INSTALLATION INSTRUCTIONS
Product Family: N2H3, H2H3
These instructions must be read and understood completely before attempting installation.
Safety Labeling and Signal Words
DANGER, WARNING, CAUTION, and
NOTE
The signal words DANGER, WARNING, CAU??? TION, and NOTE are used to identify levels of haz??? ard seriousness. The signal word DANGER is only used on product labels to signify an immediate haz??? ard. The signal words WARNING, CAUTION, and NOTE will be used on product labels and through??? out this manual and other manuals that may apply to the product.
DANGER - Immediate hazards which will result in severe personal injury or death.
WARNING - Hazards or unsafe practices which could result in severe personal injury or death.
CAUTION - Hazards or unsafe practices which may result in minor personal injury or product or property damage.
NOTE - Used to highlight suggestions which will result in enhanced installation, reliability, or opera??? tion.
Signal Words in Manuals
The signal word WARNING is used throughout this manual in the following manner:
!WARNING
The signal word CAUTION is used throughout this manual in the following manner:
!CAUTION
Signal Words on Product Labeling
Signal words are used in combination with colors and/or pictures on product labels.
TABLE OF CONTENTS
506 01 5001 00 May 2007
INSTALLATION INSTRUCTIONS3-phase
INSPECT NEW UNIT
Consult a qualified installer, service agency, or the dealer/distributor for information and assistance. The qualified installer must use factory authorized kits and accessories when modifying this product. Refer to the individual instructions packaged with the kit or accessory when installing.
The weight of the product requires careful and proper handling procedures when lifting or moving to avoid personal injury. Use care to avoid contact with sharp or pointed edges.
Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Use a heat sinking material - such as a wet rag - during brazing operations. Keep a fire extinguisher available. Consult local codes and the National Electric Code (NEC) for special requirements.
Improper installation, adjustment, alteration, service or maintenance can void the warranty.
!WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in per??? sonal injury or death.
Before installing, modifying or servicing system, turn OFF the main (remote) electrical disconnect device. There may be more than one disconnect device.
LOCATION
Check local codes for regulations concerning zoning, noise, platforms, and other issues.
Locate unit away from fresh air intakes, vents, or bedroom windows. Noise may carry into the openings and disturb people inside.
Locate unit in a well drained area, or support unit high enough so that water runoff will not enter the unit.
Locate unit away from areas where heat, lint, or exhaust fumes will be discharged onto unit (as from dryer vents).
Locate unit away from recessed or confined areas where recirculation of discharge air may occur (refer to CLEARANCES section of this document).
NOTE: Roof mounted units exposed to wind may require wind baffles. Consult the manufacturer for additional information.
CLEARANCES
Nominal minimum clearances are 48 inches above unit for discharge air and 18 inches on each side of the coil for intake air. Clearance on any one side of the coil (normally between unit and structure) may be reduced to 6 inches. Nominal minimum clearances are based on a solid parallel object such as a wall or roof overhang.
The clearance may be reduced for a single object with small surface area, such as the end of a wall, outside corner of a wall, fence section, post, etc. As a general rule, the minimum clearance from the unit should equal the width of the object. For example, a 6 inch fence post should be a minimum of 6 inches from the unit.
Do not install unit under roof overhangs unless gutters are present. A minimum vertical clearance of 48 inches is required to the overhang.
Inside corner locations on single story structures require evaluation. Large overhanging soffits may cause air recirculation in a corner area even though recommended minimum clearances are maintained. As a guide, locate the unit far enough out so that half of the discharge grille is out from under the soffit.
When placing two or more units
Provide minimum service clearance of 24 inches from control box corner and side service panel.
Refer to Figure 1.
UNIT SUPPORT
NOTE: Unit must be level | 2 degrees (a inch rise or fall per foot of run) or compressor may not function properly.
A. GROUND LEVEL INSTALLATION
The unit must be level and supported above grade by beams, platform, or a pad. Platform or pad can be of open or solid construction but should be of permanent materials such as concrete, bricks, blocks, steel, or pressure- treated timbers approved for ground contact. Soil conditions must be considered so that the platform or pad does not shift or settle and leave the unit partially supported. Minimum pad dimensions are shown in Figure 2.
If beams or an open platform are used for support, it is recommended that the soil be treated or area be graveled to reduce the growth of grasses and weeds.
To minimize vibration or noise transmission, it is recommended that supports not be in contact with the building structure. However, slabs on grade constructions with an extended pad are normally acceptable.
!CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in proper??? ty damage.
Top surface of platform must be above estimated snowfall level to prevent snow blocking coil and to allow water melt to drain from unit.
C. FASTENING UNIT DOWN
If conditions or local codes require the unit be attached in place, remove the knockouts in the base pan and install tie down bolts through the holes (refer to Figure 2).
Contact local distributor for hurricane
!CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in proper??? ty damage.
Inadequate unit support may cause excessive vibration, noise, and/or stress on the refrigerant lines, leading to refrigerant line failure.
a??? dia. Tie Down Knockouts In Base Pan (2 places)
VIEW
FROM
TOP
Base
Pan
B. ROOF TOP INSTALLATION
This type of installation is not recommended on wood frame structures where low noise levels are required.
Supporting structure or platform for the unit must be level. If installation is on a flat roof, locate unit minimum 6 inches above roof level.
Place the unit over one or more load bearing walls. If there are several units, mount them on platforms that are
NOTE: When unit is to be installed on a bonded guaranteed roof, a release must be obtained from the building owner to free the installer from all liabilities.
Depth
C
REFRIGERATION SYSTEM
A. COMPONENT MATCHES
Check to see that the proper system components are in place, especially the indoor coil.
This outdoor unit is designed for use only with indoor coils that utilize a hard
INSTALLATION INSTRUCTIONS
!CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product damage.
Indoor coil and outdoor unit must be listed as a certified combination (match) in the ARI Unitary Directory of Certified Products.
Indoor coil must have
When installing a hard
A typical hard
INDOOR
COIL
EQUALIZER
TUBE
LIQUID
TUBE
HARD
TXV
SENSING BULB
B. REFRIGERANT LINE SETS
The refrigerant line set must be properly sized to assure maximum efficiency and proper oil circulation. Select line set tube diameters as specified in Figure 4.
NOTE: If the line set actual length is to exceed 80 feet, or if there is more than 20 feet vertical separation between outdoor and indoor units, refer to the Long Line Application Guidline document for additional instructions.
NOTE: Line set actual length must not exceed 200 feet.
NOTE: A crankcase heater must be used when the refrigerant line length exceeds 80 feet.
If it is necessary to add refrigerant line in the field, use dehydrated or dry, sealed, deoxidized, copper refrigeration tubing. Do not use copper water pipe.
Do not remove rubber plugs or caps from copper tubing until connections are ready to be made.
Be extra careful when bending refrigeration tubing. Tubing can ???kink??? easily, and if this occurs, the entire length of tubing must be replaced.
!WARNING
PERSONAL INJURY HAZARD
Failure to follow this warning could result in per??? sonal injury and/or death.
Relieve pressure and recover all refrigerant before servicing existing equipment, and before final unit disposal. Use all service ports and open all
!CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in improp??? er product operation.
Do not leave system open to atmosphere any lon??? ger than absolutely required for installation. Inter??? nal system components - especially refrigerant oils - are extremely susceptible to moisture con??? tamination. Keep ends of tubing sealed during installation until the last possible moment.
NOTE: If the line set actual length is to exceed 80 feet, or if there is more than 20 feet vertical separation between outdoor and indoor units, refer to the Long Line Application Guideline document for additional instruc??? tions.
INSTALLATION INSTRUCTIONS
C.ROUTING AND SUSPENDING REFRIGERANT
LINES
Run refrigerant lines as straight and direct as possible, avoiding unnecessary bends and turns. Always insulate the entire suction line. Both lines should be insulated when routed through an attic or when routed through an underground raceway.
When routing refrigerant lines through a foundation or wall, do not allow refrigerant lines to come in direct contact with the building structure. Make openings large
enough so that lines can be wrapped with extra insulation. Fill all gaps with RTV caulk. This will prevent noise transmission between the tubing and the foundation or wall.
Along floor or ceiling joists, suspend refrigerant lines so that they do not contact the building structure, water pipes, or ductwork. Use insulated or suspension type hangers. Metal straps must be at least 1??? wide to avoid cutting into the tube insulation. Keep the liquid and suction lines separate. Refer to Figure 5.
SUCTION TUBE
SUCTION TUBE
INSULATION
1??? MIN
LIQUID TUBE
!CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in improp??? er product operation.
Do not bury more than 36??? of line set underground. Refrigerant may migrate to cooler buried section during extended periods of unit
If ANY section of the line set is buried under??? ground, provide a minimum 6??? vertical rise at the service valve.
D. OUTDOOR UNIT HIGHER THAN INDOOR UNIT
Proper oil return to the compressor should be maintained with suction gas velocity. If velocities drop below 1500 fpm (feet per minute), oil return will be decreased. To maintain suction gas velocity, do not upsize vertical suction risers. Use the ???<80 feet??? suction line sizes shown Figure 4.
Install oil traps every 20 feet of vertical suction line riser (refer to Figure 6).
NOTE: If there is more than 20 feet vertical separation between outdoor and indoor units, refer to the Long Line Application Guidline document for additional instructions.
3??? Min.
20 ft.
20 ft.
E. LIQUID LINE
Outdoor units are shipped with an appropriate
INSTALLATION INSTRUCTIONS
F. SERVICE VALVES
Service valves are closed and plugged from the factory. Outdoor units are shipped with a refrigerant charge sealed in the unit. Leave the service valves closed until all other refrigeration system work is complete or the charge will be lost. Leave the plugs in place until line set tubing is ready to be inserted.
Heat pumps require a piston metering device in the liquid service valve for proper heating operation. Piston and retainer are shipped in the piston body of the liquid service valve, temporarily held in place with a plastic cap. Do not remove the plastic cap until line set tubing is ready to be installed.
Refer to Figure 8 and follow these steps for piston installation:
1.Remove plastic cap holding piston and retainer in piston body of liquid service valve.
2.Check that piston size (stamped on side of piston) matches with number listed on unit rating plate. Return piston to piston body of liquid service valve (either direction).
Return retainer to piston body.
NOTE: Small end of retainer fits inside piston body, with
3.Find plastic bag taped to unit containing copper adapter tube with brass nut.
4.Install adapter tube against retainer and thread
brass nut onto liquid service valve. Tighten nut finger tight, then wrench additional ?? turn only.
Service valve bodies are brass and suction tube stub is copper.
PISTON BODY
LIQUID
SERVICE
VALVE
PISTON
PISTON RETAINER
BRASS NUT
SWEAT/FLARE ADAPTER TUBE
G. BRAZING CONNECTIONS
!WARNING
FIRE HAZARD
Failure to follow this warning could result in per??? sonal injury, death, and/or property damage.
Refrigerant and oil mixture could ignite and burn as it escapes and contacts brazing torch. Make sure the refrigerant charge is properly removed from both the high and low sides of the system be??? fore brazing any component or lines.
Clean line set tube ends with emery cloth or steel brush. Remove any grit or debris.
Insert line set tube ends into service valve tube stubs.
Apply heat absorbing paste or heat sink product between service valve and joint. Wrap service valves with a heat sinking material such as a wet cloth.
Braze joints using a
!CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product damage.
Braze with
INSTALLATION INSTRUCTIONS
H. EVACUATING LINE SET AND INDOOR COIL
The unit is shipped with a factory refrigerant charge. The liquid line and suction line service valves have been closed after final testing at the factory. Do not disturb these valves until the line set and indoor coil have been evacuated and leak checked, or the charge in the unit may be lost.
NOTE: Do not use any portion of the factory charge for purging or leak testing. The factory charge is for filling the system only after a complete evacuation and leak check has been performed.
!CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product damage.
Never use the outdoor unit compressor as a vacu??? um pump. Doing so may damage the compressor.
Line set and indoor coil should be evacuated using the recommended deep vacuum method of 500 microns. If deep vacuum equipment is not available, the alternate triple evacuation method may be used by following the specified procedure.
If vacuum must be interrupted during the evacuation procedure, always break vacuum with dry nitrogen.
Deep Vacuum Method
The deep vacuum method requires a vacuum pump capable of pulling a vacuum to 500 microns and a vacuum gauge capable of accurately measuring this vacuum level. The deep vacuum method is the most positive way of assuring a system is free of air and water.
Watch the vacuum gauge as the system is pulling down. The response of the gauge is an indicator of the condition of the system (refer to Figure 9).
With no leaks in the system, allow the vacuum pump to run for 30 minutes minimum at the deep vacuum level.
Triple Evacuation Method
The triple evacuation method should only be used when system does not contain any water in liquid form and vacuum pump is only capable of pulling down to 28 inches of mercury. Refer to Fig. 10 and proceed is as follows:
1.Pull system down to 28 inches of mercury and allow pump to continue operating for an additional 15 minutes.
2.Close manifold valves or valve at vacuum pump and shut off vacuum pump.
3.Connect a nitrogen cylinder and regulator to system and fill with nitrogen until system pressure is 2 psig.
4.Close nitrogen valve and allow system to stand for 1 hour. During this time, dry nitrogen will diffuse throughout the system absorbing moisture.
5.Repeat this procedure as indicated in Figure 10.
6.After the final evacuate sequence, confirm there are no leaks in the system. If a leak is found, repeat the entire process after repair is made.
I. OPENING SERVICE VALVES
Outdoor units are shipped with a refrigerant charge sealed in the unit. Opening the service valves releases this charge into the system.
NOTE: Open the Suction service valve first. If the Liquid service valve is opened first, oil from the compressor may be drawn into the indoor coil TXV, restricting refrigerant flow and affecting operation of the system.
Remove Suction service valve cap and insert a hex wrench into the valve stem. Hold the valve body steady with an
After the refrigerant charge has bled into the system, open the Liquid service valve.
INSTALLATION INSTRUCTIONS
NOTE: These are not
The service valve cap is a primary seal for the valve and must be properly tightened to prevent leaks. Make sure cap is clean and apply refrigerant oil to threads and sealing surface on inside of cap.
Tighten cap finger tight and then tighten additional 6 of a turn (1 wrench flat) to properly seat the sealing surfaces.
J. GAUGE PORTS
Check for leaks at the schrader ports and tighten valve cores if necessary. Install plastic caps finger tight.
ELECTRICAL WIRING
!WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in per??? sonal injury or death.
Before installing, modifying or servicing system, turn OFF the main (remote) electrical disconnect device. There may be more than one disconnect device.
Refer to unit rating plate for the required supply voltage. Depending on the model, required supply voltage will be:
208/230 V,
or
460 V,
Outdoor units are approved for use with copper conductors only. Do not use aluminum wire.
Refer to unit rating plate for minimum circuit ampacity and circuit protection requirements.
Grounding
Permanently ground unit in accordance with the National Electrical Code and local codes or ordinances. Use a copper conductor of the correct size from the grounding lug in control box to a grounded connection in the service panel or a properly driven and electrically grounded ground rod.
Supply Voltage Wiring Connections
Make all outdoor electrical supply (Line Voltage) connections with raintight conduit and fittings. Most codes require a disconnect switch outdoors within sight of the unit. Consult local codes for special requirements.
Route electrical supply (Line Voltage) wiring through knockout hole in bottom of Control Box.
Connect two power wires to Contactor and one power wire to Blue lead wire (use wire nut). Connect ground wire to Ground Lug. Refer to Wiring Diagram on unit and Figure 11.
Phase Monitor Relay Board
The Phase Monitor Board detects the sequence of the three phase electrical system, and a relay breaks the Y (call for cooling) control signal if the phasing is incorrect. Additionally, the board will detect the loss of voltage on any of the three phase inputs and break the Y signal in the same way.
An LED on the board displays the following status: Red LED ON - Normal function, relay contact closed.
Red LED Blinking - Abnormal function, relay contact open.
Red LED OFF - No 24 VAC control power present at board.
NOTE: Units with Comfort Alertt Diagnostics device have phase monitor feature built in.
Figure 12 Phase Monitor Relay Board
INSTALLATION INSTRUCTIONS
Thermostat Wiring Connections
Route thermostat wiring through rubber grommet in bottom of Control Box. Low voltage lead wires are provided in the control box for connection to thermostat wires (use wire nuts). Refer to Wiring Diagram on unit and Figure 13 for low voltage wiring examples.
NOTE: Use No. 18 AWG (American Wire Gage)
DEFROST SYSTEM
A. DEFROST THERMOSTAT
The defrost thermostat is factory installed on a short tube stub extending from the coil end plate. Refer to Figure 14 and confirm that the thermostat is securely fastened in place on the tube stub.
FEEDER TUBE
TUBE STUB
COIL
DEFROST
THERMOSTAT
B. DEFROST CONTROL BOARD
The defrost board is a time/temperature control which includes a
Defrost mode is identical to cooling mode except that
Initially, the defrost cycle timer starts when the contactor is energized and a 24 VAC signal is present on the T1 terminal. Then the defrost cycle begins when the defrost thermostat is closed and the cycle timer times out (30, 60, 90 or minutes).
To initiate a forced defrost cycle, the defrost thermostat must be closed. This can be accomplished as follows:
1.Turn off power to outdoor unit.
2.Disconnect outdoor
3.Restart unit in heating mode, allowing frost to accumulate on outdoor coil.
4.After a few minutes in heating mode, liquid line temperature should drop below closing point of defrost thermostat (approximately 32 ??F).
5.Short between
6.When you hear reversing valve change position, remove screwdriver immediately; otherwise, control will terminate normal
NOTE: Length of defrost cycle is dependent upon length of time it takes to remove screwdriver from test pins after reversing valve has shifted.
7.Unit will remain in defrost for remainder of
8.Turn off power to outdoor unit and reconnect
1.Set indoor thermostat selector switch to OFF.
2.Turn ON all electrical disconnect devices.
3.If unit has a crankcase heater, energize the heater and wait 24 hours before proceeding.
4.Set indoor thermostat at desired temperature. Be sure setpoint is below indoor ambient temperature to call for cooling, or above indoor ambient to call for heating.
5.Set indoor thermostat selector switch to COOL or HEAT. Operate unit for minimum 10 minutes, then check the system refrigerant charge.
Check For Proper Phasing
Observe the LED on the Phase Monitor Relay Board. If the LED is blinking, turn off power to the unit and swap any two of the supply voltage wires. Turn power back on and repeat the
REFRIGERANT CHARGE
A. COOLING MODE
Outdoor units are shipped with a refrigerant charge to match a specific indoor coil and 15 feet of refrigerant line. If shorter or longer refrigerant lines or a different indoor coil are used, the charge will have to be adjusted.
For different line lengths, add or remove charge based on 0.6 ounces charge per foot of difference. For example, a 25 foot line set is 10 feet longer than the specified 15 feet. Add 0.6 ounces charge for each of the extra 10 feet:
10 x 0.6 = 6.0 ounces additional charge
This outdoor unit is designed for use only with indoor coils that utilize a hard
1.Operate unit a minimum of 10 minutes before checking charge.
NOTE: If outdoor unit has a
motor will operate in low speed when outdoor ambient temperature is below 82 ??F. Pull one of the yellow low voltage wires off the fan control and the unit will default to high speed fan for servicing. Reconnect wire after servicing.
2.Measure liquid service valve pressure by attaching an accurate gauge to service port.
3.Measure liquid line temperature by attaching an accurate thermistor type sensor or electronic thermometer to liquid line near outdoor coil.
4.Refer to unit rating plate for required subcooling temperature.
5.Refer to Figure 16. Find the required liquid line temperature where the rating plate subcooling temperature intersects measured liquid service valve pressure.
6.If the measured liquid line temperature is higher than the chart number, add refrigerant to lower the measured temperature.
NOTE: When adding refrigerant, charge in liquid form, using a flow restricting device, into the suction port.
If the measured liquid line temperature is lower than the chart number, reclaim refrigerant to raise
the measured temperature. Tolerance is | 3 ??F.
B.HEATING MODE
To check system operation during heating cycle, refer to the Tech Label on outdoor unit. This chart indicates whether a correct relationship exists between system operating pressure and air temperature entering indoor and outdoor units. If pressure and temperature do not match on chart, system refrigerant charge may not be correct. Do not use chart to adjust refrigerant charge.
NOTE: When charging is necessary during heating season, charge must be weighed in accordance with unit rating plate ??0.6 ounces per foot of a inch liquid line above or below 15 feet respectively.
SEQUENCE OF OPERATION
A. COOLING MODEB. HEATING MODE
On a call for cooling, the thermostat makes circuits
When thermostat is satisfied, its contacts open,
NOTE: If indoor unit is equipped with a
NOTE: Low ambient cooling feature allows unit to operate safely in cooling mode down to 0?? F outdoor ambient.
On a call for heating, the thermostat makes circuits
When the thermostat is satisfied, its contacts open,
TROUBLESHOOTING
Some models are factory equipped with the Comfort Alertt Diagnostics device in the control box (refer to Figure 17). Comfort Alert provides
NOTE: Comfort Alert is required for unit operation.
Comfort Alert provides active safety protection and compressor may be shut down. Alert codes are listed in Figures 18 and 19.
Comfort Alert is factory wired and requires no modification. Low voltage lead wires are provided in the control box for connection to thermostat wires (use wire nuts).
The Comfort Alert device operates by monitoring the compressor power leads and the thermostat demand signal (Y terminal). It draws constant 24 VAC power at the R and C terminals.
Compressor Wires
Pass Through Holes (3)
MAINTENANCE
Condensate Drain
During the cooling season, check monthly for free flow of drainage and clean if necessary.
Cleanliness
These tips will help keep the air conditioner looking better and working more efficiently:
1.Free flow of air is essential. Keep fences, shrubs, trash cans, and other obstructions at least 18 inches from all coil inlets.
2.Keep the coil free of grass clippings, leaves, weeds, and other debris.
NOTE: Coil may occasionally require cleaning with a liquid solution. The coil must be cold when cleaning. Use an alkaline based cleaner only. Cleaning a hot coil or using an acid based cleaner will remove the paint from the fins and may clog the coil.
3.Never use a weather cover over the outdoor unit unless it is a ventilated type or made of breathable fabric that will allow moisture to evaporate rapidly. A cover that holds moisture in the unit will cause more rust
Module locks out compressor when compressor damaging ALERT codes appear. Lockout ALERT codes are noted in the Status LED Description; during a compressor lockout, 24VAC power must be removed from module to manually reset.
S Flash Code number corresponds to a number of LED flashes, followed by a pause and then repeated. S TRIP and ALERT LEDs flashing at same time means control circuit voltage is too low for operation.
S Reset ALERT Flash code by removing 24VAC power from module.
S Last ALERT Flash code is displayed for 1 minute after module is powered on.
S ALERT codes can be reset manually or automatically. ALERT codes that result in a lockout or compressor lockout can only be reset manually.
-For manual reset, cycle power to Comfort Alert off and on.
-For automatic reset, Comfort Alert will continue to monitor compressor and system; if condition returns to normal, the ALERT code is automatically turned off.