INSTALLATION INSTRUCTIONS FOR HEAT PUMP OUTDOOR UNIT

Transcription

1 INSTALLATION INSTRUCTIONS FOR HEAT PUMP OUTDOOR UNIT MODEL SERIES (-)PKA-, (-)PLA-, (-)PMB- (-)PMC-, (-)PNJ-, (-)PPA- DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.! WARNING THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT 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. C Certificate Number: ** CERTIFIED UNDER THE A.R.I. CERTIFICATION PROGRAMS A.R.I. STANDARD **575V MODELS ARE NOT A.R.I. CERTIFIED SUPERSEDES

2 SERVICE FITTINGS LOW VOLTAGE CONNECTION (7/8 ) HIGH VOLTAGE CONNECTION (1-11/32 ) HIGH PRESSURE CONTROL MANUAL RESET (OPTIONAL) VAPOR LINE CONNECTION TABLE 3 LIQUID LINE CONNECTION TABLES 4 & 5 (2) 7/8 DIA. ACCESSORY KNOCKOUTS REQUIRED PUMP-UP INSTALLATION LOCATIONS TABLE 1 - DIMENSIONS (-)PKA 018, , 025, 030, , 036, 042, 048, , 043, 049, 061 (-)PLA 018, 019, 024, 036, 042, 048, , 030, , 041, 049, 061 HEAT PUMP (-)PMB , 030, , 048, 060 UNIT MODEL (-)PMC , 030, 036, ,048 (-)PNJ , 031, , 049, 061 (-)PPA , 031, , 049, 061 LENGTH H 16-3/4 20-3/4 26-3/4 34-3/4 LENGTH L 38-11/ / /16 43 WIDTH W 27-1/8 27-1/ LENGTH LS OF STAND 28-31/ / / /32 LENGTH LP OF PUMP-UPS 28-5/ / / /32 2

3 CONTENTS Page DIMENSIONS Figures 1, 2, RECEIVING GENERAL LOCATING UNIT , 3 UNIT MOUNTING ELECTRICAL INTERCONNECTING TUBING EVACUATION CHARGING LEAK TEST LINE SIZE CHARGE INFORMATION FLOW CHECK PISTON INDOOR COILS DEFROST CONTROLS OPERATION AUXILIARY HEAT PRESTART START-UP CHECK TROUBLE SHOOTING CHART WIRING DIAGRAMS Installation Instructions are updated on a regular basis. This is done as product changes occur or if new information becomes available. In this publication, an arrow ( ) denotes changes from the previous edition or additional new material.!! Recognize this symbol as an indication of Important Safety Information! WARNING THE MANUFACTURER S WARRANTY DOES NOT COVER ANY DAMAGE OR DEFECT TO THE HEAT PUMP CAUSED BY THE ATTACHMENT OR USE OF ANY COMPONENTS, ACCESSORIES OR DEVICES (OTHER THAN THOSE AUTHORIZED BY THE MANUFACTURER) INTO, ONTO OR IN CONJUNCTION WITH THE HEAT PUMP. YOU SHOULD BE AWARE THAT THE USE OF UNAUTHORIZED COMPO- NENTS, ACCESSORIES OR DEVICES MAY ADVERSELY AFFECT THE OPERATION OF THE HEAT PUMP AND MAY ALSO ENDANGER LIFE AND PROPERTY. THE MANUFAC- TURER DISCLAIMS ANY RESPONSIBILITY FOR SUCH LOSS OR INJURY RESULTING FROM THE USE OF SUCH UNAUTHORIZED COMPONENTS, ACCESSORIES OR DEVICES. RECEIVING Immediately upon receipt, all cartons and contents should be inspected for transit damage. Units with damaged cartons should be opened immediately. If damage is found, it should be noted on the delivery papers and a damage claim filed with the last carrier. GENERAL The information contained in this manual has been prepared to assist in the proper installation, operation and maintenance of the air conditioning system. Improper installation, or installation not made in accordance with these instructions, can result in unsatisfactory operation and/or dangerous conditions, and can cause the related warranty not to apply. Read this manual and any instructions packaged with separate equipment required to make up the system prior to installation. Retain this manual for future reference. IMPORTANT: The outdoor unit must be installed with a compatible indoor unit as designated in the specification data and in the heat pump manufacturer s section of the Directory of Certified Unitary Heat Pumps published by the Air Conditioning and Refrigeration Institute. Using unmatched components may affect the performance of the system. IMPORTANT: We are not responsible for the performance of a mismatched system or for a match listed by another coil manufacturer. A heat gain calculation for cooling and heat loss for heating should be made. IMPORTANT The indoor coil must be located in the airstream on the inlet air side of the auxiliary heaters. If the heat pump is used with a gas or oil furnace, the indoor coil must be located on the outlet of the furnace. A Fossil Fuel Kit must be used in the control circuit to prevent the furnace and heat pump from operating at the same time. LOCATING UNIT Consult local building codes or ordinances for special installation requirements. When selecting a site to locate the outdoor unit, consider the following: A minimum clearance of 24 on the service access side, 12 for air inlet sides and 60 for air discharge (unit top) is required. NOTE: When multiple units are installed, increase distance between unit air inlet louvers from 12 inches to 24 inches. IMPORTANT: Locate the unit a sufficient distance horizontally from any gas vent termination to prevent the exhaust gases from affecting the operation or life of the unit. The unit must be located outdoors and cannot be connected to ductwork. Locate unit where operating sound will not disturb owner or neighbors. Locate unit so roof runoff water does not pour directly on the unit. Provide gutter or other shielding at roof level. Do not locate unit in an area where excessive snow drifting may occur or accumulate. If a concrete pad is used to mount unit on, do not connect slab to building foundation or structure to prevent noise transmission. Locate the slab sufficient above grade to prevent ground water from entering the unit. It is essential to provide for defrost condensate drainage to prevent possible refreezing of condensation. Provide a base pad for mounting the unit which is slightly pitched away from the structure. Route condensate off base pad to an area which will not become slippery and result in personal injury. Do not obstruct openings in bottom of the unit. The length of refrigerant piping and wiring should be as short as possible to avoid capacity losses and increased operating costs. Where snowfall is anticipated, the unit must be elevated above the base pad to prevent ice buildup and coil damage. Mount unit high enough to be above the average accumulated area snowfall. CORROSIVE ENVIRONMENT The metal parts of this unit may be subject to rust or deterioration if exposed to a corrosive environment. This oxidation could shorten the equipment s useful life. Corrosive elements include salt spray, fog or mist in seacoast areas, sulphur or chlorine from lawn watering systems, and various chemical contaminants from industries such as paper mills and petroleum refineries. If the unit is to be installed in an area where contaminants are likely to be a problem, special attention should be given to the equipment location and exposure. 3

4 ! WARNING DISCONNECT ALL POWER TO UNIT BEFORE STARTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRI- CAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH. Frequent washing of the cabinet, fan blade and coil with fresh water may remove most of the salt or other contaminants that build up on the unit. Regular cleaning and waxing of the cabinet with a automobile polish may provide some protection. UNIT MOUNTING The base pan provided elevates the outdoor coil 3/4 above the base pad. If elevating a unit, use 4 x 4 stringers or an elevation rack as shown in Figures 1 and 2. This is necessary to distribute unit weight evenly and prevent noise and vibration. If pump-ups are used, see Figure 3 for proper location. If unit must be elevated because of anticipated snow fall, secure unit and elevating stand such that unit and/or stand will not tip over or fall off. Keep in mind that someone may try to climb on unit. ELECTRICAL WIRING Field wiring must comply with the National Electric Code (C.E.C. in Canada) and any applicable local ordinance. POWER WIRING It is important that proper electrical power is available at the condensing unit contactor. Voltage should not vary more than 10% of that stamped on the rating plate when the unit is trying to start. Interphase variation on the three-phase units must not be more than 3%. For branch circuit wiring (main power supply to unit disconnect), the minimum wire size for the length of run can be determined from Table 2 using the circuit ampacity found on the unit rating plate. From the unit disconnect to unit, the smallest wire size allowable in Table 2 should be used. Check all electrical connections, including factory wiring within the unit and make sure all connections are tight. IMPORTANT: DO NOT CONNECT ALUMINUM FIELD WIRE TO OUTDOOR HEAT PUMP CONTACTOR TERMINALS. S U PP L Y W IR E TABLE 2 COPPER WIRE SIZE - AWG. (1% Voltage Drop) L E N G TH F E E T SUPPLY CIRCUIT AMPACITY FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS Thermostat Load - Amps SOLID COPPER WIRE - AWG Length of Run - Feet (1) (1) Wire length equals twice the run distance. NOTE: Do not use control wiring smaller than No. 18 AWG. GROUNDING! WARNING THE UNIT MUST BE PERMANENTLY GROUNDED. FAIL- URE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH. A grounding lug is provided near contactor for a ground wire. THERMOSTAT It is necessary that only heat pump thermostats with a B terminal be used. CONTROL WIRING Low voltage control wire should not be run in conduit with power wiring, unless Class 1 wire of proper voltage rating is used. INTERCONNECTING TUBING Vapor and Liquid Lines Keep all lines sealed until connection is made. Make connections at the indoor coil first. Refer to Line Size Information in Tables 3, 4 and 5 for correct line sizing and length of lines. The factory refrigerant charge in the outdoor unit is sufficient for 25 feet of interconnecting lines and the indoor coil. For different lengths, adjust the charge as indicated below: 1/4 line ±.3 oz. per foot 5/16 line ±.4 oz. per foot 3/8 line ±.6 oz. per foot 1/2 line ± 1.2 oz. per foot Add a crankcase heater if system charge is greater than 10 lbs. MAXIMUM LENGTH OF LINES The maximum length of interconnecting line is 150 feet. Always use the shortest length possible with a minimum number of bends. Additional compressor oil is not required for any length up to 150 feet. OUTDOOR UNIT INSTALLED ABOVE INDOOR COIL Keep the vertical separation between coils to a minimum. However, the vertical distance can be as great as 120 feet with the outdoor unit ABOVE the indoor coil. Use the following guidelines when installing the unit: 1. DO NOT exceed 120 feet maximum vertical separation. 4

5 2. DO NOT change the flow check piston sizes if the vertical separation does not exceed the table values. 3. Flow Check Piston Coil: a. The vertical separation can be greater than the table value, but no more than 120 feet. b. If the separation height exceeds the table value, REDUCE the indoor coil flow check piston by two sizes plus one size for each additional 10 feet beyond the table value. 4. Expansion Valve Coil: a. The vertical separation can be greater than the table value, but no more than 120 feet. b. No changes are required for expansion valve coils. 5. Always use the smallest liquid line size permitted to minimize the system charge. 6. Table 4 may be used for sizing horizontal runs OUTDOOR UNIT BELOW INDOOR COIL Keep the vertical separation to a minimum. Use the following guidelines when installing the unit. 1. DO NOT exceed the vertical separations as indicated on Table Always use the smallest liquid line size permitted to minimize system charge. 3. No changes are required for either flow check piston coils or expansions coils. 4. Table 4 may be used for sizing horizontal runs. TUBING INSTALLATION Observe the following when installing refrigerant tubing between the outdoor unit and indoor coil: Use clean, dehydrated, sealed refrigeration grade tubing. Always keep tubing sealed until tubing is in place and connections are to be made. Any debris in the line set can restrict refrigerant flow in the metering device. If there is any question as to how clean the liquid and vapor lines are, blow out with dry nitrogen before connecting to the outdoor unit and indoor coil. As an added precaution, you may install a properly sized biflow filter drier in the liquid line. Vapor line and liquid line must not be in contact with each other or the building. The vapor line must be insulated. If tubing has been cut, make sure tubing ends are deburred while holding in a position to prevent chips from falling into tubing. Burrs can affect performance dramatically, particularly on small liquid line sizes. For best operation, keep tubing run as short as possible with a minimum number of elbows or bends. Locations where the tubing will be exposed to mechanical damage should be avoided. If it is necessary to use such locations, copper tubing should be housed to prevent damage. If tubing is to be run underground, it must be run in a sealed watertight chase. Use care in routing tubing and do not kink or twist. Use a good tubing bender to prevent kinking. Route the tubing using temporary hangers, then straighten the tubing and install permanent hangers. Lines must be adequately supported. The vapor line must be covered with closed cell insulation to prevent dripping (sweating) and prevent performance losses. Use 1/2 minimum insulation thickness, additional insulation may be required for long runs. Do not insulate the liquid line TUBING CONNECTIONS All lines should be assembled with refrigerant tubing and not with copper water pipe. They should be brazed with the following alloys: Copper to Copper - 5% Silver Alloy (no flux) Copper to Steel or Brass - 35% Silver Alloy (no flux) Clean the inside of the fittings and outside of the tubing with steel wool or sand cloth before soldering. Always keep chips, steel wool, dirt, etc., out of the inside when cleaning. Assemble tubing part way into fitting. This procedure will keep the flux from getting inside the system. Before brazing remove the schrader cap and core from service port to protect seals from heat damage. A wet rag must be wrapped around the copper stub and the service valves before applying heat. Failure to do so can result in valve damage. Braze the tubing between the outdoor unit and indoor coil. Flow dry nitrogen into a service port and through the tubing while brazing. After brazing wrap the braze with a wet rag to cool the joint. Reinstall the schrader core and cap. This is not a backseating valve. To open the valve remove the valve cap with an adjustable wrench. Insert a 3/16 or 5/16 hex wrench into the stem. Back out counterclockwise until the valve stem just touches the retaining ring.! DO NOT USE EXTREME FORCE TO OPEN THE VALVE STEM AGAINST THE RETAINING RING WHEN OPENING THE VALVES. SYSTEM PRESSURE CAN FORCE THE VALVE STEM OUT OF THE VALVE BODY AND CAUSE SEVERE PERSONAL INJURY. IN THE EVENT THE RETAIN- ING RING IS MISSING, DO NOT ATTEMPT TO OPEN THE VALVE. Replace the valve cap finger tight then tighten an additional 1/12 turn or 1 2 hex flat. A metal-to-metal seal is now complete. LEAK TESTING Pressurize line set and coil through service fitting with dry nitrogen to 150 psig maximum. Leak test all joints. If a leak is found, recover pressure and repair.! WARNING WARNING DO NOT USE OXYGEN TO PURGE LINES OR PRESSURE SYSTEM FOR LEAK TEST. OXYGEN REACTS VIOLENTLY WITH OIL, WHICH CAN CAUSE AN EXPLOSION RESULT- ING IN SEVERE PERSONAL INJURY OR DEATH. EVACUATION PROCEDURE Evacuation is the most important part of the entire service procedure. The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air and moisture from the system. 5

6 Air in the system causes high condensing temperature and pressure, resulting in increased power input and reduced performance. Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoric and hydrochloric acids. These attack motor windings and parts, causing breakdown. After the system has been leak checked and proven sealed, connect the vacuum pump and evacuate system to 29.9 Hg vacuum. The vacuum pump must be connected to both the high and low sides of the system through adequate connections. Use the largest size connections available since restrictive service connections may make the process so slow as to unacceptable. This may lead to false readings because of pressure drop through the fittings. IMPORTANT: Compressors (especially scroll type) should never be used to evacuate the air conditioning system. Vacuums this low can cause internal electrical arcing, resulting in a damaged or failed compressor. CHECKING REFRIGERANT CHARGE Charge for all systems should be checked against the charging chart inside the access panel cover. Select the proper chart using appropriate outdoor unit/indoor coil model combination. Before using any of the charts, the indoor conditions must be within 2 F of desired comfort conditions and system must be run until operating conditions stabilize (15 to 20 min.). If the unit is in the heating mode and frost has formed on the outdoor coil, the unit should be run through a defrost cycle before checking the charge. IMPORTANT: Do not operate the compressor without charge in system. Addition of R-22 will raise pressures (vapor, liquid and discharge) and lower vapor temperature. IMPORTANT: If addition of R-22 raises both vapor pressure and temperature, unit is overcharged. CHARGING BY SUPERHEAT (HEATING OR COOLING) Superheat charging method is used for charging systems in the cooling mode when a flow check piston is used on the indoor coil. Superheat is also used in charging systems in the heating mode when a flow check piston is used on the outdoor coil and the outdoor temperature is above 42 F. Pressure reading and charging is accomplished using the service port located between the reversing valve and accumulator. This service port is connected into the vapor line and provides vapor pressure in both heating and cooling modes. Vapor temperature readings must be taken on the vapor line going from the accumulator to the compressor. A remote temperature indicator is most convenient. If this is not available, a thermometer properly located and insulated can be used. Measure and record the three values required. Find the intersection of vapor line pressure and outdoor ambient on the appropriate charging chart. The vapor line temperature should approximate the intersect value on the chart. The most likely causes for the intersection of vapor pressure and ambient temperature in the open area to (left) or (right) of table values are: (Left): Low charge, low airflow (indoorcooling), (outdoor-heating); (Right): Overcharge, low airflow (indoor-heating) (outdoor-cooling). DISCHARGE PRESSURE CHECK (HEATING) In the heating mode with the outdoor temperature below 42 F, units using a flow check piston on the outdoor coil can only be accurately charged using the weight method. At low outdoor temperatures, the accumulator holds refrigerant and adjusting the charge will change the liquid level in the accumulator with no apparent change in the system. Discharge pressure may be used only to verify system charge. The service port on the vapor service valve (large valve) is used for this purpose. Measure and record the three values required. Find the intersection of outdoor ambient and indoor temperature on the appropriate chart. The discharge pressure should approximate the intersect values on the chart. CHARGING BY LIQUID PRESSURE (HEATING OR COOLING) Liquid pressure method is used for charging systems in the cooling mode when an expansion valve is used on the indoor coil, and in the heating mode when an expansion valve is used on the outdoor coil. The service port on the liquid service valve (small valve) is used for this purpose. Measure and record the three values required. Find the intersection of outdoor ambient and indoor ambient ( F Wet Bulb for cooling, F Dry Bulb for heating) on the appropriate chart. The liquid line pressure should approximate the intersect value on the chart. CHARGING BY WEIGHT For a new installation, evacuation of interconnecting tubing and indoor coil is adequate; otherwise, evacuate the entire system. Use the system charge shown on the Charging Chart or in Table 5 of these instructions for the appropriate outdoor unit/indoor unit model combination. Note that charge value includes charge required for 25 ft. of standard size interconnecting liquid line. Calculate actual charge required with installed liquid line size and length using: (1/4 O.D. =.3 oz./ft.), (5/16 O.D. =.4 oz./ft.), (3/8 O.D. =.6 oz./ft.), (1/2 O.D. = 1.2 oz./ft.). With an accurate scale (+/ 1 oz.) or volumetric charging device, adjust charge difference between that shown on the unit data plate and that calculated for the new system installation. If the entire system has been evacuated, add the total calculated charge. FINAL LEAK TESTING After the unit has been properly evacuated and charged, a halogen leak detector should be used to detect leaks in the system. All piping within the heat pump, indoor coil, and interconnecting tubing should be checked for leaks. If a leak is detected, the refrigerant should be recovered before repairing the leak. The Clean Air Act prohibits releasing refrigerant into the atmosphere. 6

7 TABLE 3 VAPOR LINE LENGTH/SIZE versus CAPACITY MULTIPLIER (-)PKA 018, , , ,036, , , , 061 (-)PLA 018, , , , , , , 061 (-)PMB-/(-)PMC (-)PNJ (-)PPA Unit Vapor Line Connection Size 5/8 L.D. Sweat 3/4 L.D. Sweat 7/8 L.D. Sweat 1-1/8 L.D. Sweat (4) Vapor Line Run - Feet 5/8 O.D. Standard 3/4 O.D. Optional 5/8 O.D. Optional 3/4 O.D. Standard 7/8 O.D. Optional 3/4 O.D. Optional 7/8 O.D. Standard 1-1/8 O.D. Optional 7/8 O.D. Optional 1-1/8 O.D. Standard 1-3/8 O.D. Optional 25 Opt. Std. Opt. 50 Opt. Std. Opt Opt. Std. Opt Opt. Std. Opt NOTES: (1) Capacity Multiplier x Rated Capacity = Actual Capacity. (2) Additional compressor oil is not required for runs up to 150 feet. (3) Oil traps in vertical runs are not required for any height up to 125 feet. See Liquid Line charts for Vertical Separation Requirements and Limitations. (4) Adapter to 1-1/8 Factory Supplied. 7

8 TABLE 4 System Capacity Tons Line Size (Inch O.D.) LIQUID LINE SIZE OUTDOOR UNIT ABOVE INDOOR COIL TOTAL LENGTH - (ft) VERTICAL SEPARATION - (ft) /4* 5/16 1/4* 5/16 1/4* 5/16 3/8 5/16* 3/8 5/16* 3/8 3/8* 1/2 3/8* 1/ * - Standard line size Notes: ➀ ➁ ➂ ➃ ➄ ➅ If the separation height exceeds the table values, reduce the indoor coil flow-check piston two sizes plus one size for each additional 10 feet. For heat pumps, increase the outdoor flow-check piston two sizes plus one size for each additional 10 feet. Example: A 5 ton heat pump with a total line length of 100 feet with a vertical separation of 93 feet utilizing a 3/8 liquid line: Table = 72 feet maximum vertical separation for 100 feet run Separation exceeds table by (93-72) = 21 feet Therefore, reduce the indoor coil flow-check piston = 4 sizes (For example, a #89 piston would reduce to a #85 piston) Increase the outdoor flow-check piston = 4 sizes (For example, a #56 would increase to a #60) Do not exceed 120 feet maximum vertical separation. No changes are required for expansion valve coils. Always use the smallest liquid line possible to minimize system charge. For heat pumps with vertical separation do not insulate liquid line. Chart may be used to size horizontal runs. 8

9 TABLE 5 System Capacity Tons Line Size (Inch O.D.) LIQUID LINE SIZE OUTDOOR UNIT BELOW INDOOR COIL TOTAL LENGTH - (ft) VERTICAL SEPARATION - (ft) /4* 5/16 1/4* 5/16 1/4* 5/16 3/8 5/16* 3/8 5/16* 3/8 3/8* 1/2 3/8* 1/ * - Standard line size ➀ Heat pumps with any vertical separation require the use of standard line sizes only, due to the possibility of charge imbalance between heating and cooling modes. Example 1: A 3 ton heat pump with a total line length of 50 feet can have a maximum vertical separation of 23 feet. Do not increase line size to 3/8. ➁ This chart may also be used to size horizontal runs. Example 2: A 1.5 ton heat pump can have a total horizontal line length of 150 feet when using the 5/16 liquid line size. No vertical separation allowed. ➂ ➃ ➄ Do not exceed vertical separation as indicated on the chart. Always use the smallest liquid line possible to minimize system charge. No changes required for flow-check pistons or expansion valve coils. 9

10 FIGURE 4. PISTON AND DISTRIBUTOR ASSEMBLY HEAT PUMP APPROVED APPLICATION MATCHES WITH FLOW CHECK PISTON SIZES REQUIRED TABLE 5 Heat Pump Outdoor Heat Pump Indoor Piston Size Unit Model & Size Coil Model Outdoor Indoor (-)PKA-018/-019 RCBA (-)PKA-024/-025 RCBA (-)PKA-030/-031 RCBA (-)PKA-035/-036/-037 RCBA (-)PKA-042/-043 RCBA (-)PKA-048/-049 RCBA (-)PKA-060/-061 RCBA HEAT PUMP APPROVED APPLICATION MATCHES WITH PISTON SIZES REQUIRED TABLE 6 Heat Pump Outdoor Heat Pump Indoor Piston Size Unit Model & Size Coil Model Outdoor Indoor (-)PLA-018/-019 RCHA-24A (-)PLA-024/-025 RCHA-24A (-)PLA-030/-031 RCHA-36A (-)PLA-036/-037 RCHA-36A (-)PLA-043/-041 RCHA-48A (-)PLA-048/-049 RCHA-48A (-)PLA-060/-061 RCHA-60A HEAT PUMP APPROVED APPLICATION MATCHES WITH FLOWCHECK PISTON SIZES REQUIRED TABLE 7 Heat Pump Outdoor Heat Pump Indoor Piston Size Unit Model & Size Coil Model Outdoor Indoor (-)PMC-018 (-)PNJ-019 RCHJ-24A (-)PPA-019 (-)PMC-024 (-)PNJ-025 RCHJ-24A (-)PPA-025 (-)PMC-030 (-)PNJ-031 RCHJ-36A (-)PPA-031 (-)PMC-036 (-)PNJ-037 RCHJ-36A (-)PPA-037 (-)PMC-042 (-)PNJ-043 RCHJ-48A (-)PPA-043 (-)PMC-048 RCHJ-48A (-)PNJ-049 (-)PPA-049 RCHJ-51A1.157 Coil A=.120 Coil B=.086 (-)PMC-060 RCHJ-60A (-)PNJ-061 (-)PPA-061 RCHJ-61A1.157 Coil A=.140 Coil B= FLOW CHECK PISTON NOTICE For proper system operation, it may be necessary to replace the piston installed in the indoor coil. Check the service valves on this unit to see if a notice tag along with a plastic bag containing a piston is attached. If one is present a change of the piston is required. Failure to change the piston can result in improper performance of the system. The flow check piston is a multi-purpose device. With flow into the compression nut end from the liquid line, the piston is in a check position and acts as the expansion device with flow through the metering orifice in the center of the piston. The O ring on the end of the piston prevents refrigerant from bypassing the metering orifice. Flow from the metering orifice is centered into a distributor which serves to evenly distribute refrigerant to the evaporator circuits. With flow in the reverse direction (direction of arrows on the distributor body), the piston is forced off the seat and liquid from the condenser is allowed to free flow around the piston. It is essential that the heat pump indoor and outdoor sections be properly matched. Use only matched components as shown in sales specification sheets. Approved combinations for indoor and outdoor sections are shown in Tables 5, 6 and 7. A piston size that is too small will cause starving and one that is too large will cause flooding. In either case, system performance, reliability and charge balance (heating and cooling) will be unacceptable. Change the piston in the distributor on the indoor coil before installing the coil and charging the system following the procedure below: Using a back-up wrench on the distributor body, loosen the compression nut to gain access to the piston. Using the wire provided with replacement pistons, run (hooked end) through hole in piston. Hook nose end of piston and lift gently from distributor body. Replace piston with one of proper size (see Tables 5, 6 and 7), install piston with gasket end of piston in distributor. Do not force piston into distributor. NOTE: With piston in distributor, seal end should be down and should not be seen looking in end of distributor. Piston must be free to rotate and move up and down. Make sure piston is free to move in distributor body.

11 Insure distributor gasket is located properly in the distributor body. Replace compression nut using back-up wrench on distributor body. Torque compression nut with 8 to 10 ft./lbs. Original piston size is stamped on outside of distributor body. Remove new piston size label from poly bag new piston came in and install new size label on outside of distributor tube. Check fittings for leaks after installation, evacuation and charging is complete. IMPORTANT: Do not attempt to drill pistons to size in the field. Metering holes have a special chamfered inlet and cannot be modified. IMPORTANT: Do not replace the neoprene O ring on the piston with any type of seal. Contact the parts department for the exact replacement O ring. DEMAND DEFROST CONTROL The demand defrost control is a printed circuit board assembly consisting of solid state control devices with electro-mechanical outputs. The demand defrost control monitors the outdoor ambient temperature, outdoor coil temperature, and the compressor run-time to determine when a defrost cycle is required. DEFROST INITIATION A defrost will be initiated when the three conditions below are satisfied: 1) The outdoor coil temperature is below 35 F. 2) The compressor has operated for at least 34 minutes with the outdoor coil temperature below 35 F. 3) The measured difference between the ambient temperature and the outdoor coil temperature is greater than the calculated delta T. Additionally, a defrost will be initiated if six hours of accumulated compressor run-time has elapsed without a defrost with the outdoor coil temperature below 35 F. DEFROST TERMINATION Once a defrost is initiated, the defrost will continue until fourteen minutes has elapsed or the coil temperature has reached the terminate temperature. the terminate temperature is factory set at 70 F, although the temperature can be changed to 50 F, 60 F, 70 F or 80 F by relocating a jumper on the board. TEMPERATURE SENSORS The coil sensor is clipped to the top tube on the outdoor coil at the point feed by the distribution tubes from the expansion devise (short 3/8 dia. tube). The air sensor is located on the defrost control board. If the ambient sensor fails the defrost control will initiate a defrost every 34 minutes with the coil temperature below 35 F. If the coil sensor fails the defrost control will not initiate a defrost. TEST MODE The test mode is initiated by shorting the TEST pins. In this mode of operation, the enable temperature is ignored and all timers are speed up by a factor of 240. To initiate a manual defrost, short the TEST pins. Remove the short when the system switches to defrost mode. The defrost will terminate on time (14 minutes) or when the termination temperature has been achieved. Short TEST pins again to terminate the defrost immediately. TIME TEMPERATURE DEFROST CONTROL OPERATION: In operation, power is provided to the circuit board when the thermostat selector switch is in the heat position through terminals marked 24 VAC and COM. Timing periods of 50, 70, or 90 minutes between defrost may be selected by connecting the circuit board jumper wire to T1, T2, or T3, respectively. Accumulation of time for the timing period selected, starts and stops with the wall thermostat call for heating through hold or H terminal on circuit board. If the defrost sensor is not closed after the timing period, the control board is reset to zero and another timing period is started. If closed, the defrost sensor will provide power from the common side of the transformer to terminal on the circuit board marked SEN, providing power to the defrost relay (DR) through the out terminal permitting defrost. The sensor closes at 28 +/ 3 F. The defrost temperature sensor is clamped to the top tube on the outdoor coil at the point fed by the distribution tube from the expansion device (short 3/8 dia. tube). The defrost cycle is terminated and the timing is reset when the sensor opens at 50 F +/ 5 F. If the defrost cycle is not terminated due to sensor temperature, a 10 minute override terminates the defrost period and resets the timing period. TEST TERMINALS: To initiate a defrost cycle, the tow TST pins should be shorted together until a defrost cycle is initiated. The sensor must also be closed or jumpered to initiate a defrost. All timing functions are sped up by a factor of 256 from 50, 70, and 90 minutes to 11.7, 16.4, or 21.1 seconds. After defrost initiation, the short must be instantly removed or the defrost period will last only 2.3 seconds. TIME SETTING: All Heat Pump models with time-temperature defrost controls have the defrost timing factory set at 90 minutes, except for the -060 models which are factory set for 70 minutes. Factory settings may be adjusted in the field depending on application. TROUBLE SHOOTING DEMAND DEFROST Set the indoor thermostat select switch to heat and thermostat lever to a call for heat. Jumper the test pins to put the unit into defrost. If the unit goes into defrost and comes back out of defrost, the indication is that the control is working properly. If the unit did not go into defrost using the test pins, check to ensure that 24V is being supplied to the control board. If 24V is present then replace the control. TROUBLE SHOOTING TIME DEFROST IMPORTANT: In connecting jumpers to various terminals on the defrost control board, you must be careful not to short any terminals except those stated below. Shorting terminals such as OUT to 24 V will damage the board or transformer. As a precaution, turn all power off while connecting or removing test jumpers. Set indoor thermostat selector switch to heat and thermostat lever to call for heat. Check defrost sensor switch contact with 3/8 coil tube (see above for specific control). Short test pins (see above for specific control) to put unit into defrost. If the unit goes into defrost and comes back out of defrost, the indication is that the control is working properly. If the unit did not go into defrost using the test pins, connect a jumper between the OUT or RELAY (output) and COM (common) terminals on the control board. This bypasses the defrost sensor and the control board. The unit should immediately go into defrost. If it does not, the problem is not in the wiring to the defrost relay or the defrost relay itself. If it goes into defrost, remove the jumper. 11

12 On time-temperature models only, if the unit has gone into defrost with the above step and will not go in with the test pins, connect a jumper between COM and SEN terminals on control board. This bypasses the defrost sensor only. Short the TEST terminals to put the unit into defrost. If the unit goes into defrost, the sensor switch was open and the defrost board is good; if not, replace the defrost board. If the sensor is open, check the coil tube temperature where the sensor is connected. See above for temperature settings of sensor. If the problem was determined not to be the defrost control or sensor switch, check for 24 volts between terminals COM and 24V, then between COM and H (hold). Use a voltmeter, not a jumper. If you don t read 24 volts at both places, check the transformer, thermostat and wiring. If you read 24 volts at both points, check the defrost relay and relay wiring. AUXILIARY HEAT The amount of auxiliary heat required depends on the heat loss of the structure to be heated and the capacity of the heat pump. It is good practice to install strip heat to maintain at least 60 F indoor temperature in case of compressor failure. See instructions packed with indoor section. Most indoor sections are equipped with controls that eliminate the need to use outdoor thermostats. PRESTART CHECK On initial start-up, or after extended shutdown periods, make sure crankcase heat is energized for at least 4 hours, preferably 12 hours before compressor is started. (Disconnect switch closed and wall thermostat in Off position.) Is unit grounded and connected to correct voltage and phase, and all wire connections tight and properly fused? Is unit elevated to allow drainage? Is air free to travel to and from outdoor unit? Is the vapor line and duct work insulated? Have all joints been leak tested? Has indoor coil and line set been evacuated? Have the service valves been opened? START-UP CHECK Turn thermostat system switch to Off, turn fan switch to ON; indoor blower should run. Turn thermostat system switch to Auto. Turn system switch to Cool and turn temperature setting below room temperature. Both indoor and outdoor units should operate (Time Delay Optional). Turn thermostat system to Heat. Unit should stop. Raise temperature setting to above room temperature. Unit should run. After about 30 to 50 seconds, auxiliary strip heaters, if installed, should come on. If above 65 outside, check charge in the cooling mode. If below 65, check charge in the heating mode. See charge chart on access panel. After charge has been checked and adjusted per procedure on inside of access panel, record the following: Liquid service valve psig. Vapor compressor psig. Vapor line compressor F. compressor F. At contactor voltage amps. Indoor temp. D.B. F. W.B. F. Outdoor temp. D.B. F. W.B. F. Model No. Serial No. Location & Owner Instruct the owner and/or user on operation and maintenance. 12

13 13

14 14 FIGURE 5. SINGLE PHASE WIRING DIAGRAM (TIME/TEMPERATURE DEFROST CONTROL)

15 FIGURE 6. THREE PHASE WIRING DIAGRAM (TIME/TEMPERATURE DEFROST CONTROL) 15

16 16 FIGURE 7. SINGLE PHASE WIRING DIAGRAM (DEMAND DEFROST CONTROL)

17 FIGURE 8. THREE PHASE WIRING DIAGRAM (DEMAND DEFROST CONTROL) 17

18 18 FIGURE 9. THREE PHASE - 480V/575V WIRING DIAGRAM (DEMAND DEFROST CONTROL)

19 19

20 20 CM 1099