Installer's Guide

Table of Contents

• Section 1. Safety ...................................................................................... 2
• Section 2. Unit Location Considerations ............................................. 3
• Section 3. Unit Preparation.................................................................... 5
• Section 4. Setting the Unit ..................................................................... 5
• Section 5. Refrigerant Line Considerations......................................... 6
• Section 6. Refrigerant Line Routing ..................................................... 7
• Section 7. Refrigerant Line Brazing...................................................... 8
• Section 8. Refrigerant Line Leak Check ............................................. 10
• Section 9. Evacuation .......................................................................... 11
• Section 10. Service Valves .................................................................. 11
• Section 11. Electrical - Low Voltage ................................................... 13
• Section 12. Electrical - High Voltage .................................................. 15
• Section 13. Start Up.............................................................................. 16
• Section 14. System Charge Adjustment............................................. 17
• Section 15. Checkout Procedures and Troubleshooting.................. 22

Section 1. Safety

WARNING This information is intended for use by individuals possessing adequate backgrounds of electrical and mechanical experience. Any attempt to repair a central air conditioning product may result in personal injury and/or property damage. The manufacturer or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use.

WARNING These units use R-410A refrigerant which operates at 50 to 70% higher pressures than R-22. Use only R-410A approved service equipment. Refrigerant cylinders are painted a “Rose” color to indicate the type of refrigerant and may contain a “dip” tube to allow for charging of liquid refrigerant into the system. All R-410A systems use a POE oil that readily absorbs moisture from the atmosphere. To limit this “hyroscopic” action, the system should remain sealed whenever possible. If a system has been open to the atmosphere for more than 4 hours, the compressor oil must be replaced. Never break a vacuum with air and always change the driers when opening the system for component replacement. For specific handling concerns with R-410A and POE oil reference Retrofit Bulletins SS-APG006-EN and APP-APG011-EN.

WARNING UNIT CONTAINS R-410A REFRIGERANT! R-410A operating pressures exceed the limit of R-22. Proper service equipment is required. Failure to use proper service tools may result in equipment damage or personal injury.

SERVICE: USE ONLY R-410A REFRIGERANT AND APPROVED POE COMPRESSOR OIL.

WARNING Extreme caution should be exercised when opening the Liquid Line Service Valve. Turn counterclockwise until the valve stem just touches the rolled edge. No torque is required. Failure to follow this warning will result in abrupt release of system charge and may result in personal injury and /or property damage.

WARNING LIVE ELECTRICAL COMPONENTS! During installation, testing, servicing, and troubleshooting of this product, it may be necessary to work with live electrical components. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

CAUTION If using existing refrigerant lines make certain that all joints are brazed, not soldered.

CAUTION Scroll compressor dome temperatures may be hot. Do not touch the top of compressor; it may cause minor to severe burning.

Section 2. Unit Location Considerations

2.1 Unit Dimensions and Weight

Table 2.1: Unit Dimensions and Weight

* Weight values are estimated.

When mounting the outdoor unit on a roof, be sure the roof will support the unit's weight. Properly selected isolation is recommended to alleviate sound or vibration transmission to the building structure.

2.2 Refrigerant Piping Limits

1. The maximum length of refrigerant lines from outdoor to indoor unit should NOT exceed sixty (60) feet.

2. The maximum vertical change should not exceed sixty (60) feet*.

3. Service valve connection diameters are shown in Table 5.1.

Note: For line lengths greater than sixty (60) feet, Refer to Refrigerant Piping Application Guide, SS-APG006-EN or Refrigerant Piping Software Program, 32-3312-03 (or latest revision).

Diagram Description: Shows an outdoor unit with dimensions labeled H, W, D. Illustrates maximum line length of 60 feet and maximum vertical change of 60 feet.

2.3 Suggested Locations for Best Reliability

Ensure the top discharge area is unrestricted for at least five (5) feet above the unit.

Three (3) feet clearance must be provided in front of the control box (access panels) and any other side requiring service.

Do not locate close to bedrooms as operational sounds may be objectionable.

Avoid locations such as near windows where condensation and freezing defrost vapor can annoy a customer.

Position the outdoor unit a minimum of 12" from any wall or surrounding shrubbery to ensure adequate airflow.

Outdoor unit location must be far enough away from any structure to prevent excess roof runoff water or icicles from falling directly on the unit.

Diagram Description: Illustrates clearances around the outdoor unit: minimum 5 feet unrestricted above, minimum 3 feet unrestricted in front of access panel, minimum 12 inches from shrubbery/wall. Shows a 'Do Not Install Near Bedrooms' recommendation.

2.4 Cold Climate Considerations

NOTE: It is recommended that these precautions be taken for units being installed in areas where snow accumulation and prolonged below freezing temperatures occur.

• Units should be elevated 3-12 inches above the pad or rooftop, depending on local weather. This additional height will allow drainage of snow and ice melted during defrost cycle prior to its refreezing. Ensure that drain holes in unit base pan are not obstructed preventing draining of defrost water.
• If possible, avoid locations that are likely to accumulate snow drifts. If not possible, a snow drift barrier should be installed around the unit to prevent a build-up of snow on the sides of the unit.

Diagram Description: Shows an outdoor unit elevated 3-12 inches on a pad, with a snow barrier installed around it to prevent snow accumulation.

2.5 Coastal Considerations

If installed within one mile of salt water, including seacoasts and inland waterways, models without factory supplied Seacoast Salt Shields require the addition of BAYSEAC001 (Seacoast Kit) at installation time.

Section 3. Unit Preparation

3.1 Prepare The Unit For Installation

STEP 1 - Check for damage and report promptly to the carrier any damage found to the unit.

Diagram Description: Shows an outdoor unit with a large 'X' symbol over it, indicating inspection for damage.

STEP 2 - To remove the unit from the pallet, remove tabs by cutting with a sharp tool.

Diagram Description: Shows a hand holding a tool cutting tabs from the unit's pallet packaging.

Section 4. Setting the Unit

4.1 Pad Installation

When installing the unit on a support pad, such as a concrete slab, consider the following:

• The pad should be at least 1″ larger than the unit on all sides.
• The pad must be separate from any structure.
• The pad must be level.
• The pad should be high enough above grade to allow for drainage.
• The pad location must comply with National, State, and Local codes.

Diagram Description: Shows an outdoor unit being placed on a level concrete pad that is slightly larger than the unit's base.

Section 5. Refrigerant Line Considerations

5.1 Refrigerant Line and Service Valve Connection Sizes

Table 5.1: Refrigerant Line and Service Valve Connection Sizes

5.2 Factory Charge

The outdoor condensing units are factory charged with the system charge required for the outdoor condensing unit, ten (10) feet of tested connecting line, and the smallest rated indoor evaporative coil match. Always verify proper system charge via subcooling (TXV/EEV) or superheat (fixed orifice) per the unit nameplate.

5.3 Required Refrigerant Line Length

Determine required line length and lift. You will need this later in STEP 2 of Section 14.

Total Line Length = __________ Ft.

Total Vertical Change (lift) = __________ Ft.

5.4 Refrigerant Line Insulation

Important: The Vapor Line must always be insulated. DO NOT allow the Liquid Line and Vapor Line to come in direct (metal to metal) contact.

Diagram Description: Shows a cross-section of refrigerant lines with the vapor line insulated and the liquid line uninsulated, emphasizing they should not touch.

5.5 Reuse Existing Refrigerant Lines

CAUTION If using existing refrigerant lines make certain that all joints are brazed, not soldered.

For retrofit applications, where the existing indoor evaporator coil and/or refrigerant lines will be used, the following precautions should be taken:

• Ensure that the indoor evaporator coil and refrigerant lines are the correct size.
• Ensure that the refrigerant lines are free of leaks, acid, and oil.

Important: For more information see publication numbers SS-APG006-EN and APP-APG011-EN.

Section 6. Refrigerant Line Routing

6.1 Precautions

Important: Take precautions to prevent noise within the building structure due to vibration transmission from the refrigerant lines.

Comply with National, State, and Local Codes when isolating line sets from joists, rafters, walls, or other structural elements.

For Example:

• When the refrigerant lines have to be fastened to floor joists or other framing in a structure, use isolation type hangers.
• Isolation hangers should also be used when refrigerant lines are run in stud spaces or enclosed ceilings.
• Where the refrigerant lines run through a wall or sill, they should be insulated and isolated.
• Isolate the lines from all ductwork.
• Minimize the number of 90º turns.

Diagram Description: Shows two methods of routing refrigerant lines. One illustrates securing the vapor line with isolators every 8 ft to joists/rafters, and the liquid line directly to the vapor line. The other shows lines routed through a wall with sealant and insulation, and a separate diagram indicating 'DO NOT hang line sets from ductwork' with a red circle and slash symbol over ductwork.

Section 7. Refrigerant Line Brazing

7.1 Braze The Refrigerant Lines

STEP 1 - Remove caps or plugs. Use a deburring tool to debur the pipe ends. Clean both internal and external surfaces of the tubing using an emery cloth.

Diagram Description: Shows two pipe ends, one with a cap removed, and a deburring tool.

STEP 2 - Remove the pressure tap cap and valve cores from both service valves.

Diagram Description: Shows service valves with pressure tap caps and valve cores being removed.

STEP 3 - Purge the refrigerant lines and indoor coil with dry nitrogen.

Diagram Description: Shows refrigerant lines connected to a nitrogen source, with gas flowing through.

STEP 4 - Wrap a wet rag around the valve body to avoid heat damage and continue the dry nitrogen purge. Braze the refrigerant lines to the service valves. For units shipped with a field-installed external drier, check liquid line filter drier's directional flow arrow to confirm correct direction of refrigeration flow (away from outdoor unit and toward evaporator coil) as illustrated. Braze the filter drier to the Liquid Line. Continue the dry nitrogen purge. Do not remove the wet rag until all brazing is completed.

Important: Remove the wet rag before stopping the dry nitrogen purge.

Note: Install drier in Liquid Line.

NOTE: Precautions should be taken to avoid heat damage to basepan during brazing. It is recommended to keep the flame directly off of the basepan.

Diagram Description: Shows refrigerant lines being brazed to a service valve. A wet rag is wrapped around the valve body. An external filter drier is shown being brazed into the liquid line, with a directional arrow indicated. The brazing point is shown 3-4 inches from the valve.

STEP 5 - Replace the pressure tap valve cores after the service valves have cooled.

Diagram Description: Shows pressure tap valve cores being reinserted into the service valves.

Section 8. Refrigerant Line Leak Check

8.1 Check For Leaks

STEP 1 - Pressurize the refrigerant lines and evaporator coil to 150 PSIG using dry nitrogen.

Diagram Description: Shows a pressure gauge indicating 150 PSIG.

STEP 2 - Check for leaks by using a soapy solution or bubbles at each brazed location. Remove nitrogen pressure and repair any leaks before continuing.

Diagram Description: Shows bubbles forming on a brazed joint, indicating a leak.

Section 9. Evacuation

9.1 Evacuate the Refrigerant Lines and Indoor Coil

Important: Do not open the service valves until the refrigerant lines and indoor coil leak check and evacuation are complete.

STEP 1 - Evacuate until the micron gauge reads no higher than 350 microns, then close off the valve to the vacuum pump.

Diagram Description: Shows a micron gauge displaying '0350 Microns' with ON/OFF buttons.

STEP 2 - Observe the micron gauge. Evacuation is complete if the micron gauge does not rise above 500 microns in one (1) minute.

Once evacuation is complete, blank off the vacuum pump and micron gauge, and close the valves on the manifold gauge set.

Diagram Description: Shows a timer displaying '1 MIN.'

Section 10. Service Valves

10.1 Open the Gas Service Valve

Important: Leak check and evacuation must be completed before opening the service valves.

NOTE: Do not vent refrigerant gases into the atmosphere.

STEP 1 - Remove valve stem cap.

STEP 2 - Using an adjustable wrench, turn valve stem 1/4 turn counterclockwise to the fully open position.

STEP 3 - Replace the valve stem cap to prevent leaks. Tighten finger tight plus an additional 1/6 turn.

Diagram Description: Illustrates a gas service valve with components labeled: Cap, Unit Side of Valve, Valve Stem, Pressure Tap Port, Gas Line Connection. Shows the 1/4 turn counterclockwise motion for opening.

10.2 Open the Liquid Service Valve

WARNING Extreme caution should be exercised when opening the Liquid Line Service Valve. Turn counterclockwise until the valve stem just touches the rolled edge. No torque is required. Failure to follow this warning will result in abrupt release of system charge and may result in personal injury and /or property damage.

Diagram Description: Illustrates a liquid service valve with components labeled: Cap, Unit Side of Service Valve, Service Port, Rolled Edge to Captivate Stem, Hex Headed Valve System. Shows a 3/16" Hex Wrench being used.

Section 11. Electrical - Low Voltage

11.1 Low Voltage Maximum Wire Length

Table 11.1 defines the maximum total length of low voltage wiring from the outdoor unit, to the indoor unit, and to the thermostat.

Table 11.1: 24 VOLTS - Low Voltage Maximum Wire Length

11.2 Low Voltage Hook-up Diagrams

Diagram Description: Two sets of wiring diagrams are presented, one for 'With TEM 3, 4, 6, 8' and another for 'With TAM 4, 5, 7, 9'. Each diagram shows connections between Thermostat, Air Handler, and Outdoor Unit for various terminals like R, G, B/C, O, Y, W, X2.

Notes:

• Units with pigtails require wirenuts for connections.
• In AC systems for multiple stages of electric heat, jumper W1 and W2 together if comfort control has only one stage of heat.
• * Y2 for TEM6.

11.3 Defrost Control

Defrost controls have a selectable termination temperature. As shipped, defrost will terminate at 47°F. For a higher termination temperature, cut Jumper J2 to achieve 70°F. See Service Facts shipped in the outdoor unit for more information.

Pin Identification on J5 (See Illustration)

1. TEST_COMMON (Shorting to FRC_DFT causes the control to initiate Forced Defrost. Leaving this pin open results in the normal mode of operation.)
2. FRC_DFT = Forced Defrost (Short TEST_COMMON to this pin for two (2) seconds to initiate a forced defrost. Remove the short after defrost initiates.)

Defrost Control Checkout

Normal operation requires:

• Status LED on board flashing 1 time/second in standby or 2 times/second with a call for heating or cooling.
• 24V AC between R & B.
• 24V AC between Y, YO & B with unit operating.
• Defrost initiation when FRC_DFT pin is shorted to TEST_COMMON pin.

If a defrost control problem is suspected, refer to the service information in control box.

Diagram Description: Shows a detailed view of a defrost control board with various components and connectors labeled, including Jumper J2 and J5 Test Pins.

Section 12. Electrical - High Voltage

12.1 High Voltage Power Supply

WARNING LIVE ELECTRICAL COMPONENTS! During installation, testing, servicing, and troubleshooting of this product, it may be necessary to work with live electrical components. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

The high voltage power supply must agree with the equipment nameplate.

Power wiring must comply with national, state, and local codes.

Follow instructions on unit wiring diagram located on the inside of the control box cover and in the Service Facts document included with the unit.

12.2 High Voltage Disconnect Switch

Install a separate disconnect switch at the outdoor unit.

For high voltage connections, flexible electrical conduit is recommended whenever vibration transmission may create a noise problem within the structure.

Diagram Description: Shows an outdoor unit with a disconnect switch box mounted on its side.

12.3 High Voltage Ground

Ground the outdoor unit per national, state, and local code requirements.

Diagram Description: Shows a grounding symbol (three horizontal lines decreasing in length, connected by a vertical line).

Section 13. Start Up

13.1 System Start Up

STEP 1 - Ensure Sections 7 through 12 have been completed.

STEP 2 - Set System Thermostat to OFF.

Diagram Description: Shows a thermostat display set to 'OFF'.

STEP 3 - Turn on disconnect(s) to apply power to the indoor and outdoor units.

Diagram Description: Shows a disconnect switch in the 'ON' position.

STEP 4 - Wait one (1) hour before starting the unit if compressor crankcase heater accessory is used and the Outdoor Ambient is below 70°F.

Diagram Description: Shows a timer displaying '60 MIN.'

STEP 5 - Set system thermostat to ON.

Diagram Description: Shows a thermostat display set to 'ON'.

Section 14. System Charge Adjustment

14.1 Temperature Measurements

STEP 1 - Check the outdoor temperatures. Subcooling (in cooling mode) is the only recommended method of charging above 55º F ambient outdoor temperature. See Section 14.2.

For outdoor temperatures below 55º F, see Section 14.3.

Note: It is important to return in the spring or summer to accurately charge the system in the cooling mode when outdoor ambient temperature is above 55° F.

For best results the indoor temperature should be kept between 70º F to 80° F.

Diagram Description: Shows thermometer icons indicating Outdoor Temp 1 (55°F), Outdoor Temp 2 (below 55°F), and Indoor Temp (70°F to 80°F).

14.2 Subcooling Charging in Cooling (Above 55° F Outdoor Temp.)

STEP 1 - Use the refrigerant line total length and lift measurements from Section 5.3.

Total Line Length = __________ Ft.

Vertical Change (Lift) = __________ Ft.

STEP 2 - Determine the final subcooling value using total Line Length and Lift measured in STEP 1 and the charts below.

Diagram Description: A series of charts for different tonnages (1 1/2, 2, 2 1/2, 3, 3 1/2, 4, 5 Ton Heat Pumps) showing 'SUBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE)'. These charts plot Refrigerant Line Lift (FT) against Total Refrigerant Line Length (FT) and indicate corrections like 'Add 1°', 'Add 2°', 'Add 4°', and 'Use Design Subcooling'.

Design Subcooling Value = __________° F (from nameplate or Service Facts)

Subcooling Correction = __________° F

Final Subcooling Value = __________° F

STEP 3 - Stabilize the system by operating for a minimum of 20 minutes. At startup, or whenever charge is removed or added, the system must be operated for a minimum of 20 minutes to stabilize before accurate measurements can be made.

Diagram Description: Shows a timer displaying '20 MIN.'

STEP 4 - Measure the liquid line temperature and pressure at the outdoor unit's service valve.

Measured Liquid Line Temp = __________ ° F

Liquid Gage Pressure = __________ PSIG

Final Subcooling Value = __________ ° F

STEP 5 - Use the final subcooling value, refrigerant temperature and pressure from STEP 4, to determine the proper liquid gage pressure using Table 14.2.

Example: Assume a 12° F Final Subcooling value and liquid temp of 90° F.

1. Locate 12° F Final Subcooling in Table 14.2.
2. Locate the Liquid Temperature (90° F) in the left column.
3. The Liquid Gage Pressure should be approximately 327 PSIG. (This is the shown as the intersection of the Final Subcooling column and the Liquid Temperature row.

Table 14.2: R-410A REFRIGERANT CHARGING CHART

Special subcooling for application with TEM6 AH

STEP 6 - Adjust refrigerant level to attain proper gage pressure. Add refrigerant if the Liquid Gage Pressure is lower than the chart value. 1. Connect gages to refrigerant bottle and unit as illustrated. 2. Purge all hoses. 3. Open bottle. 4. Stop adding refrigerant when liquid line temperature and Liquid Gage Pressure matches the charging chart Final Subcooling value. Recover refrigerant if the Liquid Gage Pressure is higher than the chart value.

Diagram Description: Shows gauges connected to the outdoor unit's service valves and a refrigerant cylinder, with hoses connecting them.

STEP 7 - Stabilize the system. 1. Wait 20 minutes for the system condition to stabilize between adjustments. Note: When the Liquid Line Temperature and Gage Pressure approximately match the chart, the system is properly charged. 2. Remove gages. 3. Replace service port caps to prevent leaks. Tighten finger tight plus an additional 1/6 turn.

Diagram Description: Shows a timer displaying '20 MIN.'

STEP 8 - Verify typical performance. Refer to System Pressure Curves in the Service Facts to verify typical performance.

Diagram Description: Shows example performance curves (graphs) for suction and discharge pressure vs. outdoor temperature for cooling and heating modes.

STEP 9 - Record System Information for reference. Record system pressures and temperatures after charging is complete.

Outdoor model number = _________________ Measured Outdoor Ambient = __________ ° F Measured Indoor Ambient = __________ ° F Measured Liquid Line Temp = __________ ° F

Measured Suction Line Temp = __________ ° F Liquid Gage Pressure = __________ PSIG Suction Gage Pressure = __________ PSIG

14.3 Subcooling Charging Below 55° F Outdoor Temp. (In Heating Only)

The Subcooling Charging method in cooling is not recommended below 55° F outdoor temperature.

The only recommended method of charging at outdoor temperatures below 55° F is weighing in the charge in heating mode.

STEP 1 - Determine additional charge.

Note: The nameplate charge value represents the amount of refrigerant shipped in the outdoor unit and is compatible with 10 feet of AHRI rated refrigerant lines and the smallest AHRI rated coil.

Using the method below, find the charge associated with the additional length of tubing above 10 ft. and record it below.

Calculating Charge Using the Weigh-In Method

STEP 1 - Measure in feet the distance between the outdoor unit and the indoor unit. (Include the entire length of the line from the service valve to the IDU.) Subtract 10 ft from this entire length and record on line 1.

STEP 2 - Enter the charge multiplier (0.6 oz/ft). Each linear foot of interconnecting tubing requires the addition of 0.6 oz of refrigerant.

STEP 3 - Multiply the total length of refrigerant tubing (Line 1) times the value on Step 2. Record the result on Line 3 of the Worksheet.

STEP 4 - This is the amount of refrigerant to weigh-in prior to opening the service valves.

1. Total Line length (ft) –10 ft ______________

2. Charge multiplier x 0.6 oz = _____________

3. Step 1 x Step 2 = _____________

4. Refrigerant (oz) = _____________

Note: Weigh-In Method can be used for the initial installation, or anytime a system charge is being replaced. Weigh-In Method can also be used when power is not available to the equipment site or operating conditions (indoor/outdoor temperatures) are not in range to verify with the subcooling charging method.

STEP 2 - Stabilize the system by operating for a minimum of 20 minutes. At startup, or whenever charge is removed or added, the system must be operated for a minimum of 20 minutes to stabilize before accurate measurements can be made.

Diagram Description: Shows a timer displaying '20 MIN.'

STEP 3 - Check the liquid line temperature and liquid gage pressure to obtain a minimum of 10° subcooling in heating mode.

Measured Liquid Line Temp = __________ ° F

Liquid Gage Pressure = __________ PSIG

STEP 4 - Add charge if a minimum of 10° subcooling is not obtained with the nameplate charge plus additional charge previously added.

STEP 5 - Return to site for adjustment.

Important: Return in the spring or summer to accurately charge the system in the cooling mode with outdoor ambient above 55° F.

Section 15. Checkout Procedures and Troubleshooting

15.1 Operational And Checkout Procedures

Final phases of this installation are the unit Operational and Checkout Procedures. To obtain proper performance, all units must be operated and charge adjustments made.

Important: Perform a final unit inspection to be sure that factory tubing has not shifted during shipment. Adjust tubing if necessary so tubes do not rub against each other when the unit runs. Also be sure that wiring connections are tight and properly secured.

CHECKOUT PROCEDURE

After installation has been completed, it is recommended that the entire system be checked against the following list:

1. Leak check refrigerant lines. [ ]
2. Properly insulate suction lines and fittings. [ ]
3. Properly secure and isolate all refrigerant lines. [ ]
4. Seal passages through masonry. If mortar is used, prevent mortar from coming into direct contact with copper tubing. [ ]
5. Verify that all electrical connections are tight. [ ]
6. Observe outdoor fan during on cycle for clearance and smooth operation. [ ]
7. Be sure that indoor coil drain line drains freely. Pour water into drain pan. [ ]
8. Be sure that supply registers and return grilles are open and unobstructed. [ ]
9. Be sure that a return air filter is installed. [ ]
10. Be sure that the correct airflow setting is used. (Indoor blower motor) [ ]
11. Operate complete system in each mode to ensure safe operation. [ ]

15.2 Troubleshooting

SYSTEM FAULTS

C - Cooling H - Heating P - Primary Causes S - Secondary Causes * - 3 Phase Only