Allied Air Enterprises 4AC16LT User Manual

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INSTALLATION AND MAINTENANCE INSTRUCTIONS

4AC16LT SERIES

Split System Air Conditioner

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WARNING

The equipment covered in this manual is to be installed by trained and experienced service and installation technicians. Improper installation, modification, service, or use can cause electrical shock, fire, explosion, or other conditions which may cause personal injury, death, or property damage. Use appropriate safety gear including safety glasses and gloves when installing this equipment.

WARNING

Risk of electrical shock. Disconnect all remote power supplies before installing or servicing any portion of the system. Failure to disconnect power supplies can result in property damage, personal injury, or death.

WARNING

Installation and servicing of air conditioning equipment can be hazardous due to internal refrigerant pressure and live electrical components. Only trained and qualified service personnel should install or service this equipment. Installation and service performed by unqualified persons can result in property damage, personal injury, or death.

WARNING

Sharp metal edges can cause injury. When installing the unit, use care to avoid sharp edges.

TABLE OF CONTENTS

INSTALLATION ....................................................2

START-UP .......................................................... 12

OPERATION ...................................................... 16

MAINTENANCE ................................................. 20

CONNECTION DIAGRAM .................................. 22

Manufactured By

Allied Air Enterprises, Inc.

A Lennox International Inc. Company

215 Metropolitan Drive

West Columbia, SC 29170

*506467-01*

506467-01 Issue 1008 Page 1

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INSTALLATION

General

Read this entire instruction manual, as well as the instructions supplied in separate equipment, before starting the installation. Observe and follow all warnings, cautions, instructional labels, and tags. Failure to comply with these instructions could result in an unsafe condition and/or premature component failure.

Inspection of Shipment

Upon receipt of equipment, carefully inspect it for possible shipping damage. If damage is found, it should be noted on the carrier’s freight bill. Take special care to examine the unit inside the carton if the carton is damaged. Any concealed damage discovered should be reported to the last carrier immediately, preferably in writing, and should include a request for inspection by the carrier’s agent. If any damages are discovered and reported to the carrier DO NOT INSTALL THE UNIT, as claim may be denied.

These instructions are intended as a general guide only for use by qualified personnel and do not supersede any national or local codes in any way. The installation must comply with all provincial, state, and local codes as well as the National Electrical Code (U.S.) or Canadian Electrical Code (Canada). Compliance should be determined prior to installation.

4AC16LT condensing units use R410A which is an ozonefriendly HFC refrigerant. The unit must be installed with a matching indoor coil and line set. 4AC16LT units are designed for use in expansion valve (TXV) systems only. A filter drier approved for use with R410A is installed in the unit.

IMPORTANT: This product has been designed and manufactured to meet ENERGY STAR criteria for energy efficiency when matched with appropriate coil components. However, proper refrigerant charge and proper air flow are critical to achieve rated capacity and efficiency. Installation of this product should follow the manufacturer’s refrigerant charging and air flow instructions. Failure to confirm proper

charge and airflow may reduce energy efficiency and shorten equipment life.

When servicing or repairing HVAC components, ensure the fasteners are appropriately tightened. Table 1 shows torque values for fasteners.

Torque Table

Check the unit rating plate to confirm specifications are as ordered.

Location of Unit

Refer to Figure 1 for installation clearances.

Installation Clearances

36”

36” *

36”

36” *

* A service clearance of 30" must be maintained on one of the

sides adjacent to the control box. Clearance to one of the other three sides must be 36". Clearance to one of the remaining two sides may be 12" and the final side may be 6".

A clearance of 24" must be maintained between units.

48" clearance required on top of unit. Maximum soffit overhang is 36".

Figure 1

Fastener Torque

Stem Caps 8 ft. lbs.

Service Port Caps 8 ft. lbs.

Sheet Metal Screws

#8 Machine Screws

#10 Machine Screws

Compressor Bolts

16 in. lbs.

28 in. lbs.

90 in. lbs.

Table 1

506467-01 Issue 1008

Slab Mounting

When installing a unit at grade level, install on slab high enough above grade so that water from higher ground will not collect around the unit (See Figure 2).

Roof Mounting Install unit at a minimum of 4” above surface of the roof. Care must be taken to ensure weight of unit is properly distributed over roof joists and rafters. Either redwood or steel supports are recommended.

Page 2

Page 3

Building

ucture

Str

Slab Mounting

Discharge Air

Thermostat Designations

Mounting Slab

Ground Level

Figure 2

Electrical Wiring

All field wiring must be done in accordance with the National Electrical Code (NEC) recommendations, Canadian Electrical Code (CEC) and CSA Standards, or local codes, where applicable.

WARNING

Unit must be grounded in accordance with national and local codes. Failure to ground unit properly can result in personal injury or death.

Refer to the furnace or blower coil installation instructions for additional wiring application diagrams and refer to unit rating plate for minimum circuit ampacity and maximum overcurrent protection size.

See unit wiring diagram for power supply connections. If the indoor unit is not equipped with a blower relay, one must be field supplied and installed.

Do not connect C (common) connection between indoor unit and thermostat except when required by the indoor thermostat. Refer to thermostat installation instructions. C (common) connection between indoor unit and outdoor unit required for proper operation.

Figure 4

5. Do not bundle any excess 24V control wire inside control box. Run control wire through installed wire tie and tighten wire tie to provide low voltage strain relief and to maintain seperation of field-installed low and high voltage circuits.

Refrigerant Piping

WARNING

Refrigerand can be harmful if inhaled. Refrigerant must always be used and recovered responsibly. Incorrect or irresponsible use of refrigerant can result in personal injury or death.

1. Install line voltage power supply to unit from a properly sized disconnect switch. Any excess high voltage field wiring should be trimmed or secured away from the low voltage field wiring.

2. Ground unit at unit disconnect switch or to an earth ground. To facilitate conduit, a hole is in the bottom of the control box. Connect conduit to the control box using a proper conduit fitting. Units are approved for use only with copper conductors. 24V Class II circuit connections are made in the low voltage junction box. A complete unit wiring diagram is located inside the unit control box cover (see also page 22 of this instruction).

3. Install room thermostat on an inside wall that is not subject to drafts, direct sunshine, or other heat sources.

4. Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit (See Figure 3).

506467-01 Issue 1008

If the 4AC16LT unit is being installed with a new indoor coil and line set, the refrigerant connections should be made as outlined in this section. If an existing line set and/or indoor coil will be used to complete the system, refer to this section as well as the section that follows entitled - Flushing Existing Line Set and Indoor Coil.

If this unit is being matched with an approved line set or indoor coil which was previously charged with R-22 refrigerant, the line set and coil must be flushed prior to installation. If the unit is being used with and existing indoor coil which was equipped with a liquid line which served as a metering device (RFCI), the liquid line must be replaced prior to the installation of the 4AC16LT unit.

Field refrigerant piping consists of liquid and suction lines from the outdoor unit (sweat connections) to the indoor coil (flare or sweat connections).

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Page 4

Select line set diameters from Table 2 to ensure that oil return to the compressor. Size vertical suction riser to maintain minimum velocity at minimum capacity. Recommended line length is 50’ or less. If more than 50’ line set is required, contact Technical Service.

Table 2 shows the diameters for line sets up to 100’ although vertical lift applications and trapping requirements need to be reviewed with Technical Service for line sets over 50’.

WARNING

Polyolester (POE) oils used with R-410A refrigerant absorb moisture very quickly. It is very important that the refrigerant system be kept closed as much as possible. DO NOT remove line set caps or service valve stub caps until ready to make connections.

Refrigerant Line Set Diameters (in.)

Liquid Line

BTUH

24,000

36,000

48,000

60,000

BTUH

24,000

36,000

48,000

60,000 1-1/8

Line Set Length and Size

12 f t . 25 ft. 50 ft. 75 ft. 100 ft.

3/8 3/8 3/8 3/8 3/8

3/8 3/8 3/8 3/8

3/8 3/8 3/8 1/2

Suction Line

Line S et Length and S iz e

12 f t. 25 ft. 50 ft. 75 ft. 10 0 f t .

3/4 3/4

7/8

1-1/8

3/4 3/4

7/8

1-1/8

1/2

7/87/8

1-1/8

1/2

7/8

1-1/8

For installations exceeding 50’, contact

Technical Services.

Installing Refrigerant Line

During the installation of an air conditioning system, it is important to properly isolate the refrigerant line to prevent unnecssary vibration. Line set contact with the structure (wall, ceiling, or floor) may cause objectionable noise when vibration is translated into sound. As a result, more energy or vibration can be expected. Close attention to line set isolation must be observed. If refrigeration lines are routed through a wall, seal and isolate the opening so vibration is not transmitted to the building.

Following are some points to consider when placing and installing a high-efficiency outdoor unit:

Placement

Be aware that some localities are adopting sound ordinances based on how noisy the unit is at the neighbor’s home, not at the original installation. Install the unit as far as possible from the property line. When possible, do not install the unit directly outside a bedroom window. Glass has a verry high level of sound transmission. Figure 4 shows how to place the outdoor unit and line set to reduce line set vibration.

Line Set Isolation

Illustrations on the pages 6 and 7 demonstrate procedures which ensure proper refrigerant line set isolation. Figure 6 shows how to install line sets on horizontal runs. Figure 7 shows how to make a transition from horizontal to vertical. Figure 9 shows how to install line sets on vertical runs.

Table 2

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Brazing Connection Procedure

1. Cut ends of refrigerant lines square (free from nicks or dents). Debur the ends. The pipe must remain round; do not pinch end of line.

2. Before making line set connections, use dry nitrogen to purge the refrigerant piping. This will help to prevent oxidation and the introduction of moisture into the system.

3. Use silver alloy brazing rods (5% or 6% silver alloy for copper-to-copper brazing or 45% silver alloy for

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Outside Unit Placement

To hang line set from joist or rafter, use either metal strapping material or anchored heavy nylon wire ties.

Strapping Material

(around vapor line only)

8’

Tape or Wire Tie

Strap the vapor line to the joist or rafter at 8 intervals then strap the liquid line to the vapor line.

’

Floor Joist or

Roof Rafter

Metal Sleeve

Floor Joist or Roof Rafter

Tape or Wire Tie

Wire Tie

(around vapor line only)

and Installation

Install unit away

from windows

copper-to-brass or copper-to-steel brazing) which are rated for use with R410A refrigerant.

4. Remove the Schrader core assemblies before brazing

to protect them from damage due to extreme heat. Replace the cores when brazing is complete.

5. Remove light maroon washers from service valves and shield light maroon stickers to protect them during brazing. Wrap a wet cloth around the valve body and copper tube stub to protect it from heat damage.

6. Braze the line set to the service valve. Quench the joints with water or a wet cloth to prevent heat damage to the valve core and opening port. The tube end must stay

bottomed in the fitting during final assembly to ensure proper seating, sealing, and rigidity.

Two 90° elbows installed in lineset will reduce lineset vibration

Figure 4

7. Install a thermal expansion valve (which is sold separately and which is approved for use with R410A refrigerant) in the liquid line at the indoor coil (see Refrigerant Metering Device on page 8).

Refrigerant Line Sets: Installing Horizontal Runs

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Figure 5

Page 6

Refrigerant Line Sets: Transition from Vertical to Horizontal

Heavy Nylon

Wall

Stud

Metal Sleeve

Anchored

Wire Tie

Strap Liquid Line to Vapor Line

Liquid Line

Vapor Line Wrapped

–

in Armaflex

Figure 6

Muffler-Type

Wall

Stud

Metal Sleeve

Automotive

Hanger

Strap Liquid Line to Vapor Line

Liquid Line

Vapor Line Wrapped

–

in Armaflex

Refrigerant Line Sets: Installing Vertical Runs (new construction shown)

NOTE: Similar installation practices should be used if line set is to be installed on exterior of outside wall.

IMPORTANT:

Refrigerant

lines must not

contact structure.

Wood Block

Between Studs

Vapor Line Wrapped

with Armaflex

Outside Wall

Liquid Line

Caulk

IMPORTANT: Refrigerant lines must not contact wall.

Vapor Line

Liquid Line

Wire Tie

Inside Wall

Strap

Sleeve

Wire Tie

Wood Block

Wire Tie

Strap

PVC Pipe

Fiberglass Insulation

Sleeve

Figure 7

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Flushing Existing Line Set and Indoor Coil

Flushing Procedure

This procedure should not be performed on systems which contain contaminants, such as compressor burn out.

CAUTION

When flushing existing line set and/or indoor coil, be sure to empty all existing traps. Residual mineral oil can act as an insulator, preventing proper heat transfer. It can also clog the thermal expansion valve, reducing system performance and capacity. Failure to properly flush system as explained in these instructions will void warranty.

Required Equipment

The following equipment is needed to flush the existing line set and indoor coil (see Figure 8): Two clean R22 recovery bottles, an oil-less recovery machine with a “pump down” feature, and two sets of gauges (one for use with R22 and one for use with R410A).

IMPORTANT: The line set and/or indoor coil must be flushed with at least the same amount of refrigerant that previously charged the system. Check the charge in the flushing cylinder before flushing the unit.

1. Remove existing R22 refrigerant using the appropriate procedure.

If the existing outdoor unit is not equipped with shutoff valves, or if the unit is not operational AND the existing R22 refrigerant will be used to flush the system:

Disconnect all power to the existing outdoor unit. Connect the existing unit, a clean recovery cylinder, and the recovery machine according to the instructions provided with the recovery machine. Remove all R22 refrigerant from the existing system. Refer to the gauges after shutdown to confirm that the entire system is completely void of refrigerant. Disconnect the liquid and suction lines from the existing outdoor unit.

If the existing outdoor unit is equipped with manual shutoff valves AND new R22 refrigerant will be used to flush the system:

Start the existing R22 refrigerant system in cooling mode and close the liquid line valve. Pump all the existing R22 refrigerant back into the outdoor unit.

Flushing Connections

Note: The inverted R22 cylinder must contain

at least the same amount of refrigerant as was recovered from the existing system.

Figure 8

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Page 8

(It may be necessary to bypass the low pressure switches to ensure complete refrigerant evacuation.)

When the low side system pressures reach 0 psig, close the suction line valve. Disconnect all power to the existing outdoor unit. Refer to the gauges after shutdown to confirm that the valves are not allowing refrigerant to flow back into the low side of the system. Disconnect the liquid and suction lines from the existing outdoor unit.

2. Remove the existing outdoor unit. Set the new R410A unit and follow the brazing connection procedure outlined previously on this page to make line set connections. Do

not install the R410A thermal expansion valve at this time.

3. Make low voltage and line voltage connections to the new outdoor unit. Do not turn on power to the unit or

open the outdoor unit service valves at this time.

9. Close the valve on the inverted R-22 cylinder and the gauge set valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off.

10. Use nitrogen to break the vacuum on the refrigerant lines and indoor coil before removing the recovery machine, gauges, and R-22 refrigerant drum. Re-install pressure tap valve cores into the 4AC16LT unit’s service valves.

11. Install the refrigerant expansion valve approved for use with R410A refrigerant in the liquid line at the indoor coil.

Refrigerant Metering Device

4AC16LT units are designed for use with TXV systems only.

Expansion valves equipped with Chatleff-type fittings are available from the manufacturer. See Table 3 for proper TXV for each unit.

4. Remover the existing R-22 refrigerant flow control orifice or thermal expansion valve before continuing with flushing procedures. R-22 flow control devices are not approved for use with R410A refrigerant and may prevent proper flushing. Use a field-provided fitting to reconnect the lines.

5. Remove the pressure tap valve cores from the 4AC16LT units service valves. Connect an R-22 cylinder with clean refrigerant to the suction service valve. Connect the R-22 gauge set to the liquid line valve and connect a recovery maching with an empty recovery tank to the gauge set.

6. Set the recovery machine for liquid recovery and start the recovery machine. Open the gauge set valves to allow the recovery machine to pull a vacuum on the existing system line set and indoor coil.

7. Invert the cylinder of clean R-22 and open its valve to allow liquid refrigerant to flow in to the system through the suction line valve. Allow the refrigerant to pass from the cylinder and through the line set and the indoor coil before it enters the recovery machine.

8. After all of the liquid refrigerant has been recovered, switch the recovery machine to vapor recovery so that all of the R22 vapor is recovered. Allow the recovery machine to pull a vacuum on the sytem.

NOTE: A single system flush should remove all of the mineral oil from the existing refrigerant lines and indoor coil. A second flushing may be done (using clean refrigerant) if insufficient amounts of mineral oil were removed during the first flush.

After each system flush, allow the recovery machine to pull a vacuum on the system at the end of the procedure.

TXV Data

MODEL PART NUMBER

4AC16LT -24, -36

4AC16LT -48

4AC16LT -60

A4TXV01

A4TXV02

Table 3

To install an expansion valve (See Figure 9 above):

1. Separate the distributor assembly and remove the piston orifice and used teflon seal. Insert nozzle end of the expansion valve along with a new teflon seal into the distributor and tighten to 20 - 30 ft. lbs. Use backup wrench on all wrench flats. Overtightening will crush the teflon

seal and may cause a leak.

2. Attach liquid line portion of distributor assembly along with new teflon seal to the inlet of the expansion valve. Tighten to 20 - 30 ft. lbs. Use backup wrench on all wrench flats. Overtightening will crush the teflon seal and may

cause a leak.

3. Connect the external equalizer line to the equalizer port on the suction line and tighten to 8 ft.lbs.

4. Strap the superheat sensing bulb to the suction header.

If installing an expansion valve on an indoor coil that previously used a fixed orifice, be sure to remove the existing fixed orifice. Failure to remove a fixed orifice when installing an expansion valve to the indoor coil will result in improper operation and damage to the system.

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Figure 9

Manifold Gauge Set

Manifold guage sets used with systems charged with R410A refrigerant must be capable of handling the higher system operating pressures. The gauges should be rated for use with pressures 1 - 800 on the high side and a low side of 30” vacuum to 250 psi with dampened speed to 500 psi. Gauge hoses must be rated for use at up to 800 psi of pressure with a 4000 psi burst rating.

Liquid and Suction Line Service Valves

The liquid line and suction line service valves (See Figure

11) and service ports are used for leak teating, evacuation, charging, and checking charge.

Each valve is equipped with a service port which has a factory-installed Schrader valve. A service port cap protects the Schrader valve from contamination and serves as the primary leak seal.

To Access the Schrader Port:

1. Remove the service port cap with an adjustable wrench.

2. Connect gauge to the service port.

3. When testing is completed, replace service port cap. Tighten finger tight, then an additional 1/6 turn.

To Open Liquid or Suction Line Service Valve:

Remove stem cap with an adjustable wrench.

Use service wrench with a hex-head extension to back the stem out counterclockwise as far as it will go. Use a 3/16” hex head extension for liquid line service valves and a 5/16” extension for suction line service valves.

Replace the stem cap. Tighten finger tight, then tighten an additional 1/6 turn.

Figure 10

To Close Liquid or Suction Line Service Valve:

1. Remove the stem cap with an adjustable wrench.

2. Use a service wrench with a hex-head extension to turn the stem clockwise to seat the valve. Tighten firmly.

3. Replace the stem cap. Tighten finger tight, then tighten an additional 1/6 turn.

Suction Line (Ball Type) Service Valve

Suction line (ball type) service valves function the same way as the other valves; the difference is in the construction.

The ball valve is equipped with a service port with a factoryinstalled Schrader valve. A service port cap protects the Schrader valve from contamination and serves as the primary seal.

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Ball Type Service Valve

(Valve Open)

Use adjustable wrench. To open, rotate stem counterclockwise 1/4 turn (90°). To close, rotate stem clockwise 1/4 turn (90°).

Figure 11

Leak Testing

2. With both manifold valves closed, connect the cylinder of R410A refrigerant. Open the valve on the R410A cylinder (vapor only).

3. Open the high pressure side of the manifold to allow R410A into the line set and indoor unit. Weigh in a trace amount of R410A. (A trace amount is a maximum of 2 oz. of refrigerant or 3 lbs. pressure.) Close the valve on the R410A cylinder and the valve on the high pressure side of the manifold gauge set. Disconnect the R410A cylinder.

4. Connect a cylinder of nitrogen with a pressure regulating valve to the center port of the manifold gauge set.

When using high pressure gas such as nitrogen for this purpose, be sure to use a regulator that can control the pressure down to 1 or 2 psig.

5. Adjust nitrogen pressure to 150 psig. Open the valve on the high side of the manifold gauge set to pressurize the line set and the indoor coil.

6. After a short period of time, open a refrigerant port to make sure that an adequate amount of refrigerant has been added for detection (refrigerant requirements will vary with lengths). Check all joints for leaks. Purge nitrogen and R410A mixture. Correct any leaks and recheck.

After the line set has been connected to the indoor and outdoor units, the line set connections and indoor unit must be checked for leaks.

WARNING

Fire, Explosion, and Personal Safety Hazard.

Failure to follow this warning could result in damage, personal injury, or death.

Never use oxygen to pressurize or purge refrigeration lines. Oxygen, when exposed to a spark or open flame, can cause damage by fire and/or an explosion, that could result in personal injury or death.

Using an Electronic Leak Detector

1. Connect the high pressure hose of the manifold gauge set to the suction valve service port. (Normally the high pressure hose is connected to the liquid line port; however, connecting it to the suction ports helps to protect the manifold gauge set from damage caused by high pressure.)

Evacuation

Evacuating the system of noncondensables is critical for proper operation of the unit. Noncondensables are defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system. Noncondensables and water vapor combine with refrigerant to produce substances that corrode copper piping and compressor parts.

WARNING

Do not use a compressor to evacuate a system. Avoid deep vacuum operation. Extremely low vacuums can cause internal arcing and compressor failure. Danger of equipment damage. Damage caused by deep vacuum operation will void warranty.

Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns. Use an instrument that reads down to 50 microns.

1. Connect the manifold gauge set to the service valve ports as follows:

• Low pressure gauge to suction line service valve

• High pressure gauge to liquid line service valve

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Page 11

of 22 of 222. Connect micron gauge.

3. Connect the vacuum pump (with vacuum gauge) to the center port of the manifold gauge set.

4. Open both manifold valves and start vacuum pump.

5. Evacuate the line set and indoor unit to a minimum of 500 microns or lower. During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once to determine if there is a rapid rise in pressure. A rapid rise in pressure indicates a relatively large leak. If this occurs, the leak testing procedure must be repeated.

6. When 500 microns or lower is maintained, close the manifold gauge valves, turn off the vacuum pump, and disconnect the manifold gauge center port hose from the vacuum pump. Attach the manifold gauge center port hose to a nitrogen cylinder with pressure regulator set to 150 psig and purge the hose. Open the manifold gauge valves to break the vacuum in the line set and indoor unit. Close the manifold gauge valves.

7. Shut off the nitrogen cylinder and remove the manifold gauge hose from the cylinder. Open the manifold gauge valves to release the nitrogen from the line set and indoor unit.

8. Reconnect the manifold gauge to the vacuum pump, turn the pump on, and continue to evacuate the line set and indoor unit until 500 microns is maintained within a 20-minute period after shutting off the vacuum pump and closing the manifold gauge valves.

9. When the requirements above have been met, disconnect the manifold hose from the vacuum pump. Open the service valves to break the vacuum in the line set and indoor unit.

506467-01 Issue 1008 Page 11

Page 12

START-UP

Refrigerant Charge Adjustment

CAUTION

If unit is equipped with a crankcase heater, it should be energized 24 hours before unit start-up to prevent compressor damage as a result of slugging.

1. Rotate fan to check for frozen bearings or binding.

2. Inspect all factory and field-installed wiring for loose connections.

3. After evacuation is complete, open liquid line and suction line service valves to release refrigerant charge (contained in outdoor unit) into system.

4. Replace the stem caps and secure finger tight, then tighten an additional 1/6 of a turn.

5. Check voltage supply at the disconnect switch. The voltage must be within the range listed on the unit nameplate. If not, do not start equipment until the power company has been consulted and the voltage condition corrected.

6. Set thermostat for cooling demand, turn on power to indoor blower and close the outdoor unit disconnect switch to start the unit.

7. Recheck unit voltage with unit running. Power must be within range shown on unit nameplate.

Refrigerant Charging

This system is charged with R410A refrigerant which operates at much higher pressures than R22. The liquid line drier provided with the unit is approved for use with R410A. Do not replace it with one designed for use with R22. This

unit is NOT approved for use with coils which use capillary tubes as a refrigerant metering device.

teSeniLdiuqiL

retemaiD

.ni8/3.tf5rep.zo3

* If line length is greater than 15 ft., add this amount.

If line length is less than 15 ft., remove this amount.

tsujda.tf5rep.zO *tesenil.tf51morf

Table 4

IMPORTANT

Mineral oils are not compatible with R410A. If oil must be added, it must be a polyol ester oil.

If the system is void of refrigerant, clean the system using the procedure described below.

1. Use dry nitrogen to pressurize the system and check for leaks. Repair leaks, if possible.

2. Evacuate the system to remove as much of the moisture as possible.

3. Use dry nitrogen to break the vacuum.

4. Evacuate the system again.

5. Weigh the appropriate amount of R410A refrigerant (listed on unit nameplate) into the system.

6. Monitor the system to determine the amount of moisture remaining in the oil. Use a test kit to verify that the moisture content is within the kit’s dry color range. It may be necessary to replace the filter drier several times to achieve the required dryness level. If

system dryness is not verified, the compressor will fail in the future.

R410A refrigerant cylinders are rose colored. Refrigerant should be added through the vapor valve in the liquid state.

Certain R410A cylinders are identified as being equipped with a dip tube. These allow liquid refrigerant to be drawn from the bottom of the cylinder without inverting the cylinder. Do not turn this type of cylinder upside down to draw refrigerant.

Units are factory charged with the amount of R410A refrigerant indicated on the unit rating plate. This charge is based on a matching indoor coil and outdoor coil with 15' line set. For varying lengths of line set, refer to Table 4 for refrigerant charge adjustment.

506467-01 Issue 1008 Page 12

The outdoor unit should be charged during warm weather. However, applications arise in which charging must occur in the colder months. The method of charging is determined by the outdoor ambient temperature.

Measure the liquid line temperature and the outdoor ambient temperature as outlined below:

1. Connect the manifold gauge set to the service valve ports as follows:

• Low pressure gauge to suction line service valve

• High pressure gauge to liquid line service valve

Page 13

2. Close manifold gauge set valves. Connect the center manifold hose to an upright cylinder of R410A.

Blocking Outdoor Coil

3. If room temperature is below 70°F, set the room thermostat to call for heat. This will create the necessary load for properly charging the system in the cooling cycle.

4. Use a digital thermometer to record the outdoor ambient temperature.

5. When the heating demand has been satisfied, switch the thermostat to cooling mode with a set point of 68°F. When pressures have stabilized, use a digital thermometer to record the liquid and suction line temperatures.

6. The outdoor temperature will determine which charging method to use. Proceed with the appropriate charging method.

Charge Using Weigh-In Method

If the system is void of refrigerant, or if the outdoor ambient temperature is cool, first locate and repair any leaks then use the weigh-in method to charge the unit.

1. Recover the refrigerant from the unit.

2. Conduct a leak check, then evacuate as previously outlined.

3. Weigh in the charge according to the total amount shown on the unit nameplate.

If weighing facilities are not available, use one of the following procedures to charge the unit.

Outdoor coil should be blocked one side at a time with cardboard or plastic sheet until proper testing pressures are reached.

Cardboard or Plastic Sheet

Figure 12

4. Subtract the liquid line temperature from the saturation temperature (according to the chart) to determine subcooling.

_____ ° Saturation Temperature °F

–

_____ ° Liquid Line Temperature °F

_____ ° Subcooling Value °F

5. Compare the subcooling value with those shown in Table 6 on page 14. If subcooling is greater than shown, recover some refrigerant. If subcooling is less than shown, add some refrigerant.

Charge Using Approach Method – Outdoor Temperatures 65°F or Above

The following procedure is intended as a general guide and is for use on expansion valve systems only. For best results, indoor temperature should 70°F to 80°F. Monitor system pressures while charging.

Charge Using Subcooling Method – Outdoor Temperatures Below 65°F

When the outdoor ambient temperature is below 65°F, the subcooling method can be used to charge the unit. It may be necessary to restrict the air flow through the outdoor coil to achieve pressures in the 200-250 psig range. These higher pressures are necessary for checking the charge. Block equal sections of air intake panels and move obstructions sideways until the liquid pressure is in the 200-250 psig range (see Figure 12).

1. With the manifold gauge hose on the liquid service port and the unit operating stably, use a digital thermometer to record the liquid line temperature.

2. At the same time, record the liquid line pressure reading.

3. Use the temperature/pressure chart (Table 5 on page 14) to determine the saturation temperature for the liquid line pressure reading.

506467-01 Issue 1008 Page 13

1. Record outdoor ambient temperature using a digital thermometer.

2. Attach high pressure gauge set and operate unit for several minutes to allow system pressures to stabilize.

3. Compare stabilized pressures with those provided in Table 8 on page 15. Minor variations in these pressures may be expected due to differences in installations. Significant differences could mean that the

system is not properly charged or that a problem exists with some component in the system.

Pressures higher than those listed indicate that the system is overcharged. Pressures lower than those listed indicate that the system is undercharged. Verify adjusted charge using the approach method.

4. Use the same digital thermometer to check liquid line temperature.

5. Subtract the outdoor ambient temperature from the liquid line temperature to determine the approach temperature.

Page 14

Outdoor Ambient Temperature °F

Liquid Line Temperature °F

Approach Temperature °F

R410A Temperature/Pressure Chart

Temp.

Pressure

32 100.8 74 214.0 116 396.0

33 102.9 75 217.4 117 401.3

34 105.0 76 220.9 118 406.7

35 107.1 77 224.4 119 412.2

36 109.2 78 228.0 120 417.7

37 111.4 79 231.6 121 423.2

38 113.6 80 235.3 122 428.8

39 115.8 81 239.0 123 434.5

40 118.0 82 242.7 124 440.2

41 120.3 83 246.5 125 445.9

42 122.6 84 250.3 126 451.8

43 125.0 85 254.1 127 457.6

44 127.3 86 258.0 128 463.5

45 129.7 87 262.0 129 469.5

46 132.2 88 266.0 130 475.6

47 134.6 89 270.0 131 481.6

48 137.1 90 274.1 132 487.8

49 139.6 91 278.2 133 494.0

50 142.2 92 282.3 134 500.2

51 144.8 93 286.5 135 506.5

52 147.4 94 290.3 136 512.9

53 150.1 95 295.1 137 519.3

54 152.8 96 299.4 138 525.8

55 155.5 97 303.8 139 532.4

56 158.2 98 308.2 140 539.0

57 161.0 99 312.7 141 545.6

58 163.9 100 317.2 142 552.3

59 166.7 101 321.8 143 559.1

60 169.6 102 326.4 144 565.9

61 172.6 103 331.0 145 572.8

62 175.5 104 335.7 146 579.8

63 178.5 105 340.5 147 586.8

64 181.6 106 345.3 148 593.8

65 184.3 107 350.1 149 601.0

66 187.7 108 355.0 150 608.1

67 190.9 109 360.0 151 615.4

68 194.1 110 365.0 152 622.7

69 197.3 111 370.0 153 630.1

70 200.6 112 375.1 154 637.5

71 203.9 113 380.2 155 645.0

72 207.2 114 385.4

73 210.6 115 390.7

72 207.2 114 385.4

73 210.6 115 390.7

Psig

Temp.

Pressure

Psig

Temp.

Pressure

Psig

Subcooling Values

Table 6

6. Compare the approach value with those shown in Table

7. If the values do not agree with those provided in Table 7, add refrigerant to lower the approach temperature or recover refrigerant from the system to increase the approach temperature.

Check Charge Using Normal Operating Pressures

Use Table 8 to perform maintenance checks. Table 8 is not a procedure for charging the system. Minor variations in these pressures may be due to differences in installations. Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the system.

Approach Values for TXV Systems

Approach value is the liquid line temperature minus the outdoor ambient temperature (± 1°F).

Note: For best results, use the same digital thermometer to check both outdoor ambient and liquid temperatures.

Table 7

Table 5

506467-01 Issue 1008 Page 14

Page 15

Normal Operating Pressures

L = Liquid S = Suction

Values provided above are typical pressures. Indoor unit matchup, indoor air quality, and indoor load will cause pressures to vary.

Table 8

506467-01 Issue 1008 Page 15

Page 16

OPERATION

Thermostat Demand Wiring

Outdoor unit and indoor blower cycle on demand from the room thermostat. When the thermostat blower switch is moved to the ON position, the indoor blower operates continuously.

System Diagnostic Module

4AC16LT units contain a diagnostic module for troubleshooting air conditioning system failures. By monitoring and analyzing data from the compressor and thermostat demand, the module can accurately detect the cause of electrical and system related failure without any sensors. If a system problem occurs, a flashing LED indicator communicates the failure code.

LED Description

POWER LED (Green) indicates voltage is present at the power connection of the module.

ALERT LED (Yellow) communicates an abnormal system condition through a unique flash code. The ALERT LED will flash a number of times consecutively, pause, and then repeat the process. The number of consecutive flashes correlates to a particular abnormal condition.

The diagnostic module requires a thermostat demand signal to operate properly. The thermostat demand signal input, labeled Y on the module, should always be connected to the compressor contactor coil so that when the coil is energized, the demand signal input is 24VAC. When the coil is not energized, the demand signal input should be less than 0.5VAC.

Miswired Module Codes

Depending on the system configuration, some ALERT flash codes may not be active. The presence of safety switches affects how the system alerts are displayed by the module.

Miswiring the diagnostic module will cause false LED codes. Table 11 on page 19 describes LED operation when the module is miswired and what troubleshooting action is required to correct the problem.

TRIP LED (Red) indicates there is a demand signal from the thermostat but no current to the compressor is detected by the module. The TRIP LED typically indicates the compressor protector is open or may indicate missing supply power to the compressor.

Interpreting the Diagnostic LEDs

When an abnormal system condition occurs, the diagnostic module displays the appropriate ALERT and/or TRIP LED. The yellow ALERT LED will flash a number of times consecutively, pause, and then repeat the process. To identify a flash code number, count the number of consecutive flashes. Refer to Table 9 on page 17 and Table 10 on page 18 for information on the flash codes.

Every time the module powers up, the last ALERT LED flash code that occurred prior to shutdown is displayed for 60 seconds. The module will continue to display the previous flash code until the condition returns to normal or 24VAC is removed from the module. TRIP and ALERT LEDs flashing at the same time means control circuit voltage is too low for operation.

24VAC Power Wiring

The diagnostic module requires a constant nominal 24VAC power supply. The wiring to the module’s R and C terminals must be directly from the indoor unit or thermostat.

506467-01 Issue 1008 Page 16

Page 17

Flash Codes

DEL

sutatS

REWOP

)neerG(

PIRT

)deR(

TRELA

)wolleY(

hsalF

1edoC

noitpircseDtluaF noitamrofnIgnitoohselbuorT

rewopsaheludoMslanimreteludomtatneserpsiegatlovylppuS

dnamedtatsomrehT

,tneserpsi1Ylangis

rosserpmocehttub

gninnurtonsi

miTnuRgnoLeeeee

sirosserpmoC

gninnur

nurgnolylemertxe

selcyc

neposirotcetorprosserpmoC.1

erusserpdaehhgihrofkcehC*

egatlovylppusrosserpmockcehC*

nepositcennocsidrewoptinuroodtuO.2

neposi)s(esufrorekaerbtiucricrosserpmoC.3

tcatnocgnikamtonsirotcennocroeriwnekorB.4

metsysnitneserpfinepohctiwserusserpwoL.5

nepodeliafsahrotcatnocrosserpmoC.6

egrahctnaregirferwoL.1

gninnurtonsirewolbrotaropavE.2

stcatnocdnaliocyalerrewolbkcehC*

roticapacrotomrewolbkcehC*

egakcolbroeruliafrofrotomrewolbkcehC*

rotcennocdnagniriwrewolbrotaropavekcehC*

draoblortnocrewolbroodnikcehC*

tiucricneporofgniriwtatsomrehtkcehC*

nezorfsiliocrotaropavE.3

erusserpnoitcuswolrofkcehC*

gnittestatsomrehtwolylevissecxerofkcehC*

)retlifrianruterrosegakcolblioc(wolfriarotaropavekcehC*

egakcolbrofsretsigerrokrowtcudkcehC*

ecivedgniretemytluaF.4

)tcatnocdna,noitacol,ezis(noitallatsniblubVXTkcehC*

evitcefedrodesolckcutssiecifirodexif/VXTfikcehC*

ytridsiliocresnednoC.5

)metsysnitneserpfidekcolbreirdretlif(noitcirtserenildiuqiL.6

gninoitcnuflamsitatsomrehT.7

tiucrictrohsrofgniriwroesab-bustatsomrehtkcehC*

)level,noitacol(noitallatsnitatsomrehtkcehC*

erusserpdaehhgiH.1

metsysnitneserpfihctiwserusserphgihkcehC*

metsyS

TRELA

)wolleY(

hsalF

2edoC

pirTerusserP

noitcusroegrahcsiD

erusserp

rostimilfotuo

rosserpmoc

dedaolrevo

gninnurtonsinafresnednoC.3

roticapacnafkcehC*

metsysnielbasnednoc-nonrofkcehC*

srotcennocdnagniriwnafkcehC*

egakcolbroeruliafrofrotomnafkcehC*

egakaellaitnatsbussahtcudrianruteR.4

tnaregirferhtiwdegrahcrevosimetsysfikcehC*

)degamad,dekcolb,ytrid(noitalucricriaroopliocresnednoC.2

ofni1edoChsalFkcehc,metsysnitneserphctiwserusserpwolfI.5

Table 9

506467-01 Issue 1008 Page 17

Page 18

Flash Codes (cont.)

DEL

sutatS

TRELA

)wolleY(

hsalF

3edoC

TRELA

)wolleY(

hsalF

4edoC

TRELA

)wolleY(

hsalF

5edoC

noitpircseDtluaF noitamrofnIgnitoohselbuorT

gnilcyCtrohS

sirosserpmoC

gninnur

ylfeirbylno

rotoRdekcoL

tiucriCnepO

nisilangisdnamedtatsomrehT.1

deliafsahroticapacnuR.1

snoitcennocgniriwkcehC*

dezieserasgniraebrosserpmoC.4

levelliorosserpmocerusaeM*

tnettimret

evitcefeddraoblortnocroyaleryaledemiT.2

ofni2edoChsalFotog,tneserphctiwserusserphgihfI.3

ofni1edoChsalFotog,tneserphctiwserusserpwolfI.4

)wolsitcennocsidtaegatlovfiytilitutcatnoc(egatlovenilwoL.2

rosserpmocnitnaregirferdiuqilevissecxE.3

nepositcennocsidrewoptinuroodtuO.1

neposi)s(esufrorekaerbtiucricrosserpmoC.2

nepodeliafsahrotcatnocrosserpmoC.3

srotcennocdnagniriwrotcatnocrosserpmockcehC*

)neporo,dettip,denrub(eruliafrotcatnocrosserpmocrofkcehC*

rosserpmocdnaylppusneewtebsrotcennocdnagniriwkcehC*

liocrotcatnocrosserpmoctaegatlovtolipwolrofkcehC*

teserlaunamseriuqerdnaneposihctiwserusserphgiH.4

snoitcennocrogniriwylppusrosserpmocnitiucricnepO.5

erutarepmettneibmaemertxeoteudemitteserrotcetorprosserpmocgnolyllausunU.6

degamaderasgnidniwrosserpmoC.7

ecnatsisergnidniwrotomrosserpmockcehC*

TRELA

)wolleY(

hsalF

6edoC

TRELA

)wolleY(

hsalF

7edoC

TRELA

)wolleY(

hsalF

8edoC

TRELA

)wolleY(

hsalF

9edoC

snur

tiucriCtratSnepO

nurniylnotnerruC

tiucric

tiucriCnuRnepO

tratsniylnotnerruC

tiucric

rotcatnoCdedleW

syawlarosserpmoC

egatloVwoL

sseltiucriclortnoC

CAV71naht

deliafsahroticapacnuR.1

snoitcennocrogniriwtratsrosserpmocnitiucricnepO.2

lanimretSrosserpmocehtdnaylppusneewtebsrotcennocdnagniriwkcehC*

degamadsignidniwtratsrosserpmoC.3

ecnatsisergnidniwrotomrosserpmockcehC*

snoitcennocrogniriwnurrosserpmocnitiucricnepO.1

lanimretRrosserpmocehtdnaylppusneewtebsrotcennocdnagniriwkcehC*

degamadsignidniwnurrosserpmoC.2

ecnatsisergnidniwrotomrosserpmockcehC*

desolcdeliafsahrotcatnocrosserpmoC.1

eludomotdetcennoctonlangisdnamedtatsomrehT.2

dedaolrevosiremrofsnarttiucriclortnoC.1

)wolsitcennocsidtaegatlovfiytilitutcatnoc(egatlovenilwoL.2

snoitidnocgniriwkcehC*

Table 10

506467-01 Issue 1008 Page 18

Page 19

Miswired Module Troubleshooting

noitacidnIeludoMderiwsiM noitcAgnitoohselbuorTdednemmoceR

,notonsiDELneerG

.purewoptonseodeludom

,tnettimretniDELneerG

ylnopusrewopeludom

.snurrosserpmocnehw

metsystubnosiDELPIRT

.KOkcehcrosserpmocdna

DELTRELAdnaDELPIRT

.rehtegotgnihsalf

3edoChsalFTRELA

)gnilcyCtrohSrosserpmoC(

.yltcerrocnideyalpsid

7ro,6,5edoChsalFTRELA

tratSnepO,tiucriCnepO(

)tiucriCnuRnepOro,tiucriC

.yltcerrocnideyalpsid

6edoChsalFTRELA )tiucriCtratSnepO( 7edoCrofdeyalpsid

tiucriCnuRnepO(

.asrevecivro

.gniriwCdnaR

.gniriwCdnaRrof

.ffonehwCAV5.0wolebsllafslioc

.ffonehwCAV5.0wolebsllaflioc

.selohgnisnes

eraslanimreteludomCdnaRhtobfienimreteD

CdnaRs'eludomyfireV.esrevernideriweraslanimretYdnaRfienimreteD

.CAV82-91htiwdeilppuseraslanimretCdnaRyfireV

.ffonehwCAV5.0wolebsllafliocrotcatnoc

tneserpsiegatlovyfireV.detcennoc

rof61egapnonoitcesgniriWrewoPCAV42weiveR.slanimretCdnaRs'eludomta

61egapnonoitcesgniriWrewoPCAV42weiveR.ecruostnatsnocaevahslanimret

rotcatnoctaegatlovyfireV.liocrotcatnoctaCAV42otdetcennocsilanimretYyfireV

gnisnestnerrucs'eludomhguorhteraseriwtratsdnanurrosserpmoctahtkcehC

taegatlovyfireV.liocrotcatnoctaCAV42otdetcennocsilanimretYyfireV.seloh

eludomtcerrochguorhtdetuoreraseriwtratsdnanurrosserpmoctahtkcehC

8edoChsalFTRELA )rotcatnoCdedleW(

.yltcerrocnideyalpsid

taCAV42otdetcennocsilanimretYyfireV.detcennocsilanimretYs'eludomfienimreteD

silangisdnamedtatsomrehtnehwCdnaYssorcatneserpsiCAV42yfireV.liocrotcatnoc

wolebsllafliocrotcatnoctaegatlovyfireV.deriwesrevereraCdnaR,tonfI.tneserp

.gniriwCdnaYrof61egapnogniriWdnameDtatsomrehTweiveR.ffonehwCAV5.0

Table 11

506467-01 Issue 1008 Page 19

Page 20

MAINTENANCE

WARNING

Before performing maintenance operations on system, turn the electric power to unit OFF at disconnect switch(es). Unit may have multiple power supplies. Electrical shock could cause personal injury or death.

Maintenance and service must be performed by a qualified installer or service agency.

At the beginning of each cooling season, the system should be checked as follows:

1. Clean and inspect condenser coil. Coil may be flushed with a water hose. Be sure the power is off before using water to clean the coil.

2. Outdoor fan motor is pre-lubricated and sealed. No further lubrication is needed.

4. Check all wiring for loose connections.

5. Check for correct voltage at unit (with unit operating).

6. Check amp-draw on blower motor.

Unit nameplate _________ Actual _________

3. Visually inspect connecting lines and coils for evidence of oil leaks.

4. Check wiring for loose connections.

5. Check for correct voltage at unit (with unit operating).

6. Check amp-draw outdoor fan motor.

Unit nameplate _________ Actual _________

NOTE – If owner complains of insufficient cooling, the unit should be gauged and refrigerant charge checked. Refer to the Refrigerant Charging section on page 12.

Indoor Coil

1. Clean coil, if necessary.

2. Check connecting lines and coils for evidence of oil leaks.

3. Check condensate pan line and clean, if necessary.

Indoor Unit

1. Clean or change filters.

2. Adjust blower speed for cooling. Measure the pressure drop over the coil to determine the correct blower CFM.

3. Belt drive blowers: Check belt for wear and proper tension.

506467-01 Issue 1008 Page 20

Page 21

Start-Up and Performance Checklist

Job Name _______________________________ Job No. ________________ Date ______________

Job Location _____________________________ City ___________________ State ______________

Installer _________________________________ City ___________________ State ______________

Unit Model No.______________ Serial No. ___________________

Service Technician ________________________________________ Nameplate Voltage ______________

Rated Load Ampacity ________ Compressor _______________ Outdoor Fan ___________________

Maximum Fuse or Circuit Breaker ________________________

Electrical Connections Tight? Indoor Filter Clean? Supply Voltage (Unit Off) ________________

Indoor Blower RPM _____________ S.P. Drop Over Indoor (Dry) ____________

Outdoor Coil Entering Air Temperature _____________ Voltage with Compressor Operating _____________

Discharge Pressure ___________ Vapor Pressure ____________

Refrigerant Charge Checked? Outdoor Fan Checked?

Refrigerant Lines: Leak Checked? Properly Insulated?

Service Valves: Fully Opened? Caps Tight?

Thermostat: Calibrated? Properly Set? Level?

506467-01 Issue 1008 Page 21

Page 22

OUTDOOR

FAN

PURPLE

BLACK

ORANGE

YELLOW

RED

COMPRESSOR

CRANKCASE HEATER

(IF USED)

BLACK

R C

YELLOW

LT BLUE

DUAL

CAPACITOR

FCH

RED

BLUE

CONTACTOR

COMPRESSOR

TO 24 VAC

POWER SOURCE

20 VA MINIMUM

NEC CLASS 2

GROUND LUG

K1-1

BLACK

YELLOW

RED

C12

208-230/60/1

HR1

EQUIPMENT

GROUND

FOR USE WITH COPPER CONDUCTORS ONLY. REFER TO UNIT RATING

PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE.

WARNING-ELECTRIC SHOCK HAZARD, CAN CAUSE INJURY OR DEATH. UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL AND LOCAL CODES.

LINE VOLTAGE FACTORY INSTALLED

LINE VOLTAGE FIELD INSTALLED

24 VOLT FACTORY INSTALLED

CLASS II VOLTAGE FIELD INSTALLED

ORANGE

BLACK

PURPLE

A132

208-230/60/1

GROUND

S4 HIGH

PRESSURE

SWITCH

KEY COMPONENT

A4 CONTROL - TIMED OFF

A132 DIAGNOSTIC MODULE

B1 COMPRESSOR B4 MOTOR - OUTDOOR FAN

C12 CAPACITOR - DUAL HR1 HEATER - COMPRESSOR K1-1 CONTACTOR - COMPRESSOR

S4 SWITCH - HIGH PRESSURE

S24 SWITCH - LOSS OF CHARGE

S24 LOSS

OF CHARGE

SWITCH

R Y2

POWER SOURCE

20 VA MINIMUM

NEC CLASS 2

DESCRIPTION

S24

TO 24 VAC

Wiring Diagram P/N 48440-002

Figure 13

506467-01 Issue 1008 Page 22