INSTALLATION MANUAL TABLE OF CONTENTS GENERAL.................................... 3 REFERENCE................................. 3 INSPECTION.................................. 4 OPERATION................................. 14 START-UP.................................. 16 MAINTENANCE.............................. 18 COMMERCIAL SPLIT SYSTEM COOLING UNITS 4 PIPE SYSTEMS HB 180 & 240 15 thru 20 Nominal Tons See the following page for a complete Table of Contents. NOTES, CAUTIONS AND WARNINGS The 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. ISO 9001 Certified Quality Management System CAUTION: READ ALL SAFETY GUIDES BEFORE YOU BEGIN TO INSTALL YOUR UNIT. SAVE THIS MANUAL 278803-YIM-A-1106
TABLE OF CONTENTS GENERAL.......................................3 REFERENCE....................................3 INSPECTION....................................4 NOTES, CAUTIONS, AND WARNINGS...............4 INSTALLATION..................................4 LIMITATIONS................................. 4 LOCATION................................... 4 ROOF-TOP LOCATIONS....................... 4 GROUND LEVEL LOCATIONS.................. 4 RIGGING AND HANDLING...................... 5 CLEARANCES................................ 5 COMPRESSOR CRANKCASE HEATER............ 5 POWER AND CONTROL WIRING................. 7 CONTROL WIRING........................... 7 REFRIGERANT PIPING........................ 11 GENERAL GUIDELINES...................... 11 LINE SIZING............................... 11 EVACUATING AND CHARGING................. 13 ALTERNATE CHARGING METHODS............. 13 METHOD 1:................................ 13 METHOD 2:................................ 13 OPERATION....................................14 SIMPLICITY SYSTEM SEQUENCE OF OPERATION FOR 15 & 20 TON, 4-PIPE OUTDOOR SPLIT SYSTEMS.. 14 CONDENSING UNIT MATCHED WITH A SINGLE (TWO STAGE) INDOOR UNIT....................... 14 FAN CONTROL SWITCH OPERATION.......... 14 LOW AMBIENT SWITCH...................... 14 HIGH PRESSURE LIMIT SWITCH.............. 14 PUMP-OUT OPTION......................... 14 LOW PRESSURE LIMIT SWITCH............... 14 FLASH CODES............................. 15 UNIT CONTROL BOARD OPTION SETUP......... 16 OPTION BYTE SETUP....................... 16 START-UP.....................................16 PHASING................................... 16 CRANKCASE HEATER........................ 16 PRE-START CHECK.......................... 17 INITIAL START-UP............................ 17 SAFETY FEATURES.......................... 17 SECURE OWNER S APPROVAL...................17 MAINTENANCE.................................18 CLEANING.................................. 18 LUBRICATION............................... 18 REPLACEMENT PARTS....................... 18 NOTICE TO OWNER.......................... 18 LIST OF FIGURES Fig. # Pg. # 1 PRODUCT NOMENCLATURE.................... 3 2 CORNER WEIGHT AND CENTER OF GRAVITY..... 5 3 TYPICAL RIGGING............................ 6 4 TYPICAL LOW VOLTAGE WIRING DIAGRAM....... 7 5 UNIT DIMENSIONS............................ 9 6 PIPING AND ELECTRICAL CONNECTION LOCATIONS................................. 10 7 UNIT CONTROL BOARD....................... 16 8 CHARGING CURVE FOR HB180................ 18 9 CHARGING CURVE FOR HB240................ 19 10 TYPICAL WIRING DIAGRAM.................... 20 LIST OF TABLES Tbl. # Pg. # 1 UNIT APPLICATION DATA...................... 4 2 HB CORNER WEIGHTS AND CENTER OF GRAVITY. 5 3 OUTDOOR UNIT PHYSICAL DATA............... 6 4 ELECTRICAL DATA COMPRESSORS............. 8 5 ELECTRICAL DATA FAN MOTORS............... 8 6 ELECTRICAL DATA, MINIMUMS AND MAXIMUMS... 8 7 CONNECTIONS............................... 9 8 UNIT CLEARANCES........................... 9 9 PIPING AND ELECTRICAL CONNECTION SIZES... 10 10 REFRIGERANT LINE CHARGE.................. 11 11 SUCTION LINES............................. 12 12 LIQUID LINES................................ 12 13 UNIT CONTROL BOARD FLASH CODES......... 15 2 Unitary Products Group
PRODUCT NOMENCLATURE OUTDOOR SPLIT CONDENSING UNITS AND HEAT PUMPS H A 120 C 00 A 2 A AA 1 A Model Model Number Options # Description H Product Category H = Air Conditioner Split System E = Heat Pump Split System A Product Identifier A = R-22 Standard Efficiency 2-Pipe B = R-22 Standard Efficiency 4-Pipe 120 Nominal Cooling Capacity MBH 090 = 7-1/2 Ton 120=10 Ton 150 = 12-1/2 Ton 180 = 15 Ton 240 = 20 Ton 300 = 25 Ton * 360 = 30 Ton * 480 = 40 Ton * 600 = 50 Ton * C Heat Type C = Cooling Only 00 Nominal Heating Capacity A Airflow Options 2 Voltage 00 = No Heat Installed A = Standard Motor 2= 208/230-3-60 4= 460-3-60 5= 575-3-60 A AA Installation Options Additional Options A = None B = Disconnect AA = None AC = Technicoated Coil 1 Product Generation 1 = 1 st Generation 2 = 2 nd Generation A Product Style A = Style A B = Style B * NOT AVAILABLE IN HEAT PUMP. FIGURE 1: PRODUCT NOMENCLATURE GENERAL The outdoor units are completely piped and wired at the factory and are shipped ready for immediate installation. Only the interconnecting liquid and suction lines, control wiring, and the main power wiring are required to complete the installation. Every 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. To eliminate the costly cabinet deterioration problems usually associated with outdoor equipment, all sheet metal parts are constructed of commercial grade (G90) galvanized steel. After fabrication, each part is thoroughly cleaned to remove any grease or dirt from its surfaces. The majority of parts that will be exposed to the weather are then coated with a desert sand powder paint to assure a quality finish for many years. This coating system has passed the 1000 hour, salt spray test per ASTM Standard B117. Every unit includes 2 heavy-duty scroll compressors, 2 outdoor fan motors with inherent protection, and copper tube/aluminum fin coil. 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. REFERENCE This instruction covers the installation and operation of the basic condensing unit. For information on the installation and operation of the matching indoor units, refer to instruction Part Number 035-18494-001. All accessories come with a separate Installation Manual. Refer to Parts Manual for complete listing of replacement parts on this equipment. Unitary Products Group 3
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. NOTES, CAUTIONS, AND WARNINGS Installer should pay particular attention to the words: NOTE, CAUTION and WARNING. Notes are intended to clarify or make installation easier. Cautions are given to prevent equipment damage. Warnings are given to alert installer that personal injury and/or equipment damage my result if installation procedure is not handled properly. INSTALLATION LIMITATIONS These units must be installed in accordance with all national and local safety codes. If no local codes apply, installation must conform with the appropriate national codes. See Table 1 for unit application data. 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. TABLE 1: LOCATION UNIT APPLICATION DATA APPLICATION LIMITATIONS MIN. MAX Voltage Variation (208/230-3-60) - Volts 187 253 Voltage Variation (460-3-60) - Volts 414 506 Voltage Variation (575-3-60) - Volts 540 630 Ambient Air on Outdoor Coil (Cooling Cycle) - F 40 115 Ambient Air on Indoor Coil (Cooling Cycle) - F 68 86 4. All units require certain clearances for proper operation and service. On either rooftop or ground level installations, rubber padding can be applied between the base rails and their supports to lessen any transmission of vibration. ROOF-TOP 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. The unit must be mounted on solid level supports. The supports can be channel iron beams or wooden beams treated to reduce deterioration. A minimum 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 unit to distribute the load on the roof, (3) Be capable of adequately supporting the entire unit weight. Refer to Figure 1 and Table 2 for load distribution and weights. 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 The units must be installed on a substantial base that will not settle. Any strain on the refrigerant lines may cause a refrigerant leak. 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 because noise and vibration will be transmitted into the building. A unit can also be supported by concrete piers. These piers should: (1) extend below the frost line, (2) be located under the unit's four corners and (3) be sized to carry the entire unit weight. Refer to Figure 2 and Table 2 for the center of gravity and unit weight. Use the following guidelines to select a suitable location for these units. 1. The outdoor units must be installed outside the building. The outdoor fans are the propeller type and are not suitable for use with duct work. 2. The outdoor and indoor units should be installed as close together as possible and with a minimum number of bends in the refrigerant piping. Refer to REFRIGERANT PIPING for additional information. 3. The outdoor unit should not be installed beneath windows or between structures where normal operating sounds may be objectionable. Care should be taken to protect the unit from tampering and unauthorized persons from injury. Screws on access panels will prevent casual tampering. Additional safety precautions such as fences around the unit or locking devices on the panels may be advisable. Check local authorities for safety regulations. 4 Unitary Products Group
TABLE 2: HB CORNER WEIGHTS AND CENTER OF GRAVITY UNIT SIZE SHIPPING WEIGHT OPERATING WEIGHT A B C D UNIT LENGTH UNIT WIDTH DIM X DIM Y 15 Ton Outdoor 944 959 205 275 275 205 110 46 47 23 20 ton Outdoor 1124 1141 232 339 339 232 128 46 52 23 D C WIDTH CG LENGTH OF FORKS MUST BE A MINIMUM OF 52". DIM Y A DIM X B Remove the nesting brackets from the four corners on top of the unit. All screws that are removed to take these brackets off must be replaced on the unit. FIGURE 2: CORNER WEIGHT AND CENTER OF GRAVITY RIGGING AND HANDLING LENGTH Exercise care when moving the unit. Do not remove any packaging until the unit is near the place of installation. Rig the unit by attaching chain or cable slings with hooks to the round lifting holes provided in the base rails. Spreaders, longer than the largest dimension across the unit, MUST be used across the top of the unit. See Figure 3. CLEARANCES All units require certain minimum clearances for proper operation and service. Refer to Table 8 for these clearances. Do not permit overhanging structures or shrubs to obstruct air discharge. Additional height may be required for snow clearance if winter operation is expected. COMPRESSOR CRANKCASE HEATER The compressor is equipped with a crankcase heater to prevent refrigerant from mixing with crankcase oil during the OFF cycle. The heaters will be energized when the compressor is not running providing the unit disconnect switch is closed. Before lifting a unit, make sure that its weight is distributed equally on the cables so that it will lift evenly. Units may also be moved or lifted with a fork-lift from either side but only through the slotted openings provided in the base rails. Do not attempt to start the compressor without at least eight hours of crankcase heat or compressor damage may occur. Unitary Products Group 5
If a unit has just been installed or the unit disconnect switch has been open for a long period of time, move the system switch on the room thermostat to the OFF position before closing the unit disconnect switch. Eight hours of crankcase heat are required to drive the liquid refrigerant out of the compressor before the compressor can be started. FIGURE 3: TYPICAL RIGGING TABLE 3: OUTDOOR UNIT PHYSICAL DATA Description HB180 Unit Model HB240 Compressor1 Rating - (Qty) Tons 2 X 7.5 = 15 Tons 2 X 10 = 20 Tons Quantity 2 2 Diameter - inches 24 30 Fans Blades/Pitch ( ) 3/34 3/22 Nominal CFM 12,400 15,000 Fan Motors 2 RPM 1140 1140 HP 1 1.5 Rows Deep X Rows High 2 X 30 2 X 30 Finned Length - inches each slab 60 78 Coil Face Area - square feet (both slabs) 25 32.5 Tube(Copper) OD - inches 3/8 3/8 Fins(Aluminum) per inch 16 16 Holding Charge (sys1/sys2) 3 1-0 / 1-0 lbs. 1-0 / 1-0 lbs. Refrigerant - 22 (lbs -oz.) Operating Charge (sys1/sys2) 4 14.0/14.0 lbs. 17.0/17.0 lbs. Unit Weight (lbs) Shipping 944 1124 Operating 957 1140 1. These compressors are fully hermetic. 2. The ball bearing, 56 frame, single phase condenser fan motors have internal protection and are directly connected to the condenser fans. Motor rotation is counterclockwise when viewing the lead end, which is opposite the shaft end. 3. The amount of charge in the unit as shipped from the factory. 4. Total operating charge for the condensing unit, matching indoor unit, and 25 feet of interconnecting pipe. 6 Unitary Products Group
POWER AND CONTROL WIRING Install electrical wiring in accordance with the latest National Electrical Code (NFPA Standard No. 70) and/or local regulations. The unit should be grounded in accordance with these codes. Use only copper conductors when connecting field wiring to the unit. Check the voltage of the power supply against the data on the unit nameplate. Check the size of the power wire, the disconnect switch and the fuses against the data in Table 4, 5 and 6. NOTE: Copper conductors must be installed between the disconnect switch and the unit. Refer to Figure 6 for the location of the power wire access opening through the front of the unit. This opening will require a field-supplied conduit fitting. If a field-supplied disconnect switch must be used, it must be suitable for an outdoor location. Although it should be installed near the unit, do NOT secure it to the unit cabinet. Refer to Figure 4 for typical low-voltage field wiring. CONTROL WIRING Refer to Figure 6 for the location of the control wire access opening through the front of the unit. Route the necessary low voltage control wires from terminal block TB2 of the unit control box through this access opening to the indoor unit and to the room thermostat. Refer to Figure 4 for typical field wiring. The room thermostat should be mounted about 5 feet above the floor and located where it will be exposed to normal room air circulation. Do not locate it on an outside wall, near a supply air grille, or where it may be affected by sunlight and/or drafts. Circulation of air to the thermostat should not be blocked by curtains, drapes, furniture, partitions, etc. Some installations may require a locking cover to protect the thermostat from tampering and/or damage. FIGURE 4: TYPICAL LOW VOLTAGE WIRING DIAGRAM Unitary Products Group 7
TABLE 4: ELECTRICAL DATA COMPRESSORS Model Number Power Supply Compressors System 1 System 2 RLA LRA RLA LRA HB180 208/230-3-60 25.6 190.0 25.6 190.0 HB180 460-3-60 12.8 95.0 12.8 95.0 HB180 575-3-60 10.2 75.0 10.2 75.0 HB240 208/230-3-60 42.0 239.0 42.0 239.0 HB240 460-3-60 19.2 125.0 19.2 125.0 HB240 575-3-60 13.8 80.0 13.8 80.0 TABLE 5: ELECTRICAL DATA FAN MOTORS Model Number Power Supply Condenser Fans Qty. FLA ea. HB180 208/230-3-60 2 3.7 HB180 460-3-60 2 1.85 HB180 575-3-60 2 1.7 HB240 208/230-3-60 2 5.8 HB240 460-3-60 2 2.9 HB240 575-3-60 2 2.2 TABLE 6: ELECTRICAL DATA, MINIMUMS AND MAXIMUMS Model Number Power Supply Min. Circuit Ampacity Max. Fuse Size 1 HB180 208/230-3-60 65.1 90 HB180 460-3-60 32.5 45 HB180 575-3-60 26.4 35 HB240 208/230-3-60 106.1 125 HB240 460-3-60 49.0 60 HB240 575-3-60 35.5 45 1. Maximum fuse or maximum circuit breaker (HACR type per NEC). 8 Unitary Products Group
C A All dimensions are in inches. They are subject to change without notice. Certified dimensions will be provided upon request. B Unit Dimensions (In.) A B C 15 Ton 37.5 45.75 110.5 20 Ton 37.5 45.75 128.1 FIGURE 5: UNIT DIMENSIONS TABLE 7: CONNECTIONS TABLE 8: UNIT CLEARANCES Connection Size Connection Entry 15 Ton 1 20 Ton1 Suction Line 1-1/8 ID 1-3/8 ID Liquid Line 5/8 ID 5/8 ID Power Wiring 2 KO 2 KO Location Dimensions Overhead (Top) 1 120 Front access panels 36 Left Side 30 Right Side 30 Rear 24 Control Wiring 7/8 KO 7/8 KO Bottom 2 0 1. Refer to Tables 11 and 12 for appropriate suction and liquid line sizes. 1. Units must be installed outdoors. Overhanging structures or shrubs should not obstruct condenser air discharge. 2. Adequate snow clearance must be provided if winter operation is expected. Unitary Products Group 9
FIGURE 6: PIPING AND ELECTRICAL CONNECTION LOCATIONS TABLE 9: PIPING AND ELECTRICAL CONNECTION SIZES CONNECTION ENTRY SIZE A SUCTION LINE SYS #1 1-1/8 ID (15 Ton) 1-3/8 ID (20 Ton) B LIQUID LINE SYS. #1 5/8 ID C SUCTION LINE SYS. #2 1-1/8 ID (15 Ton) 1-3/8 ID (20 Ton) D LIQUID LINE SYS. #2 5/8 ID E POWER WIRING 2 KO F CONTROL WIRING 7/8 KO 10 Unitary Products Group
REFRIGERANT PIPING GENERAL GUIDELINES 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 with established standards. Use hard drawn copper tubing where no appreciable amount of bending around pipes or other obstructions is necessary. Use long radius ells wherever possible with one exception - small radius elbows for the traps in all vapor risers. If soft copper is used, care should be taken to avoid sharp bends which may cause a restriction. Pack fiber glass insulation and a sealing material such as permagum around refrigerant lines where they penetrate a wall to reduce vibration and to retain some flexibility. Support all refrigerant lines at minimum intervals with suitable hangers, brackets or clamps. Braze all copper to copper joints with Sil Fos-5 or equivalent brazing material. Do not use soft solder. Insulate all vapor 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 vapor and liquid lines together. They can be taped together for convenience and support purposes, but they must be completely insulated from each other. LINE SIZING When sizing refrigerant lines for a split-system air conditioner, check the following: When the condensing unit is below the evaporator coil, the liquid line must be designed for the pressure drop due to both friction loss and vertical rise. If the total pressure drop exceeds 40 psi, some refrigerant may flash before it reaches the thermal expansion valve. This flashing will not only cause erratic valve operation and poor system performance, but could also damage the expansion valve. TABLE 10: REFRIGERANT LINE CHARGE 1 Refrigerant Line 2 Line Size O.D. (in.) Refrigerant Charge (lb./ft.) Liquid 5/8 0.113 Vapor 1-1/8 1-3/8 0.013 1. Charges are based on 40 F suction temperature and 105 F liquid temperature. 2. Type L copper tubing If the unit has already lost its holding charge, it should be leak tested and the necessary repairs should be made. If the unit has maintained its holding charge, you can assume that it has no leaks and proceed with the installation. Dry nitrogen should always be supplied through a connection while it is being brazed or unbrazed because 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. The flow of nitrogen should be continued until the joint has cooled. 1. Suction line pressure drop due to friction at full capacity, 2. Liquid line pressure drop due to friction at full capacity, 3. Suction line velocity for oil return at part capacity, and 4. Liquid line pressure drop due to static head. NOTE: Never base refrigerant line sizes on the OD of the suction and liquid connections on the unit. Tables 11 and 12 list friction losses for both the suction and liquid lines on the system. Table 10 shows the amount of refrigerant charge required per foot of refrigerant line. When the evaporator coil is below the condensing unit, the suction line must be sized for both pressure drop and for oil return. For certain piping arrangements, different suction line sizes may have to be used. The velocity of the suction gas must always be great enough to carry oil back to the compressor. The dry nitrogen must always be supplied through a pressure regulating valve. Before installing the liquid line between the outdoor and indoor units, remove the copper disc from the liquid connection on the outdoor unit per the following procedure: 1. Make sure the refrigerant in the line has been recovered and that the liquid service valve on the unit is front-seated and closed. The valve stem should be turned to its maximum clockwise position. 2. Drill a small hole through the disc before unbrazing it to permit a flow of dry nitrogen through the connection while it is being unbrazed. Unitary Products Group 11
TABLE 11: SUCTION LINES 1 2 Model Designation Nominal Capacity (Tons) Refrigerant Flow Rate 3 (Lbs./ Min.) Copper Tubing (Inches, O.D.) Refrigerant Gas Velocity (Ft./Min.) Friction Loss 4 5 (PSI/100 Ft.) 1 1/8 2050 4.3 System # 1 7 1/2 24.6 1 3/8 1680 1.6 HB180 4-Pipe System 1 5/8 1140 0.7 1 1/8 2050 4.3 System # 2 7 1/2 24.6 1 3/8 1680 1.6 1 5/8 1140 0.7 1 1/8 3500 8.0 System # 1 10 32.5 1 3/8 2280 2.8 HB240 4-Pipe System 1 5/8 1560 1.2 1 1/8 3500 8.0 System # 2 10 32.5 1 3/8 2280 2.8 1 5/8 1560 1.2 1. All horizontal suction lines should be pitched at least 1 inch every 20 feet in the direction of the refrigerant flow to aid the return of oil to the compressor. 2. Every vertical suction riser greater than 25 feet in height should have a P trap at the bottom to facilitate the return of oil to the compressor. Use short radius fittings for these traps. 3. Based on Refrigerant-22 at the nominal capacity of the condensing unit, a saturated suction temperature of 45 F and a liquid temperature of 110 F. 4. Although suction lines should be sized for a friction loss equivalent to a 2 F change in saturation temperature (or approximately 3psi), sizing the lines for the proper return of oil is more important. 5. These friction losses do not include any allowances for valves or fittings. TABLE 12: LIQUID LINES Model Designation Nominal Capacity (Tons) Refrigerant Flow Rate 1 (Lbs./Min.) Copper Tubing (Inches, O.D.) Friction- Loss 2 3 (PSI/100 Ft.) Vertical Rise (PSI/Ft.) HB180 4-Pipe System System # 1 7 1/2 24.6 System #2 7 1/2 24.6 1/2 11.0 0.5 5/8 3.5 0.5 1/2 11.0 0.5 5/8 3.5 0.5 HB240 4-Pipe System System #1 10 32.5 System # 2 10 32.5 5/8 5.8 0.5 3/4 2.3 0.5 5/8 5.8 0.5 3/4 2.3 0.5 1. Based on Refrigerant-22 at the nominal capacity of the condensing unit, a saturated suction temperature of 45 F and a liquid temperature of 110 F. 2. The total pressure drop of the liquid line for both friction and vertical rise must not exceed 40 PSI. If the pressure drop exceeds 40 PSI, the liquid refrigerant could flash before it reaches the expansion valve. This flashing will not only cause erratic valve operation and poor system performance, but could also damage the expansion valve. 3. These friction losses do not include any allowances for a strainer, filter-drier, solenoid valve, isolation valve or fittings. 12 Unitary Products Group
3. Remove the cap from the 1/4" access port on the liquid line stop valve. 4. Connect a supply of dry nitrogen to this access port. 5. Unbraze the copper disc from the liquid connection while maintaining a minimum flow of dry nitrogen through the connection. After the disc has been removed, 1. Clean the external surfaces of the liquid connection on the outdoor unit and the end of the field-supplied piping being used for the liquid line. NOTE: Clean surfaces are essential for a well brazed connection. 2. Carefully clean the internal surfaces of the above. Any particles left on these surfaces may lead to a future system malfunction. NOTE: Use only copper tubing that has been especially cleaned and dehydrated for refrigerant use. If the tubing has been open for an extended period of time, it should be cleaned before being used. The liquid and vapor line connections can now be brazed while maintaining a minimum flow of dry nitrogen through the piping. After the liquid and vapor lines have been installed, the system should be evacuated and charged. EVACUATING AND CHARGING With the liquid and suction line service valves closed, connect a vacuum pump through a charging manifold to the access ports on both the liquid and suction line service valves. NOTE: This hole is also required to prevent the internal pressure from building up as the disc is being unbrazed and from blowing the disc off. This warning applies to any disc being removed from a service valve, coil connection, etc. The vacuum pump connections should be short and no smaller than 3/8" O.D. To continue charging refrigerant, open the liquid and the suction line service valves fully. Turn the stem of the liquid service valve clockwise 1/4 turn to open its access port for reading pressure. Start the compressor (after 8 hours of crankcase heat), turn the stem of the suction line service valve clockwise 1/4 turn to open its service port and continue to charge refrigerant gas through this suction access port until you meet the conditions shown on the charging curve, Figures 8 and 9. Open the liquid and vapor line service valves fully to close their access ports after the system has been charged. ALTERNATE CHARGING METHODS If you are starting a unit when the ambient temperature is higher or lower than those shown in Figures 8 and 9, either of the following methods may be used. Method 1: Determine the total weight of the refrigerant for the total system by adding the required charge for outdoor unit, the indoor unit and the refrigerant lines using information in Tables 3 and 10. Using the charging procedures outlined above, weigh the required amount of refrigerant charge into the unit. Method 2: Do not charge liquid refrigerant through the compressor suction connection. Do not attempt to start the compressor without at least 8 hours of crankcase heat or compressor damage will occur. Install a field supplied moisture indicating sight glass in the liquid line between the filter-drier and the evaporator coil. Using the charging procedure outlined above, charge refrigerant until the moisture indicating sight glass is clear. Add approximately 2 extra pounds of refrigerant to assure a liquid refrigerant seal at the expansion valve under all operating conditions. Block the flow of the condenser air, if necessary, to assure a head pressure of 280 psig during the charging procedure. The refrigerant lines and the evaporator coil can now be evacuated to 500 Microns without disturbing the charge in the condenser coil or the compressor. After proper evacuation and dehydration, charge refrigerant through the access port on the liquid line service valve allowing the vacuum to draw in as much refrigerant as possible. NOTE: The installer should return to the job to verify the operating charge when the ambient temperature is within the conditions shown in Figures 8 and 9. Unitary Products Group 13
OPERATION SIMPLICITY SYSTEM SEQUENCE OF OPERATION FOR 15 & 20 TON, 4-PIPE OUTDOOR SPLIT SYS- TEMS Condensing Unit Matched with a Single (two stage) Indoor Unit 1. Thermostat calls for cooling. 2. 24V is supplied to the Y1 terminal on the Simplicity control board, which is located in the electrical box of the outdoor unit. 3. System 1 compressor starts and power is provided to both outdoor fans (see section on fan control switch operation). In addition, a 24-volt signal is sent to the indoor unit to bring on the indoor fan. This signal is supplied via terminal block 2 in the electrical control box at either the G1 or G2 terminal. Both terminals (G1 and G2) will be jumped together. 4. If a second stage of cooling is needed, the thermostat will call for a second stage of cooling. 5. 24V is supplied to the Y2 terminal on the Simplicity control board. 6. System 2 Compressor will start. 7. Once the second stage of cooling is satisfied, the System 2 compressor will shut down. 8. When the cooling demand is satisfied, the System 1 compressor and both outdoor fans will shut down. 9. After a 10-second off delay, the signal to run the indoor fan will be terminated. 10. Once a compressor is shut down, a 5-minute short cycle delay period must pass before the compressor can be restarted. Condensing Unit Matched with Two Indoor Units The 15 and 20 Ton 4-pipe units can also be used with two appropriately sized indoor units. In this case, each indoor unit will have its own thermostat. One thermostat will connect to Y1 on the Simplicity control board and the other thermostat will connect to Y2. In addition, the jumper between G1 and G2 must be removed. Both G1 and G2 will provide the 24V signal to operate the indoor fan for the indoor units providing the Y1 and Y2 signals respectively. Both condenser fans may run when either one of the indoor units is calling for cooling (see section on fan control switch operation). Fan Control Switch Operation The 15 and 20 Ton 4-pipe outdoor split units have condenser fan pressure switches installed as standard equipment. When outdoor ambient conditions are cool, the head pressure of any air conditioning system may drop too low for optimal performance. On the 15 and 20 ton 4-pipe outdoor split units, once the head pressure of both systems drop below 180 psig, condenser Fan 2 will be shut down. It will not start again until the pressure of one of the systems has reached 320 psig. Low Ambient Switch All units are equipped with a low ambient switch set to close at 40ºF. Below this outdoor temperature the unit will not run. In order to operate at temperatures down to 0ºF, the optional low ambient kit must be field installed. (See Low Ambient Installation Instructions, Part Number 035-18502-000 for details.) High Pressure Limit Switch During cooling operation, if a high-pressure limit switch opens, the control board will de-energize the associated compressor, initiate the anti-short cycle time delay (5 min.), and, if the other compressor is not running, stop the condenser fans. 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. Pump-Out Option See document Part Number 035-18495-000 for 208/230/ 460 V Units and 035-19878-000 for 575 V Units for details on this field installation option. If a high pressure switch opens three times within two hours of operation, the control board will lock-out the associated compressor and flash a code (see Table 19). Low Pressure Limit Switch If the low-pressure switch opens during normal operation, the control board will de-energize the associated compressor, indicate the anti-short cycle time delay, and, if the other compressor is not running, stop the condenser fans. On start-up, if the low-pressure switch opens, the control board will monitor the low-pressure switch to make sure it closes within one minute. If the low-pressure switch fails to close, the unit will shut down the associated compressor and begin an anti-short cycle time delay. 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 control board will lock-out the associated compressor and flash a code (See Table 19). 14 Unitary Products Group
FLASH CODES Various flash codes are utilized by the unit control board (UCB) to aid in troubleshooting. Flash codes are distinguished by the short on and off cycle used (approximately 200ms on and 200ms off). To show normal operation, the control board flashes a 1 second on, 1 second off "heartbeat" during normal operation. This is to verify that the UCB is functioning correctly. Do not confuse this with an error flash code. To prevent confusion, a 1-flash, flash code is not used. Alarm condition codes are flashed on the UCB lower left Red LED, See Figure 7. While the alarm code is being flashed, it will also be shown by the other LEDs: lit continuously while the alarm is being flashed. The total of the continuously lit LEDs equates to the number of flashes, and is shown in the table. Pressing and releasing the LAST ERROR button on the UCB can check the alarm history. The UCB will cycle through the last five (5) alarms, most recent to oldest, separating each alarm flash code by approximately 2 seconds. In all cases, a flashing Green LED will be used to indicate non-alarm condition. In some cases, it may be necessary to "zero" the ASCD for the compressors in order to perform troubleshooting. To reset all ASCDs for one cycle, press and release the UCB TEST/ RESET button once. Flash codes that do and do not represent alarms are listed in Table 13. TABLE 13: UNIT CONTROL BOARD FLASH CODES FLASH CODE DESCRIPTION GREEN LED 16 On Steady This is a Control Failure - - - - - 1 Flash Not Applicable - - - - - 2 Flashes Control waiting ASCD 1 Flashing Off Off On Off 3 Flashes HPS1 Compressor Lockout Off Off Off On On 4 Flashes HPS2 Compressor Lockout Off Off On Off Off 5 Flashes LPS1 Compressor Lockout Off Off On Off On 6 Flashes LPS2 Compressor Lockout Off Off On On Off 7 Flashes FS1 Compressor Lockout Off Off On On On 8 Flashes FS2 Compressor Lockout Off On Off Off Off 10 Flashes Compressors Locked Out on Low Outdoor Air Temperature 1 Flashing On Off On Off 12 Flashes Unit Locked Out due to Fan Overload Switch Failure Off On On Off Off 13 Flashes Compressor Held Off due to Low Voltage 1 Flashing On On Off On 14 Flashes EEPROM Storage Failure Off On On On Off OFF No Power or Control Failure Off Off Off Off Off 1. Non-alarm condition. RED LED 8 RED LED 4 RED LED 2 RED LED 1 Unitary Products Group 15
Check Alarm History Reset All ASCDs for One Cycle Non Alarm Condition Green LED Flashing Current Alarm Flashed Red LED FIGURE 7: UNIT CONTROL BOARD UNIT CONTROL BOARD OPTION SETUP OPTION BYTE SETUP Enter the Option Setup mode by pushing the OPTION SETUP / STORE button, and holding it for at least 2 seconds. The green status LED (Option Byte) will be turned on and the red status LED (Heat Delay) is turned off. The 4 LED will then show the status of the labeled option Low Ambient Lockout. Press the UP or Down button to change the LED status to correspond to the desired Option Setup. To save the current displayed value, push the OPTION SETUP / STORE button and hold it for at least 2 seconds. When the value is saved, the green LED will flash a few times and then normal display will resume. NOTE: While in either Setup mode, if no buttons are pushed for 60 seconds, the display will revert to its normal display, exiting the Option Setup mode. When saving, the control board only saves the parameters for the currently displayed mode (Option Byte or Heat Delay). (Heat Delay not applicable on these units.) START-UP PHASING Units are properly phased at the factory. Check for proper compressor rotation. If the blower 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 condenser fans, or compressor rotate correctly. CRANKCASE HEATER The crankcase heaters must be energized at least 8 hours before starting the compressor. To energize the crankcase heaters, the main disconnect switch must be closed. During this 16 Unitary Products Group
8 hour period, the system switch on the room thermostat must be OFF to prevent the compressor from starting. Do not attempt to start the compressor without at least 8 hours of crankcase heat or compressor damage will occur. Make sure that the bottom of the compressor is warm to the touch to prove crankcase heater operation. 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 outdoor 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. Have the fuses, disconnect switch and power wire been sized properly? 7. Are all compressor hold-down nuts properly secured? (If equipped) 8. Are any refrigerant lines touching each other or any sheet metal surface? Rubbing due to vibration could cause a refrigerant leak. 9. Are there any visible signs of a refrigerant leak, such as oil residue? INITIAL START-UP 1. Supply power to the unit through the disconnect switch prior to starting the compressor. 2. Move the system switch on the room thermostat to the COOL position, and lower its set point to energize the compressor. Cool air will be supplied to the conditioned space. 3. Check the compressor amperage. It should not exceed the RLA rating printed on the unit data plate or in Table 4 unless the ambient temperature is above 105 F. 4. Verify that the scroll compressors are rotating in the proper direction. If the rotation is found to be wrong, reverse two of the main incoming power legs at TB1. Do not change compressor legs or condenser fan leads. These units have been factory tested and properly phased on the internal wiring. 5. Check the entire system for refrigerant leaks. 6. Check for any abnormal noises and/or vibrations, and make the necessary adjustments to correct (e.g. fan blade touching shroud, refrigerant lines hitting on sheet metal, etc.) 7. 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. 8. Repeat this procedure for system 2. SAFETY FEATURES 1. All outdoor fan motors have inherent protection with automatic reset. 2. Every compressor is internally protected against excessive current and temperature by a line break motor protector that is mounted inside the compressor housing and is connected between each winding and the common terminal. This motor protector will interrupt power to the compressor if any of the following overload conditions occur: a. primary single phasing b. locked rotor c. compressor overload d. insufficient motor cooling This type of motor protection works even with the contactor welded closed. Do not attempt to start the compressor without at least 8 hours of crankcase heat or compressor damage will occur. 3. Every compressor is protected by crankcase heaters to prevent refrigerant from accumulating in the crankcases of the compressor during an OFF cycle. 4. Outdoor fan motors and the secondary of the control transformer are grounded. 5. Outdoor fan motors are subfused. SECURE OWNER S APPROVAL 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, how to adjust temperature settings within the limitations of the system. Unitary Products Group 17
MAINTENANCE CLEANING Do not allow dirt to accumulate on the outdoor coil. Clean the coil with a brush or vacuum cleaner as often as necessary to assure good system performance and efficient operation. If the coil is extremely dirty, it may be necessary to use an industrial grade detergent and a hose to clean the fin surface. LUBRICATION The outdoor fan motors are equipped with factory lubricated and sealed ball bearings. They do not require any maintenace. REPLACEMENT PARTS Contact your local UPG distribution Center for replacement compressors, fan motors, controls, etc. NOTICE TO OWNER If a lockout occurs, check the indoor filters and the outdoor coil before calling a serviceman. If the filters are dirty, clean or replace them. If there is an accumulation of snow, leaves or debris blocking the outdoor air coil, remove the blockage. Reset the thermostat and wait 5 minutes. If the unit doesn t start, call a serviceman. Discharge Pressure (psi) 400 350 300 250 200 150 15 Ton charging Chart Outdoor Temp 115º 105º 95º 85º 75º 65º 100 60 70 80 90 100 Suction Pressure (psi) 1. Make sure that both condenser fans are running when charging. One fan may switch off at lower ambient temperatures making the chart above inaccurate. 2. This chart is applicable to unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, The charging chart may no longer apply. FIGURE 8: CHARGING CURVE FOR HB180 18 Unitary Products Group
400 20 Ton charging Chart Outdoor Temp 115º 350 105º Discharge Pressure (psi) 300 250 200 95º 85º 75º 65º 150 100 60 65 70 75 80 85 90 95 100 Suction Pressure (psi) FIGURE 9: CHARGING CURVE FOR HB240 1. Make sure that both condenser fans are running when charging. One fan may switch off at lower ambient temperatures making the chart above inaccurate. 2. This chart is applicable to unit with the TXV's left to the factory setting. If the TXV's have been adjusted in the field, The charging chart may no longer apply. Unitary Products Group 19
FIGURE 10:TYPICAL WIRING DIAGRAM Subject to change without notice. Printed in U.S.A. 278803-YIM-A-1106 Copyright 2006 by Unitary Products Group. All rights reserved. Supersedes: 66329/035-18448-001-B-0804 Unitary 5005 Norman Products York OK Group Drive 73069