warm up kit, Honeywell W973 control or Honeywell W7400 control connect to the unit with jack plugs. When plugged in the controls become an integral part of the unit wiring. Commercial units are also equipped with a low voltage terminal strip to facilitate thermostat field wiring. CHA16 SERIES UNITS 2 THROUGH 5 TON UNITS All specifications in this manual are subject to change. TABLE OF CONTENTS Introduction Page 1 Heating Elements Page 29 Specifications Pages 2-4 IV PLACEMENT AND INSTALLATION Page 30 Electrical Data Page 5 V ELECTRICAL CONNECTIONS Page 30 Accessory Air Resistance Data Page 5 VI START-UP Page 30 Diffuser Air Resistance Data Page 5 VII REFRIGERATION SYSTEM SERVICE CHECKS. Pages 30,31 Blower Performance Data Pages 6-8 Gauge Manifold Attachment Page 30 Parts Arrangement Page 8 Charging Pages I APPLICATION Page 9 VIII BLOWER OPERATION AND ADJUSTMENT Page 32 II UNIT COMPONENTS Page 3 Blower Operation Page 32 Control Box Components Pages 9-13 Determining Unit CFM Page 32 Control Transformer Page 11 Blower Speed Adjustment Pages Low Voltage Terminal Strip Page 11 IX MAINTENANCE Page 35 Low Voltage Fuse Page 11 Filters Page 35 Cooling Contactor Page 11 Lubrication Page Volt Autotransformer Page 12 Electric Heat Page 36 Indoor Blower Relay Page 12 Evaporator Coil Page 36 Potential Relay Page 12 Condenser Coil Page 36 Start Capacitor Page 12 Electrical Page 36 Dual Capacitor Page 12 X ACCESSORIES Page 36 Compressor Run Capacitor Page 13 Lifting Lugs Page 36 Condenser Fan Capacitor Page 13 RMF16 Roof Mounting Frame Pages Cooling Components Pages Economizers Pages Compressor Page 15 Condenser Coil Guard Kit Page 46 Loss of Charge Switch Page 15 Compressor Crankcase Heater Page 46 Condenser Coil Page 15 DF16 Downflow Filter Kit Page 46 Evaporator Coil Page 16 Timed-off Control Kit Page 46,47 Thermometer Well Page 17 Optional Compressor Monitor Pages 46,48 Fan and Blower Components Pages Low Ambient Kit Pages 49,50 Condenser Fan and Motor Page 17 Roof Curb Power Kit Page 51 Condenser Fan Motor Capacitor Page 17 Transitions and Supply/Return Diffusers Page 51 Blower Motor Pages 17,18 Status Panels Pages Blower Motor Capacitor Page 18 XI FIELD WIRING Pages III OPTIONAL ECH16 ELECTRIC HEAT Page 18 XII WIRING DIAGRAMS AND SEQUENCE OF OPERATION Matchups and Ratings Page 18 Components Pages Wiring Diagrams and Sequence of Operation Pages Basic Residential Unit with Basic Thermostat. Pages 68,69 Conventional Relays Page 18 CHA16H with Three-Position Economizer..... Pages 70,71 Electric Heat Specification Tables Pages CHA16H with Modulating Economizer Pages 72,73 Electric Heat Parts Arrangements Pages Basic Single-Phase Commercial Unit Pages 74,75 Thermal Heat Relays Page 27 Basic 208/230V Three-Phase Commercial Unit Pages 75,76 Resistor Page 28 Basic 460V or 575V Commercial Unit Pages 78,79 Pilot Relay Page 28 Basic Three-Position Economizer Operation.. Pages 80,81 Time Delay Page 28 Basic Modulating Economizer Operation..... Pages 82,83 Current Limiting Fuses Page 28 Warm Up Kit Operation with 3-Position Econ. Pages 84,85 Primary High Temperature Limit Pages 28,29 Warm Up Kit Operation with Modulating Econ Pages 85,86 Secondary High Temperature Limit Page 29 Night Kit Operation Pages 87,88 Thermal Cutoff Page 29 Electric Heat Operation Pages Page Lennox Industries Inc.

2 ARI Standard 270 SRN (bels) *ARI Standard 210 Ratings SPECIFICATIONS CHA16H RESIDENTIAL HORIZONTAL ONLY UNITS Model No. CHA16H 261 CHA16H 311 Total Cooling Capacity (Btuh) Total unit watts SEER (Btuh/Watts) EER (Btuh/Watts) Refrigerant (R 22) charge Evaporator Blower Evaporator Coil Condenser Coil Condenser Fan Blower wheel nominal diameter x width (in.) Motor horsepower Air volume range (cfm) Net face area (sq. ft.) Tube diameter (in.) & Number of rows Fins per inch Net face area (sq. ft.) Tube diameter (in.) & Number of rows Fins per inch Diameter (in.) & Number of blades Air volume (cfm) Motor horsepower Motor watts Condensate drain size mpt (in.) Electrical characteristics Optional Electric Heat Ratings ECH16R 5 ECH16R 7 ECH16R 10 ECH16 15 Output Btuh A.F.U.E. Output Btuh A.F.U.E. Output Btuh A.F.U.E. Output Btuh A.F.U.E. Line voltage data Recommended max. fuse size (amps) Minimum circuit ampacity Optional Lifting Lug Kit Optional Condenser Coil Guards Optional Duct Enclosure Number and size of filters (in.) Optional Roof Mounting Frame (used with RDE16 41 only) Optional Model 3 position Economizer No. Modulating Dampers Number and Indoor with Gravity Exhaust size of filters (in.) Outdoor Step Down Optional Ceiling Supply and Flush Return Air Diffusers Transition Optional Outdoor Air Dampers (manual) Annual Fuel Utilization Efficiency based on DOE test procedures and FTC labeling regulations. Two stage cooling thermostat required with economizer applications. Sound Rating Number in accordance with ARI Standard 270. Indoor filter is not furnished and must be field provided , lbs. 12 oz. 9 x 7 1/ / / / / /230 volts 60 hz 1 phase LB 62125DB LB 82199CA RDE16 41 (1) 20 x 24 x 1 (fiberglass) RMF16 41 REMD16 41 REMD16M 41 (1) 16 x 25 x 1 (1) 14 x 25 x 1 (aluminum mesh) *Rated in accordance with ARI Standard 210 and DOE; 95 F outdoor air temperature and 80 F db/67 F wb entering evaporator air. **For LPG units a field changeover kit is required and must be ordered extra. 19, % 25, % 35, % 52, % RTD9 65 FD9 65 SRTH16 65 OAD3 46/ , lbs. 10 oz. 9 x 8 1/ / / / /4 19, % 25, % 35, % 52, % Page 2

3 SPECIFICATIONS CHA16R RESIDENTIAL UNITS Model No. ARI Standard 270 SRN (bels) *ARI Total Cooling Capacity (Btuh) Standard Total unit watts 210 SEER (Btuh/Watts) Ratings EER (Btuh/Watts) Refrigerant (R 22) charge Blower wheel nom. dia. x width (in.) Evaporator Motor horsepower Blower Air volume range (cfm) Net face area (sq. ft.) Evaporator Tube dia. (in.) & Number of rows Coil Fins per inch Outer coil Net face area (sq. ft.) Inner coil Condenser Tube dia. (in.) & Number of rows Coil Fins per inch Diameter (in.) & Number of blades Condenser Air volume (cfm) Fan Motor horsepower Motor watts Condensate drain size mpt (in.) Line voltage Recommended max. fuse size (amps) data Minimum circuit ampacity Electrical characteristics Output Btuh ECH16R 5 A.F.U.E. Output Btuh ECH16R 7 A.F.U.E. Optional Electric Heat Ratings ECH16R 10 ECH16 15 ECH16R 10 ECH16 15 Optional Lifting Lug Kit Optional Condenser Coil Guards Output Btuh A.F.U.E. Output Btuh A.F.U.E. Output Btuh A.F.U.E. Output Btuh A.F.U.E. Optional Downflow Adaptor Kit Model no, Filters Optional Outdoor Air Dampers (manual) CHA16R , lbs. 12 oz. 10 x 7 1/ / / / / LB 82199CB OAD16 41 CHA16R , lbs. 9 oz. 10 x 8 1/ / / / / /230 volts 60 hz 1 phase DF16 65, (1) 20x25x1 LB 62125DB(polyurethane) LB 82199CC OAD16 65 CHA16R , lbs. 0 oz. 12 x 8 3/ / , % 26, % 36, % 53, % 70, % DF16 41, (1) 16x25x1 (polyurethane) 27, % 37, % 54, % 71, % 88, % 3/ / / , % 37, % 54, % 71, % 88, % Annual Fuel Utilization Efficiency based on DOE test procedures and FTC labeling regulations. Sound Rating Number in accordance with ARI Standard 270. *Rated in accordance with ARI Standard 210 and DOE; 95 F outdoor air temperature and 80 F db/67 F wb entering evaporator air. **For LPG units a field changeover kit is required and must be ordered extra. Page 3

4 Model No. ARI Standard 270 SRN (bels) *ARI Standard 210 Ratings Refrigerant (R 22) charge Evaporator Blower Evaporator Coil Condenser Coil Condenser Fan Total Cooling Capacity (Btuh) Total unit watts SEER (Btuh/Watts) EER (Btuh/Watts) Blower wheel nominal dia. x width (in.) Motor horsepower Air volume range (cfm) Net face area (sq. ft.) Tube dia. (in.) & No of rows & Fins/in. Net face area (sq. ft.) outer/inner Tube diameter (in.) & Number of rows Fins per inch Diameter (in.) & Number of blades Air volume (cfm) Motor horsepower & Motor watts Condensate drain size mpt (in.) Recommended max. Line voltage fuse size (amps) Data (60hz) Minimum circuit ampacity Electrical characteristics ECH16R 5 ECH16R 7 SPECIFICATIONS CHA16 COMMERCIAL UNITS 208/230v 1 ph 3 ph 460v 3 ph 1 ph 208/230v 3 ph 460v 3 ph Output Btuh A.F.U.E. Output Btuh A.F.U.E. Output Btuh A.F.U.E. Output Btuh CHA CHA CHA CHA CHA CHA , lbs. 12 oz. 10 x 7 1/ / /8.40 3/ / /4 45 *Rated in accordance with ARI Standard 210 and DOE; 95 F outdoor air temperature and 80 F db/67 F wb entering evaporator air. Older CHA16 series units use optional field installed lifting lug kit LB 62125DB , lbs. 9 oz. 10 x 8 1/ / /5.90 3/ / / , lbs. 0 oz. 12 x 8 3/ / / / / / /230 volts 60 hz 1 or 3 phase 460 or 575 volts 3 phase 19, % 26, % 36,000 27, % 37,000 27, % 37,000 Optional ECH16R 10 Electric 99.0% 99.0% 99.0% 53,000 54,000 54,000 Heat ECH16 15 A.F.U.E. Ratings 99.0% 99.0% 99.0% Output Btuh 70,000 71,000 71,000 ECH16R 10 A.F.U.E. 99.0% 99.0% 99.0% ECH16 15 Output Btuh 88,000 88,000 A.F.U.E. 99.0% 99.0% Lifting Lugs (Brackets) Optional Condenser Coil Guards Furnished, Field Installed LB 82199CB Furnished, Factory Installed LB 82199CC Number and Size of Filters (in.) (1) 16x25x1 (polyurethane) (1) 20x25x1 (polyurethane) Optional Roof Mounting Frame RMF16 41 RMF16 41 or RMF position REMD16 41 REMD16 65 Optional Economizer Model No. Modulating REMD16M 41 REMD16M 65 Dampers No. & size Indoor (1) 14 x 25 x 1 (polyurethane) (1) 18 x 25 x 1 (polyurethane) of filters (in.) Outdoor (1) 14 x 25 x 1 (aluminum mesh) (1) 18 x 25 x 1 (aluminum mesh) Optional 3 position EMDH16 41 EMDH16 65 Horizontal Modulating EMDH16M 41 EMDH16M 65 Economizer Model No. No. & size Indoor (1) 20 x 24 x 1 (fiber glass) (1) 16 x 25 x 1 & (1) 14 x 25 x 1 (fiber glass) Dampers of filters (in.) Outdoor (1) 8 x 24 x 1 (aluminum mesh) (1) 8 x 28 x 1 (aluminum mesh) Optional Outdoor Air Dampers (manual) OAD16 41 OAD16 65 Step Down RTD9 65 Optional Ceiling Supply and Return Air Diffusers Flush FD9 65 Transition SRT16 65 Electromechanical Thermostat Honeywell W973 Control System with T7067 Thermostat Optional Controls Selection Honeywell W7400 Control System with T7400 Thermostat Flexstat Thermostat (discontinued as an option after August 1989) Prostat Thermostat T7300 Thermostat Downflow application 23H13 23H14 Optional Control Mounts Horizontal application 24H61 Commercial Controls Furnished Factory Installed Optional Gravity Exhaust Dampers GEDH16 65 (use with EMDH16 or EMDHM16) Optional Roof Curb Power Entry Kit Annual Fuel Utilization Efficiency based on DOE test procedures and FTC labeling regulations. 18H70 (1/2 ) Furnished as standard.consists of: factory installed controls wiring harness, high pressure switch, loss of charge switch, low voltage terminal strip and compressor crankcase heater. Sound Rating Number in accordance with ARI Standard 270. Page 4

5 Model No. ELECTRICAL DATA CHA16H AND CHA16(R) MODELS SINGLE PHASE VOLTAGE CHA16H-261 CHA16H-311 CHA16(R) 411 CHA16(R) 511 CHA16(R) 651 Line Voltage Data - 60Hz. 1ph Rated Load Amps Compressor Locked Rotor Amps Condenser Full Load Amps Fan Motor Locked Rotor Amps Evaporator Full Load Amps Blower Locked Rotor Amps Recommended Max. Fuse Size (amps) Unit Power Factor *Minimum Circuit Ampacity 208/230v 208/230v /230v /230v /230v Model No. CHA MODELS THREE PHASE VOLTAGE CHA CHA CHA Line Voltage Data - 60Hz. 3ph 208/230v 460v 575v 208/230v 460v 575v 208/230v 460v Compressor Rated Load Amps Locked Rotor Amps Condenser Full Load Amps Fan Motor Locked Rotor Amps Evaporator Full Load Amps Blower Locked Rotor Amps Recommended Max. Fuse Size (amps) Unit Power Factor *Minimum Circuit Ampacity Where current does not exceed 60 amps, HACR circuit breaker may be used in place of fuse. NOTE Extremes of operating range are plus and minus 10% of line voltage. *Refer to National Electrical Code manual to determine wire, fuse and disconnect size requirements. Motors are rated at 460 volts. Full Load Amps shown are for step-down transformer output. 575v Unit Model No. CHA16H 261 CHA16H 311 CHA CHA CHA Air Volume (cfm) With 1 Filter REMD16 Downflow Economizer Without Filter NOTE Electric heaters have no appreciable air resistance. *Air resistance is with air filter in place. Air resistance is with pleated non-woven cotton fabric filter. With Pleated 2 Filter ACCESSORY AIR RESISTANCE With Fiberglass 2 Filter Total Resistance (inches water gauge) EMDH16 Economizer Downflow With 1 Filter Without Filter *RDE16 41 Duct Enclosure DF16 Downflow Filter Adaptor Kit With 1 Filter With Pleated 2 Filter With Fiberglass 2 Filter Wet Evaporator Coil Page 5

6 Unit Model Number CHA16H-261 CHA16H-311 CHA CHA CHA DIFFUSER AIR RESISTANCE Air Volume (cfm) Ends Open RTD9 65 Diffuser 1 Side 2 Ends Open All Ends & Sides Open FD9 65 Diffuser CHA16H-261 BLOWER 230 VOLTS (With Horizontal Supply and Return Air Openings) External Static Air Volume Various Speeds Pressure(in. wg) High Med High Med Low Low NOTE All cfm data is measured external to unit. CHA16(R) BLOWER 230 VOLTS (With Horizontal Supply and Return Air Openings) External Static Air Volume Various Speeds Pressure(in. wg) High Med High Med Low Low NOTE All cfm data is measured external to unit. CHA16(R) BLOWER 230 VOLTS (With Horizontal Supply and Return Air Openings) External Static Air Volume Various Speeds Pressure(in. wg) High Med High Med Low Low NOTE All cfm data is measured external to unit. CHA16H-311 BLOWER 230 VOLTS (With Horizontal Supply and Return Air Openings) External Static Air Volume Various Speeds Pressure(in. wg) High Med High Med Low Low NOTE All cfm data is measured external to unit. CHA16(R) BLOWER 230 VOLTS (With Down Flow Supply and Return Air Openings) External Static Air Volume Various Speeds Pressure(in. wg) High Med High Med Low Low NOTE All cfm data is measured external to unit. Page 6

7 CHA16(R) BLOWER 230 VOLTS (With Down Flow Supply and Return Air Openings) External Static Air Volume Various Speeds Pressure(in. wg) High Med High Med Low Low NOTE All cfm data is measured external to unit. CHA BLOWER 460/575 VOLTS (With Horizontal Supply and Return Air Openings) External Static Air Various Speeds Pressure (in. wg) High Medium Low NOTE All cfm data is measured external to unit. CHA BLOWER 460/575 VOLTS (With Horizontal Supply and Return Air Openings) External Static Air Various Speeds Pressure (in. wg) High Medium Low NOTE All cfm data is measured external to unit. CHA BLOWER 460/575 VOLTS (With Horizontal Supply and Return Air Openings) External Static Air Various Speeds Pressure (in. wg) High Medium Low NOTE All cfm data is measured external to unit. CHA BLOWER 460/575 VOLTS (With Down Flow Supply and Return Air Openings) External Static Air Various Speeds Pressure (in. wg) High Medium Low NOTE All cfm data is measured external to unit. CHA BLOWER 460/575 VOLTS (With Down Flow Supply and Return Air Openings) External Static Air Various Speeds Pressure (in. wg) High Medium Low NOTE All cfm data is measured external to unit. Page 7

8 CHA BLOWER 460/575 VOLTS (With Down Flow Supply and Return Air Openings) External Static Air Various Speeds Pressure (in. wg) High Medium Low NOTE All cfm data is measured external to unit. CHA16(R) BLOWER PERFORMANCE@ 230 VOLTS (With Down Flow Supply and Return Air Openings) External Static Air Volume Various Speeds Pressure (in. wg) High Med High Med Med Low Low NOTE All cfm data is measured external to unit. CHA16(R) BLOWER PERFORMANCE@ 230 VOLTS (With Horizontal Supply and Return Air Openings) External Static Air Volume Various Speeds Pressure (in. wg) High Med High Med Med Low Low NOTE All cfm data is measured external to unit. CHA16H PARTS ARRANGEMENT CONDENSER FAN OPTIONAL RETURN CHA AND CHA16 510/650 PARTS ARRANGEMENT OPTIONAL SUPPLY SUPPLY EVAPORATOR COIL SUPPLY COMPRESSOR RETURN DRAIN CONTROL SUPPLY BOX BLOWER CONTACTOR EVAPORATOR COIL OPTIONAL ELECTRIC HEAT BLOWER RETURN FIGURE 1 Page 8 CONTROL BOX OPTIONAL ELECTRIC HEAT CONDENSER COIL COMPRESSOR

9 I APPLICATION CHA ton units are available in three model and three cabinet sizes (refer to the Engineering Handbook for more specific application data). CHA16H models are available only in the smallest cabinet and are applicable for residential installations with horizontal supply and discharge air only. CHA16H units are singlephase only and are not equipped for installation of Lennox optional thermostat control systems. CHA16R models are residential only units available in both the small and large convertible (downflow or horizontal) cabinets. CHA16R models, like the CHA16H models, are single-phase only and are not equipped for installation of Lennox optional thermostat control systems. CHA16 models are residential or commercial units available in single or three-phase and available in both the small and large convertible (downflow or horizontal) cabinets. CHA16 models are factory equipped with the hardware required for installing Lennox optional thermostat control systems. Lennox optional thermostat control systems are the same controls, harnesses, and harness plugs used in all 16 series commercial air conditioners, heat pumps and gas/electrics. For example, a Honeywell W973 control will plug in to a CHA as easily as it will plug in to a CHA (and no field wiring is required for either). II UNIT COMPONENTS CHA16 unit components are shown in figure 1. A Control Box Components CHA16H control box is shown in figure 2. The control box is located adjacent to the compressor compartment behind the electric heat access panel. CHA16R 411 and CHA control box is shown in figures 3 and 4. CHA16R 511/651 and CHA16 510/650 control box is shown in figures 5 and 6. In both units, the control box is located in the heating compartment behind the heating compartment access panel. The indoor blower access panel (all units) is located on the opposite side of the unit from the control box access. Figure 1 shows typical blower compartment access. CHA16H CONTROL BOX C1 CAPACITOR WIRING GROMMET K3 BLOWER RELAY C5 CAPACITOR T1 TRANSFORMER ELECTRIC HEAT SECTION K1 CONTACTOR FIGURE 2 Page 9

10 CHA16R 411 CONTROL BOX COMPONENTS WIRING GROMMET K3 BLOWER RELAY C12 DUAL CAPACITOR F1 FUSE T1 TRANSFORMER ELECTRIC HEAT SECTION K1 COMPRESSOR CONTACTOR FIGURE 3 WIRING GROMMET T1 TRANSFORMER CHA16 411/413 CONTROL BOX COMPONENTS C12 DUAL CAPACITOR (-411 Units) C1 FAN CAPACITOR (-413 UNITS) F1 FUSE K3 BLOWER RELAY T4 AUTO TRANSFORMER (CHA J only) TB1 TERMINAL BOARD WIRING GROMMET K31 POTENTIAL RELAY K3 BLOWER RELAY FIGURE 4 CHA16R 511/651 CONTROL BOX ELECTRIC HEAT SECTION K1 COMPRESSOR CONTACTOR C7 START CAPACITOR C12 DUAL CAPACITOR F1 FUSE T1 TRANSFORMER FIGURE 5 ELECTRIC HEAT SECTION K1 COMPRESSOR CONTACTOR Page 10

11 K3 BLOWER RELAY WIRING GROMMET CHA16 511/513/651/653 CONTROL BOX K31 POTENTIAL RELAY CHA16 511/651 units only C7 START CAPACITOR CHA16 511/651 units only T4 AUTO TRANSFORMER (CHA16 513/ v only) LOCATION FOR P AND Y VOLTAGE T1 TRANSFORMER F1 FUSE TB1 TERMINAL BOARD 1 Transformer T1 K1 COMPRESSOR CONTACTOR FIGURE 6 3 Transformer Fuse F1 LOCATION FOR G AND J VOLTAGE C12 DUAL CAPACITOR (CHA16 511/651 only) OR C1 CAPACITOR (CHA16 513/653 only) CHA16 series units use a single line voltage to 24VAC transformer located in the control box. The transformer supplies power to control circuits in the unit. Transformers are rated as shown in table 1. P voltage (208/230V) transformers use two primary voltage taps as shown in figure 7. Unit CHA16H-261 CHA16H-311 CHA16R-411/511/651 CHA16-411P/413Y CHA16-511P/513Y CHA16-651P/653Y CHA16-413G CHA16-513/653G CHA16-413/513/653J 2 Terminal Strip TB1 208 / 230 VOLT TRANSFORMER PRIMARY ORANGE 240 VOLTS RED 208 VOLTS BLACK TABLE 1 T1 TRANSFORMER RATING Primary Secondary 230VAC FIGURE 7 24VAC SECONDARY YELLOW BLUE VA Rating Internal Fuse 45 No Fuse 208/ 230VAC 24VAC A 480VAC 24VAC A 440VAC 24VAC A 575VAC 24VAC A All CHA16 commercial units are equipped with a low voltage terminal strip (TB1). The strip is used for making up all indoor thermostat and outdoor unit low voltage control wiring connections (see figures 4 and 6). The terminal strip is located at the bottom left corner of the control box. Transformers used in CHA16H and CHA16R units are not equipped with internal secondary voltage overcurrent protection. Transformers in all other units are equipped with an integral fuse connected in series with the blue secondary voltage wire. The fuse may be accessed outside the transformer and is rated as shown in table 1. 4 Cooling Contactor K1 K1 is a 24V to line voltage contactor used to energize the compressor and condenser fan in response to thermostat demand. Three-phase units use three-poledouble-break contactors. Single-phase units use single-pole contactors. WARNING Electric shock hazard. Can cause injury or death. Single-phase units are equipped with single-pole contactors. One leg of compressor, capacitor and condenser fan are always connected to line voltage. Turn off power at disconnect before servicing. NOTE Contactor K1 is energized by the thermostat control system. Depending on the control system installed, the contactors may or may not be immediately energized upon demand. Refer to the operation sequence for the control system installed. Page 11

12 5 Autotransformer T4 CHA (575V) units use a line voltage to 460V autotransformer to power the indoor blower. The autotransformer is connected directly to line voltage and is powered at all times. It has a maximum VA rating of 3.4A. See figure 8. AUTOTRANSFORMER T4 CHA J ONLY BROWN 460V 575V BLACK FIGURE 8 6 Indoor Blower Relay K3 (Cooling Speed) 208/230 volt units use a single 2PDT relay to energize the indoor blower motor. 460 volt and 575 volt units use a single 3PDT relay. The relay coil is energized by blower demand from indoor thermostat terminal G (cooling demand or fan switch in ON position). When the coil is energized, a set of N.O. contacts closes to energize the blower motor on high speed. When there is a demand for heat, the blower is energized by the blower relay located inside the electric heat section of the unit. 460 (G) and 575(J) voltage units use a unique blower motor. The motor utilizes a set of N.C. relay contacts (K3) to complete an internal circuit when the motor is on low or medium (heating) speed. 7 Potential Relay K31 Relay K31 is used in single-phase 511 and 651 units only and is located in the control box. It is a potential relay which controls the operation of the starting circuit. The relay is normally closed when the compressor (contactor K1) is de energized. Capacitor (C7) is connected to a set of N.C. K31 contacts and is used to assist the compressor in starting. When K1 energizes, the compressor immediately begins startup. K31 remains de energized during compressor start up and the start capacitor (C7) remains in the circuit. As the compressor gains speed K31 is energized by electromotive forces generated by the compressor. When K31 energizes, its contacts open to take the start capacitor out of the circuit. 8 Start Capacitor C7 TABLE 2 Unit CHA CHA16R-511 CHA CHA16R-651 Start Capacitor Ratings C7 Start Capacitor Rating VAC VAC RED All single-phase units (size 511 and larger) use a compressor start capacitor (C7) connected in parallel with the compressor side of dual capacitor C12. The start capacitor is energized during compressor startup and is switched off by potential relay K31 when the compressor nears full speed. Three-phase units do not use start capacitors. Table 2 shows start capacitor ratings for single-phase CHA16s. The capacitor is mounted in the unit control box. See figures 5 and 6 for capacitor location. NOTE Before servicing unit, be sure to identify the compressor and fan sides of dual capacitor C12. The start capacitor uses a 15K ohm 2 watt bleed resistor connected in parallel with the capacitor terminals. A resistor is used to slowly discharge the capacitor when not in use. 9 Dual Capacitor C12 CHA16 and CHA16R three, four and five ton singlephase units use permanent split capacitor (PSC) motors in both compressor and condenser fan. A single dual capacitor is used for both. A dual capacitor is two independent capacitors inside one can. The fan side of the capacitor and the compressor side of the capacitor have different ratings. The capacitor is located inside the compressor compartment. Refer to table 3. See figures 3, 4, 5 and 6 for location. TABLE 3 Run Capacitor Ratings Unit CHA16H-261 CHA16H-311 CHA CHA16R-511 CHA CHA16R-651 CHA CHA16R-411 CHA16H-261 CHA16H-311 CHA16-413Y CHA16-413G/413J CHA16-513Y/513G/513J CHA16-653Y/653G/653J Key Number C5 C5 C12 C12 C12 C1 C1 Type/ Rating Single Capacitor 30 mfd 370V Single Capacitor 35 mfd 370V Dual Capacitor 40 mfd compressor 7.5 mfd 440V Dual Capacitor 45 mfd compressor 7.5 mfd 440V Dual Capacitor 40 mfd compressor 5 mfd 370V Single Capacitor 5 mfd 370V Single Capacitor 7 mfd 370V Page 12

13 10 Compressor Run Capacitor C5 All single-phase units use permanent-split-capacitor compressor motors which require run capacitors to maximize compressor efficiency. Three ton and larger units use the compressor side of dual capacitor C12 while units smaller than three tons use a single run capacitor C5. Table 3 shows C5 run capacitors used in CHA16 single-phase units. Three-phase units do not use run capacitors. See figures 2 through 6 for capacitor location. 11 Fan Capacitor C1 All three-phase CHA16 units use single-phase PSC condenser fan motors. Motors are equipped with a fan run capacitor to maximize motor efficiency. The fan capacitor is located in the compressor compartment and is electrically connected as shown in the unit wiring diagram. Capacitor ratings are shown in table 3. In some single phase units, the fan capacitor is combined with the compressor run capacitor in C12. Refer to dual capacitor C12. B Cooling Components Summary of Features All units use DX cooling. Cooling in commercial units (CHA16) may also be supplemented by field-installed economizer. CHA16H 261/311, CHA16 411/413 and CHA16R 411 units use a single slab type enhanced fin evaporator with rifled tubing and capillary cap tubes as the primary expansion device (figure 10). CHA16R 511/651 and CHA16 511/513/651/653 units use a single slab type enhanced fin evaporator with rifled tubing and a thermal expansion valve TXV as the primary expansion device (figure 9). CHA16R and CHA16H series units are not equipped with crankcase heater, high pressure switch or loss of charge switch. All 510/ 650 units are equipped with thermometer well for charging. All models use draw through type condenser fans. PLUMBING COMPONENTS THERMAL EXPANSION VALVE SYSTEMS HIGH PRESSURE AND LOSS OF CHARGE SWITCHES USED ON CHA16 UNITS ONLY. EXPANSION VALVE SUCTION LINE GAUGE PORT CHA CHA16(R) 510/650 THERMOMETER WELL and LIQUID GAUGE PORT LIQUID LINE GAUGE PORT LIQUID LINE EVAPORATOR COIL CONDENSER COIL SUCTION LINE GAUGE PORT CHA DISCHARGE LINE LOSS OF CHARGE SWITCH (CHA16 only) HIGH PRESSURE SWITCH (CHA16 only) COMPRESSOR TERMINAL BOX FIGURE 9 Page 13

14 CHA16H 261 PLUMBING COMPONENTS CAPILLARY TUBE SYSTEMS SUCTION LINE EVAPORATOR COIL SUCTION LINE GAUGE PORT CONDENSER COIL CAPILLARY TUBES LIQUID LINE GAUGE PORT LIQUID LINE DISCHARGE LINE COMPRESSOR TERMINAL BOX CHA16H 311 SUCTION LINE GAUGE PORT SUCTION LINE EVAPORATOR COIL CONDENSER COIL CAPILLARY TUBES LIQUID LINE LIQUID LINE GAUGE PORT CHA16(R) 410 DISCHARGE LINE SUCTION LINE COMPRESSOR TERMINAL BOX LIQUID LINE GAUGE PORT LIQUID LINE EVAPORATOR COIL CONDENSER COIL COMPRESSOR TERMINAL BOX SUCTION LINE GAUGE PORT DISCHARGE LINE HIGH PRESSURE SWITCH (CHA16 only) LOSS OF CHARGE SWITCH (CHA16 only) FIGURE 10 Page 14

15 TABLE 4 CHA16 SERIES UNITS COMPRESSOR SPECIFICATIONS Unit Voltage/ Phase Locked Rotor Amps Rated Load Amps Oil Charge Fl. Oz. Viscosity Oil Type Crankcase Heater CHA16H 261 CHA16H 311 CHA16R 411 CHA CHA Y CHA CHA16R 511 CHA CHA CHA CHA CHA16R 651 CHA CHA CHA CHA /230/1 208/230/1 208/230/1 208/230/1 208/230/3 575/3 208/230/1 208/230/1 208/230/3 460/3 575/3 208/230/1 208/230/1 208/230/3 460/3 575/ *** *** ** *** *** *** ** *** * ** None 40 watt Insertion Type Self Regulating None 30 watt Insertion Type Self Regulating None 30 watt Insertion Type Self Regulating 40 watt Insertion Type Self Regulating *Texaco Capella WF 32 or Suniso 3GS or White Oil M/M Sontex 200 LT **Heat Pump Grade Mineral ***Not Specified 1 Compressor B1 Table 4 shows the specifications of compressors used in all units. Compressors used in CHA16 commercial units are equipped with insertion type crankcase heaters. All compressors are protected by internal pressure relief valves and internal overload protection circuitry. WARNING 2 High Pressure Limit S4 Electric Shock Hazard. Can cause injury or death. Do not operate without protective cover over terminals. Disconnect power before removing protective cover. Discharge capacitors before servicing unit. The high pressure limit is a manually reset SPST N.C. switch which opens on a pressure rise. All commercial units (CHA16) are equipped with the limit. CHA16R and CHA16H are not equipped with the limit. The switch is located in the compressor discharge line and is wired in series with the compressor contactor. When discharge pressure rises above psig (indicating a problem in the system) the switch opens and the compressor is de energized ( the economizer can continue to operate.) After the problem has been found and corrected, the switch can be reset by pushing the reset button. 3 Loss of Charge Switch S24 The loss of charge switch is an auto-reset SPST N.C. switch which opens on a pressure drop. All commercial units (CHA16) are equipped with the switch. CHA16R and CHA16H are not equipped with the switch. The switch is located in the compressor discharge line and is wired in series with the high pressure switch and compressor contactor. When discharge pressure drops below 25+5 psig (indicating a loss of charge in the system) the switch opens and the compressor is de energized. The switch automatically resets when refrigerant is added and discharge line pressure rises above 55+5 psig. 4 Condenser Coil All CHA16s have a single condenser coil. Each coil has two rows (CHA16 511/513 and CHA16R 511 have 1 1/2 rows) of copper tubes fitted with ripple edged aluminum enhanced fins. Page 15

16 5 Evaporator Coil All CHA16s have a single slab evaporator coil. The coil has two rows of rifled copper tubes fitted with ripple edged aluminum fins. An expansion device feeds multiple parallel circuits through the coil. EVAPORATOR PLUMBING CHA16H 261, CHA16H 311, CHA16 411/413 and CHA16R 411 SUCTION LINE EVAPORATOR a Capillary Tube Systems CHA16H 261, CHA16H 311, CHA16 411/413 and CHA16R 411 units use capillary tubes as the primary expansion device in the indoor coil. Multiple cap tubes feed independent parallel circuits through the coil. Expansion takes place at the point where the cap tubes enter the coil. See figure 11. EVAPORATOR PLUMBING CHA16 511/513, CHA16 651/653 CHA16R 511 and CHA16R 651 CAP TUBES CAPILLARY TUBE EXPANSION DEVICE EVAPORATOR EVAPORATOR LIQUID LINE EXPANSION VALVE FED BY LIQUID LINE EVAPORATOR SENSING BULB STRAPPED TO SUCTION LINE CAPILLARY TUBE EXPANSION DEVICE LIQUID LINE CAP TUBES EQUALIZER LINE FEEDER TUBES SUCTION LINE FEEDER TUBES SUCTION LINE FIGURE 11 FIGURE 12 Page 16

17 b Expansion Valve CHA through 650 series units use a Thermal Expansion Valve (TXV) as the primary expansion device. See figure Thermometer Well (Figure 13) All CHA16 510/650 series units are factory equipped with a thermometer well for charging the unit. The well is used to accurately measure the temperature of the liquid line. The temperature measured is then used to calculate the approach or subcooling temperature. Approach and THERMOMETER WELL THERMOMETER WELL LIQUID LINE GAUGE PORT LIQUID LINE FIGURE 13 subcooling temperatures are compared to tables printed in the charging section of this manual to determine the correct charge. Thermometer wells are equipped with a gauge port for connection of high pressure gauge. To accurately measure the temperature of the liquid line, the well should be filled with a light mineral oil before using. This will ensure good heat transfer to the thermometer. C Fan and Blower 1 Condenser Fan and Motor B4 3 Blower Motor B3 All CHA16 series units use single-phase PSC blower motors. A single run capacitor is mounted on the blower housing. All motors use multiple speed taps. Typically, the high speed tap is energized during compressor operation and a lower speed tap is energized during heating operation. Blower motors in CHA16 261, 311, 411 and 511 units have four speed taps. Motors in CHA units have five speed taps. All 460 voltage units have three taps. Blower motor specifications are listed in table 6. Blower performance ratings are listed in the tables on pages 6, 7 and 8. TABLE 6 BLOWER MOTOR 1075 RPM CCW ROTATION Unit Motor Volts Phase HP FLA CHA16H 261 CHA16H 311 CHA16 411/413 CHA16R 411 CHA / / / /3 1/3 1/3 1/ CHA16 511/513 CHA16R 511 CHA / /2 3/ CHA /4 0.7 CHA16 651/653 CHA16R / /4 4.6 CHA /4 1.8 CHA /4 0.7 The table on pages 2, 3 and 4 in this manual show the specifications of condenser fans used in CHA16s. The condenser fan in all units is controlled by cooling contactor K1. The condenser fan can be accessed by removing the fan grill located on top of the unit. 2 Condenser Fan Motor Capacitor C1 All CHA16s use single-phase PSC condenser fan motors. Table 5 shows fan run capacitor ratings for CHA16s. TABLE 5 CONDENSER FAN MOTOR CAPACITOR Unit & Unit Voltage Type Volts CHA16H /230 Single CHA16H /230 Single CHA CHA16R /230 Dual (shared with compressor) CHA /230 Single CHA16 511/651 CHA16R 511/ /230 Single CHA16 413/513/653 ALL Single Page 17 A third (blue) tap on G (460V) and J (575V) volt motors is used to complete an internal circuit during low or medium speed operation. It must never be connected to line voltage. During low speed (red tap) operation, the high speed (black) tap is disconnected from line voltage and is connected to blue internal wiring tap. Internal wiring is shown in figure VOLT BLOWER MOTOR WINDINGS HIGH SPEED MEDIUM SPEED LOW SPEED WINDING WINDING WINDING ORANGE BLACK BLUE YELLOW RED The motor has three sets of windings. The high speed winding is independent of the other two and the medium and low speed windings are tied together with a center tap. High speed is accomplished by energizing the high speed windings. Medium speed is accomplished by connecting the medium speed and high speed windings in series. Low speed is accomplished by connecting the low, medium and high speed windings in series. Refer to unit wiring diagram and Corp L7. FIGURE 14

18 CAUTION Potential for damage to 460V and 575V blower motors and/or unit electrical circuits. The blue blower motor lead must never be connected to a line voltage power lead (blower demand from heat relay or blower relay). Refer to unit wiring diagram for proper wiring. Can result in improper operation, increased current flow and/or burnt windings. 4 Indoor Blower Motor Capacitor C4 All CHA16 208/230v units use single-phase PSC motors. A run capacitor is mounted on the blower housing. Capacitor ratings are shown in table v and 575v units use single-phase PSC 460v blower motors. A run capacitor is located on the blower housing. TABLE 7 Unit 208/230v Blower Capacitor Rating CHA16H 261/ 311 CHA16 411P/ 413Y CHA16R 411 CHA16 511P/ 513Y CHA16R MFD at 370 V 10 MFD at 370 V 20 MFD at 370 V CHA16 651P/ 653Y CHA16R MFD at 370 V CHA16 413G,J 10 MFD at 370 V CHA16 513G,J 10 MFD at 370 V CHA16 653G,J 20 MFD at 370 V III OPTIONAL ECH16 ELECTRIC HEAT A Matchups and Ratings Tables 8, 9, 10, 11 and 12 show all possible CHA16 to ECH16 matchups. Also shown in the tables are ECH16 electrical ratings. B Electric Heat Components ECH16 parts arrangement is shown in figures 15, 16, 17, 18, 19, 20 and 21. All ECH16 units consist of electric heating elements exposed directly to the airstream. Elements are sequenced on and off by heat relays or contactors in response to thermostat demand. 1 Relay K15 Relay K15 is a single-pole single-throw relay located on the control panel of all commercial singlephase ECH16 units (15, 20 and 25 kw). K15 is equipped with a 24VAC coil which is energized when pilot relay K43 closes. When K15 is energized, the first stage heating elements are energized. (HE1 in ECH16-15; HE1 and HE2 in ECH16-20 and ECH16-25). 2 Contactor K15 Contactor K15 is a three-pole double break contactor used in all commercial three-phase ECH16 units. K15 is equipped with a 24VAC coil which is energized when pilot relay K43 closes. When K15 is energized, the first stage heating elements are energized. Contactor K15 used in ECH Y and ECH G units is equipped with a set of auxiliary single-pole double-throw contacts. The auxiliary contacts are not used in this application. 3 Relay K16 Relay K16 is a single-pole single-throw relay located on the control panel of all commercial singlephase ECH16 units (15, 20 and 25 kw). K16 is equipped with a 24VAC coil which is energized when pilot relay K43 closes. When K16 is energized, the second stage heating elements are energized (HE2 in ECH16-15; HE3 and HE4 in ECH16-20 and ECH16-25). 4 Contactor K16 Contactor K16 is a three-pole double break contactor used in commercial 20 and 25 kw three-phase ECH16 units. K16 is equipped with a 24VAC coil which is energized when time delay DL2 closes. When K16 is energized, the second stage heating elements are energized. 5 Relay K17 Relay K17 is a single-pole single-throw relay located on the control panel of all commercial singlephase ECH16 units (15, 20 and 25 kw). K17 is equipped with a 24VAC coil which is energized when pilot relay K43 closes. When K17 is energized, the third stage heating elements are energized (HE3 in ECH16-15; HE5 and HE6 in ECH16-20 and ECH16-25). Page 18

19 TABLE 8 CHA & CHA ELECTRIC HEAT DATA Optional Single Point Power Source Boxes Single Package Unit Model No. Electric Heater Model No. & Net Weight No. of Steps & Phase Volts Input Heater Only *Minimum Circuit Ampacity Electric Heat Kw Input Electric Heat Btuh Input Heater Sub- Fuse Box Model No. Unit Sub- Fuse Box Model No. Total Unit & Electric Heat *Minimum Circuit Ampacity , ECH16R-5 1 step ,300 ECH16R- ECH (4 lbs.) (1 phase) ,700 26/ , , ECH16R-7 1 step ,100 ECH16R- ECH (5 lbs.) (1 phase) ,800 26/ CHA16H , , ECH16R-10 1 step ,700 ECH16R- ECH (5 lbs.) (1 phase) ,400 26/ , , ECH step , ECH (18 lbs.) (1 phase) , , , ECH16R-5 1 step ,300 ECH16R- ECH (4 lbs.) (1 phase) ,700 26/ , , ECH16R-7 1 step ,100 ECH16R- ECH (5 lbs.) (1 phase) ,800 26/ CHA , , ECH16RR-10 1 step ,700 ECH16R- ECH (5 lbs.) (1 phase) ,400 26/ , , ECH step , ECH (18 lbs.) (1 phase) , , *Refer to National Electrical Code manual to determine wire, fuse and disconnect size requirements. Use wires suitable for at least 167 F. Page 19

20 Single Package Unit Model No. Electric Heater Model No. & Net Weight No. of Steps & Phase TABLE 9 CHA16(R) ELECTRIC HEAT DATA Volts Input Heater Only *Minimum Circuit Ampacity Electric Heat Kw Input Electric Heat Btuh Input Optional Single Point Power Source Boxes Heater Sub- Fuse Box Model No. Unit Sub- Fuse Box Model No. Total Unit & Electric Heat *Minimum Circuit Ampacity , ECH16R-5 1 step ,300 ECH16R- ECH (4 lbs.) (1 phase) ,700 26/ , , ECH16R-7 1 step ,100 ECH16R- ECH (5 lbs.) (1 phase) ,800 26/ , , ECH16R-10 1 step ,700 ECH16R- ECH CHA (5 lbs.) (1 phase) ,400 26/ CHA16R , , ECH step , ECH (18 lbs.) (1 phase) , , , ECH step , ECH (19 lbs.) (1 phase) , , , ECH step , ECH (17 lbs.) (3 phase) , , , , ECH , ECH step , (17 lbs.) (3 phase) , , ECH , , , ECH , CHA ECH step , (17 lbs.) (3 phase) , , ECH , , , ECH , ECH step , (20 lbs.) (3 phase) , , ECH , , , ECH , ECH steps , (20 lbs.) (3 phase) , , ECH , *Refer to National Electrical Code manual to determine wire, fuse and disconnect size requirements. Use wires suitable for at least 167 F. Page 20