Amana AVZC200241AA, AVZC200241AB, AVZC200241AC, AVZC200361AA, AVZC200361AB Installation Manual

...

HEAT PUMP UNIT

AVZC20 HEAT PUMP INSTALLATION & SERVICE REFERENCE

Index

IMPORTANT SAFETY INSTRUCTIONS .......................................... 1

SHIPPING INSPECTION ............................................................ 2

CODES & REGULATIONS ........................................................ 2

FEATURES............................................................................ 2

INSTALLATION CLEARANCES .................................................... 2

ROOFTOP INSTALLATIONS........................................................ 3

SAFE REFRIGERANT HANDLING ............................................... 3

REFRIGERANT LINES .............................................................. 3

REFRIGERANT LINE CONNECTIONS........................................... 5

LEAK TESTING (NITROGEN OR NITROGEN-TRACED) ................... 5

SYSTEM START-UP PROCEDURE.............................................. 5

ELECTRICAL CONNECTIONS .................................................... 6

HEAT PUMP ADVANCED FEATURE MENU ............................... 22

WIRING DIAGRAM ............................................................... 25

CAPACITOR ........................................................................ 28

TROUBLESHOOTING .............................................................. 33

ETTING THE MODE DISPLAY ............................................... 38

S 7-S

EGMENT DISPLAY ........................................................... 44

START-UP CHECKLIST .......................................................... 47

MPORTANT SAFETY INSTRUCTIONS

The following symbols and labels are used throughout this manual to indicate immediate or potential safety hazards. It is the owner’s and installer’s responsibility to read and comply with all safety information and instructions accompanying these symbols. Failure to heed safety information increases the risk of personal injury, property damage, and/or product damage.

W ARNING

HIGH VOLTAGE !

ISCONNECT

ULTIPLE POWER SOURCES MAY BE PRESENT TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

NLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL, ADJUST, SERVICE OR REPAIR (HEREINAFTER MANUAL SHOULD SERVICE THE EQUIPMENT BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM IMPROPER SERVICE OR SERVICE PROCEDURES ASSUME RESPONSIBILITY FOR ANY INJURY OR PROPERTY DAMAGE WHICH MAY RESULT LICENSES TO SERVICE THE EQUIPMENT SPECIFIED IN THIS MANUAL, ONLY LICENSED PERSONNEL SHOULD SERVICE THE EQUIPMENT INSTALLATION, ADJUSTMENT, SERVICING OR REPAIR OF THE EQUIPMENT SPECIFIED IN THIS MANUAL, OR ATTEMPTING TO INSTALL, ADJUST, SERVICE OR REPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER TRAINING MAY RESULT IN PRODUCT DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH

ALL

POWER BEFORE SERVICING

. F

AILURE

, “

SERVICE

”)

THE EQUIPMENT SPECIFIED IN THIS

. THE

MANUFACTURER WILL NOT

. IF

YOU SERVICE THIS UNIT, YOU

. IN

ADDITION, IN JURISDICTIONS THAT REQUIRE ONE OR MORE

. I

MPROPER

IOA-4013C 8/2016

“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.”

All information contained herein is subject to change without notice.

5151 San Felipe St., Suite 500, Houston, TX 77056

www.amana-hac.com

CAUTION

THE

UNIT HAS ITS OWN PUMP-DOWN MODE MODE WHILE VACUUMING THE UNIT CAUSE INTERNAL ELECTRICAL ARCING, RESULTING IN A DAMAGED OR FAILED COMPRESSOR

HIPPING INSPECTION

. USE

THE PUMP-DOWN

. V

ACUUMING TOO LOW CAN

Always keep the unit upright; laying the unit on its side or top may cause equipment damage. Shipping damage, and subsequent investigation is the responsibility of the carrier. Verify the model number, specifications, electrical characteristics, and accessories are correct prior to installation. The distributor or manufacturer will not accept claims from dealers for transportation damage or installation of incorrectly shipped units.

ODES

& R

EGULATIONS

EA TURES

This heat pump is part of a system that uses inverter technology to more efficiently remove or add heat with better efficiency and achieve the target comfort conditions. System may ONLY be installed using a ComfortNet™ thermostat with model number CTK04 as part of the digital communicating system. The ComfortNet system reduces the number of required thermostat wires, provides additional setup features and enhanced active diagnostics. Due to components using inverter technology, the heat pump will not function properly if used with a CTK03, 02 or 01 ComfortNet thermostat.

NOTICE

NOT

APPROVED FOR USE WITH A

NST ALLATION CLEARANCES

CTK01, CTK02 OR CTK03.

This product is designed and manufactured to comply with national codes. Installation in accordance with such codes and/or prevailing local codes/regulations is the responsibility of the installer. The manufacturer assumes no responsibility for equipment installed in violation of any codes or regulations. Rated performance is achieved after 72 hours of operation. Rated performance is delivered at the specified airflow. See outdoor unit specification sheet for split system models or product specification sheet for packaged and light commercial models. Specification sheets can be found at www.amana-hac.com for Amana brand products. Within the website, please select the residential or commercial products menu and then select the submenu for the type of product to be installed, such as air conditioners or heat pumps, to access a list of product pages that each contain links to that model’s specification sheet.

The United States Environmental Protection Agency (EPA) ha s issued various regulations regarding the introduction and disposal of refrigerants. Failure to follow these regulations may harm the environment and can lead to the imposition of substantial fines. Should you have any questions please contact the

local office of the EPA.

If replacing a condensing unit, heat pump or air handler, the system must be manufacturer approved and Air Conditioning, Heating and Refrigeration Institute (AHRI) matched.

NOTE: The installation of an inverter heat pump with unmatched

system units will not allow for proper operation.

NOTICE

NVERTER AIR HANDLER OR RESULTING FROM OPERATION WITH ANY OTHER COMBINATION IS NOT COVERED BY OUR WARRANTIES

Outdoor inverter units are approved for operation above 0°F in cooling mode and -20°F (RH10%) in heating mode with no additional kit necessary.

Damage resulting from operation of the units in a structure that is not complete (either as port of new construction or renovation) is not covered by our warranties.

A/H

MODELS CAN ONLY BE MATCHED WITH AN

TXV-V**

EXPANSION VALVE KIT

. D

AV**PVC

AMAGE

Special consideration must be given to location of the heat pump unit(s) in regard to structures, obstructions, other units, and any/ all other factors that may interfere with air circulation. Where possible, the top of the unit should be completely unobstructed; however, if vertical conditions require placement beneath an ob-

struction there should be a minimum of 60 inches between the top of the unit and the obstruction(s). The specified dimensions

meet requirements for air circulation only. Consult all appropriate regulatory codes prior to determining final clearances.

Another important consideration in selecting a location for the unit(s) is the angle to obstructions. Either side adjacent the valves can be placed toward the structure provided the side away from the structure maintains minimum service clearance. Corner installations are strongly discouraged.

NOT

RECOMMENDED

B B B

AA AAA

Model Type A B C AA

Residential

Light Commercia l

Minim um Airflow Clear ance

10" 10" 18" 20" 12" 12" 18" 24"

OK!

This unit can be located at ground floor level or on flat roofs. At ground floor level, the unit must be on a solid, level foundation

that will not shift or settle. To reduce the possibility of sound transmission, the foundation slab should not be in contact with or be an integral part of the building foundation. Care should be taken to ensure the unit is installed away from noise sensitive locations such as bedrooms, windows and outdoor living areas. Ensure the foundation is sufficient to support the unit. A concrete slab raised above ground level provides a suitable base.

OOFTOP INST ALLATIONS

If it is necessary to install this unit on a roof structure, ensure the roof structure can support the weight and that proper consideration is given to the weather-tight integrity of the roof. Since the unit can vibrate during operation, sound vibration transmission should be considered when installing the unit. Vibration absorbing pads or springs can be installed between the heat pump unit legs or frame and the roof mounting assembly to reduce noise vibration.

ELECTRICAL NOISE

The unit should be well grounded so that potential effects of electrical noise from the inverter to surrounding equipment can be minimized.

When selecting an installation location, keep sufficient distance from the heat pump unit and wiring to radios, personal computers, stereos, etc., as shown in the following figure.

Circuit Breaker

To Indoor Unit and Thermostat

WARNING

AVOID POSSIBLE EXPLOSION, USE ONLY RETU RNABL E (NOT DISPOSABLE) SERVICE CYLINDERS WHEN REMOVING REFRIGERANT FROM A SYSTEM

• E

• E W

NSURE THE CYLINDER IS FREE OF DAMAGE WHICH COUL D LEAD TO A

LEAK OR EXPLOSION

NSURE THE HYDROSTATI C TEST DATE DOES NOT EXCEED NSURE THE PRESSURE RATING MEETS OR EXCEEDS

HEN IN DOUBT, DO NOT USE CYLINDER

400

PSIG

YEARS

WARN ING

EFRIGERANTS ARE HEAVIER THAN AIR OXYGEN IN YOUR LUNGS OR IN ANY ENCLOSED SPACE POSSIBLE DIFFICULTY IN BREATHING OR DEATH

EVER PURGE REFRIGERANT INTO AN ENCLOSED ROOM OR SPACE

• N

LAW, ALL REFRIGERANTS MUST BE RECLAIMED

F AN INDOOR LEAK IS SUSPECTED, THOROUGHLY VENTILATE THE AREA

• I

BEFORE BEGINNING WORK

IQUID REFRIGERANT CAN BE VERY COLD

• L

OR BLINDNESS, AVOID CONTACT AND WEAR GLOVES AND GOGGLES

LIQUID REFRIGERANT DOES CONTACT YOUR SKIN OR EYES, SEEK MEDICAL

HELP IMMEDIATELY

LWAYS FOLLOW

• A

OISONOUS GAS WILL BE PRODUCED

EP A

REGULATIONS

. T

HEY CAN “PUSH OUT” THE

. TO

AVOID

. TO

AVOID POSSIBLE FROST BITE

. N

EVER BURN REFRIGERANT, AS

. BY

. IF

WARNING

Radio, TV

(In.)

Placement to Minimize Electronic Noise

AFE REFRIGERANT HANDLING

”

While these items will not cover every conceivable situation, they should serve as a useful guide.

WARNING

AVOID POSSIBLE INJURY, EXPLOSION OR DEATH, PRACTICE SAFE

HANDLING OF REFRIGERANTS

AVOID POSSIBLE EXPLOSION

EVER APPLY FLAME OR STEAM TO A REFRIGERANT CYLINDER

•N

MUST HEAT A CYLINDER FOR FASTER CHARGING, PARTIALLY IMMERSE IT IN WARM WATER

EVER FILL A CYLINDER MORE THAN

•N

REFRIGERANT

EVER ADD ANYTHING OTHER THAN

•N R-410A OR

•S

EFRIGERANT LINES

CYLINDER

CERTIFIED FOR THE TYPE OF REFRIGERANT USE

TORE CYLINDERS IN A COOL, DRY PLACE

PLATFORM OR A ROLLER

. THE

. IF

YOU

80%

FULL OF LIQUID

R-410A TO A

SERVICE EQUIPMENT USED MUST BE LISTED

RETURNABLE

. N

EVER USE A CYLINDER

CAUTION

THE

COMPRESSOR SUSCEPTIBLE TO MOISTURE ABSORPTION AND COULD CAUSE COMPRESSOR FAILURE ANY LONGER THAN NECESSARY FOR INSTALLATION

PVE

OIL FOR

R-410A

. DO

NOT LEAVE SYSTEM OPEN TO ATMOSPHERE

UNITS IS EXTREMELY

Use only refrigerant grade (dehydrated and sealed) copper tubing to connect the heat pump unit with the indoor unit. After cutting the tubing, install plugs to keep refrigerant tubing clean and dry prior to and during installation. Tubing should always be cut square keeping ends round and free from burrs. Clean the tubing to prevent contamination. The liquid line must be insulated if more than 50 ft. of liquid line will pass through an area that may reach temperatures of 30 °F or higher than ambient in cooling

mode and/or if the temperature inside the conditioned space may reach a temperature lower than ambient in heating mode. Never attach a liquid line to any uninsulated potion of the gas line.

Do NOT let refrigerant lines come in direct contact with plumbing, ductwork, floor joists, wall studs, floors, and walls. When running refrigerant lines through a foundation or wall, openings should allow for sound and vibration absorbing material to be placed or installed between tubing and foundation. Any gap between foundation or wall and refrigerant lines should be filled with a pliable silicon-based caulk, RTV or a vibration damping material. Avoid suspending refrigerant tubing from joists and studs with rigid wire or straps that would come in contact with the tubing. Use an insulated or suspension type hanger. Keep both lines separate and always insulate the gas line.

Heat Pump BEL OW Indoor Coil

Insulation is necessary to prevent condensation from forming and dropping from the gas line. Armflex or satisfactory equivalent with 3/8” min. wall thickness is recommended. In severe conditions (hot, high humidity areas) 1/2” insulation may be required. Insulation must be installed in a manner which protects tubing and connections from damage and contamination.

Where possible, drain as much residual compressor oil from existing systems, lines, and traps; pay close attention to low areas

where oil may collect. NOTE: If changing refrigerant, the indoor

coil and metering device must be replaced. Only AV**PVC air handlers or TXV** expansion valves are compatible and have been manufacturer approved for use with these models. See unit specifications or AHRI for an approved system match.

Oil Trap Construction

SHORT RADIUS

STREET ELL

STREET

Maximum line set

equivalent length of 250 ft*.

The maximum line set actual length is 200 ft.

*Includes pressure losses of any elbow, bends, etc.

Heat Pump ABOVE Indoor Coil

Maximum line set

equivalent length of 250 ft.*

The maximum line set

actual length is 200 ft.

LONG RADIUS

STREET EL L

ELL

*Includes pressure losses of any elbow, bends, etc.

Maximum vertical

separation of 200 ft.

RECOMMEND ED

INTERCONNECT ING TUB ING (Ft)

Line Set Length

0 - 250' Equivalent

Do NOT make final refrigerant line connection until plugs are removed from refrigerant tubing.

EAK TESTING

ITROGEN OR NITROGEN-TRACED

)

Heat Pump

Unit

& Li n e Diamet er (I n . OD)

Line Type

(Tons) Suct Liq

23/43/8 37/83/8 41 1/83/8

51 1/83/8

EFRIGERANT LINE CONNECTIONS

IMPORT ANT

To avoid overheating the service valve, TXV or filter drier while brazing, wrap the component with a wet rag, or use a thermal heat trap compound. Be sure to follow the manufacturer’s instruction when using the heat trap compound. Note: Remove Schrader valves from service valves before brazing tubes to the valves. Use a brazing alloy of 2% minimum silver content. Do not use flux.

Torch heat required to braze tubes of various sizes is proportional to the size of the tube. Tubes of smaller size require less heat to bring the tube to brazing temperature before adding brazing alloy. Applying too much heat to any tube can melt the tube. Service personnel must use the appropriate heat level for the size of the tube being brazed.

NOTE: The use of a heat shield when brazing is recommended

to avoid burning the serial plate or the finish on the unit.

1. The ends of the refrigerant lines must be cut square, deburred, cleaned, and be round and free from nicks or dents. Any other condition increases the chance of a refrigerant leak.

2. “Sweep” the refrigerant line with nitrogen or inert gas during brazing to prevent the formation of copper-oxide inside the refrigerant lines. The FVC oils used in R-410A applications will clean any copper-oxide present from the inside of the refrigerant lines and spread it throughout the system. This may cause a blockage or failure of the metering device.

3. After brazing, quench the joints with water or a wet cloth to prevent overheating of the service valve.

4. A bi-flow filter drier is shipped with the unit as a separate component and must be brazed on by the installer onsite. Ensure the bi-flow filter drier paint finish is intact after brazing. If the paint of the steel filter drier has been burned or chipped, repaint or treat with a rust preventative.

The recommended location of the filter drier is before the expansion device at the indoor unit.

WARNING

AVOID THE RISK OF FIRE OR EXPLOSION, NEVER USE OXYGEN, HIGH PRESSURE AIR OR FLAMMABLE GASES FOR LEAK TESTING OF A REFRIGERATION SYSTEM

WARNING

AVOID POSSIBLE EXPLOSION, THE LINE FROM THE NITROGEN CYLINDER MUST INCLUDE A PRESSURE REGULATOR AND A PRESSURE RELIEF VALVE NO MORE THAN

. THE

PRESSURE RELIEF VALVE MUST BE SET TO OPEN AT

150

PSIG

To locate leaks, pressure test the system using dry nitrogen or leak detector fluid per the manufacturer’s recommendation. If you wish to use a leak detector, charge the system to 10 psi using the appropriate refrigerant then use nitrogen to finish charging the system to working pressure then apply the detector to suspect areas. If leaks are found, repair them. After repair, re-

peat the pressure test. If no leaks exist, proceed to System Start-

up Procedure.

YSTEM START-UP PROCEDURE

GENERAL NOTES:

Adequate refrigerant charge for the matching indoor coil and 15 feet of line set is supplied with the heat pump unit. If liquid line set exceeds 15 feet in length, refrigerant should be added at 0.6 ounces per foot of liquid line.

NOTICE

IOLATION OF

PENALTIES

EPA

REGULATIO NS MAY RESU LT IN FINES OR OTHER

NOTICE

ALL

UNITS SHOULD HAVE A HIGH VOLTAGE POWER SUPPLY CONNECTED

HOURS PRIOR TO STARTUP

WARNING

REFRIGERANT UNDER PRESSURE!

• DO

NOT OVERCHARGE SYSTEM WITH REFRIG ERANT

O NOT OPERATE UNIT IN A VACUUM OR AT NEGATIVE PRESSURE

• D

AILURE TO FOLLOW PROPER PROCEDURES MAY CAUSE PROPERTY

DAMAGE, PERSONAL INJURY OR DEATH

CAUTION

PERATING THE COMPRESSOR WITH THE GAS VALVE CLOSED WILL CAUSE SERIOUS COMPRESSOR DAMAGE COVERED BY OUR WARRANTIES

SUCH DAMAGE IS NOT

NOTE: Be careful not to kink or dent refrigerant lines. Kinked or

dented lines will cause poor performance or compressor damage.

CAUTION

USE

REFRIGERANT CERTIFIED TO MAY CAUSE COMP RESSOR DAMAGE, AND WARRANTY REFRIGERANT TO MEET

. M

OST PORTABLE MACHINES CANNOT CLEAN USED

AHRI

STANDARDS

. U

SED REFRIGERANT

IS NOT COVERED UNDER

THE

START-UP PROCEDURE DETAIL

Liquid and gas valves on heat pump unit are closed to contain the charge within the unit. The unit is shipped with the valve stems

closed and caps installed. Do not open valves until the indoor coil

and line set is evacuated.

CAUTION

ROLONGED OPERATION AT SUCTION PRESSURES LESS THAN FOR MORE THAN SCROLLS AND PERMANENT DAMAGE TO THE SCROLL TIPS, DRIVE BEARINGS AND INTERNAL SEAL

SECONDS WILL RESULT IN OVERHEATING OF THE

PSIG

LECTRICAL CONNECTIONS

WARNING

HIGH VOLTAGE!

ISCONNECT

ULTIPLE POWER SOURCES MAY BE PRESENT TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH DUE TO ELECTRIC SHOCK MUST CONFO RM WITH CODES EQUIPM EN T PERFORMANCE, EQUIPM EN T DAMAGE OR FIRE

AVOID THE RISK OF FIRE OR EQUIPM EN T DAMAGE, USE COPPER

CONDUCTORS

ALL

POWER BEFORE SERVICING

NEC OR CEC

. U

NDERSIZED WIRES COUL D CAUSE POOR

AND ALL LOCAL

WARNING

. W

. F

AILURE

IRING

1. Connect the vacuum pump with 250 micron capability to the service valves.

2. Evacuate the system to 250 microns or less using gas and

liquid service valves. Using both valves is necessary as some compressors create a mechanical seal separating the sides of the system.

3. Close pump valve and hold vacuum for 10 minutes. Typically pressure will rise during this period.

• If the pressure rises to 1000 microns or less and remains steady the system is considered leak-free; proceed to start-up.

• If pressure rises above 1000 microns but holds steady below 2000 microns, moisture and/or noncondensibles may be present or the system may have a small leak. Return to step 2: If the same result is encountered check for leaks as previously indicated and repair as necessary then repeat evacuation.

• If pressure rises above 2000 microns, a leak is present. Check for leaks as previously indicated and repair as necessary then repeat evacuation.

5000

4500

4000

3500

3000

2500

2000

VACUUM IN MICRONS

1500

1000

500

0 1 2 3 4 5 6 7 8 9

CONDENSIBLES OR SMALL LEAK PRESENT

NO LEAKS NO CONDE NSIBLES

MINUT ES

LEAK(S) PRESENT

CAUTION

GROUNDIN G R EQUIRED!

LWAYS INSPECT AND USE PROPER SERVICE TOOLS

INSPECTION OR IMPROPER TOOLS MAY CAUSE EQUIPMENT DAMAGE OR PERSONAL INJURY RECONNECTED BEFORE INSTALLING OR SERVICING COMPONENTS OF THIS UNIT MAY CONDUCT ELECTRICAL CURRENT THESE ARE GROUNDED OF GROUNDING WIRES, SCREWS, STRAPS, CLIPS, NUTS OR WASHERS USED TO COMPLETE THE GROUND ORIGINAL POSITION AND PROPERLY FASTENED

. ALL

DISCONNECTED GROUNDING DEVICES

. IF

SERVICING THE UNIT, ANY DISCONNECTION

MUST BE

. L

ACK OF

MUST BE

. M

ULTIPLE

RETURNED TO THEIR

;

The heat pump unit rating plate lists pertinent electrical data necessary for proper electrical service and overcurrent protection. Wires should be sized to limit voltage drop to 2% (max.) from the main breaker or fuse panel to the condensing unit. Consult the NEC, CEC, and all local codes to determine the correct wire gauge and length.

Local codes often require a disconnect switch located near the unit; do not install the switch on the unit. Refer to the installation instructions supplied with the indoor furnace/air handler for specific wiring connections and indoor unit configuration.

OVERCURRENT PROTECTION

The inverter control system software provides sufficient time delay to protect from overcurrent conditions and permit the compressor and fan motors to adjust their rotational speed.

HIGH VOLTAGE CONNECTIONS

Route power supply and ground wires through the high voltage port and terminate in accordance with the wiring diagram provided inside the control panel cover.

LOW VOLTAGE CONNECTIONS

The unit is designed to work as part of a fully communicating HVAC system, utilizing a ComfortNet™ CTK04 thermostat, ComfortNet compatible indoor unit, and up to four wires. Route control wires through the low voltage port and terminate in accordance with the wiring diagram provided inside the control panel cover.

NOTICE

OTAL REFRIGERANT

ACTORY CHARGE

OF A

CTUAL LINE SET

The following table shows refrigerant amounts for every 5 feet of line.

+ (0.6 OZ./FT. * A

DDITIONAL FEET

Unit Tonnage

Voltage Ports

NOTE: The communicating thermostat is able to search and iden-

tify the indoor and outdoor units when power is applied to the system. Refer to the communicating thermostat’s installation instruction manual for more information.

Connect low voltage communication wires (1, 2) to low voltage pigtail provided.

THERMOSTAT WIRING

NOTE: A removable plug connector is provided with the control

to make thermostat wire connections. This plug may be removed, wire connections made to the plug, and replaced. It is STRONGLY recommended that you do not connect multiple wires into a single terminal without mechanically twisting the tips together with a set of pliers. Failure to do so may result in intermittent operation.

Typical 18 AWG thermostat wire may be used to wire the system components. However, communications reliability may be improved by using a high quality, shielded, twisted pair cable for the data transmission lines. In either case, 250 feet is the maximum length of wire between indoor unit and outdoor unit, or between indoor unit and thermostat.

TWO-WIRE OUTDOOR, FOUR-WIRE INDOOR WIRING

Low voltage wiring consists of two wires between the indoor unit and outdoor unit and four wires between the indoor unit and thermostat. The required wires are data lines 1 and 2, “R” (24 VAC hot) and “C” (24 VAC common).

12RC

CTK04 Thermostat

Compatible

ir Handler/Furnace

Integrated Control Module

Compatible AC/HP Integrated Control Module

System Wiring

Actual Line Set Length

(ft.)

15 (Factory Charge) 165 272 272 242

20 168 275 275 245 25 171 278 278 248 30 174 281 281 251 35 177 284 284 254 40 180 287 287 257 45 183 290 290 260 50 186 293 293 263 55 189 296 296 266 60 192 299 299 269 65 195 302 302 272 70 198 305 305 275 75 201 308 308 278 80 204 311 311 281 85 207 314 314 284 90 210 317 317 287

95 213 320 320 290 100 216 323 323 293 105 219 326 326 296 110 222 329 329 299 115 225 332 332 302 120 228 335 335 305 125 231 338 338 308 130 234 341 341 311 135 237 344 344 314 140 240 347 347 317 145 243 350 350 320 150 246 353 353 323 155 249 356 356 326 160 252 359 359 329 165 255 362 362 332 170 258 365 365 335 175 261 368 368 338 180 264 371 371 341 185 267 374 374 344 190 270 377 377 347 195 273 380 380 350 200 276 383 383 353

2-Ton 3-Ton 4-Ton 5-Ton

Refrigerant (Oz.)

STEP 1. CALCULATE REFRIGERANT CHARGE BASED ON LINE SET LENGTH

The heat pump unit is shipped with a predetermined factory charge level as shown below. For longer line sets greater than 15 feet, add 0.6 ounces of refrigerant per foot.

STEP 2. CONNECT HEAT PUMP UNIT TO SYSTEM

OPEN THE LIQ UID VALVE FI R S T! IF

OPENED FIRST, OIL FROM THE COMPRESSOR MAY BE DRAWN INTO THE INDOOR COIL OR OPERATION OF THE SYSTEM

TXV

RESTRICTING REFRIGERANT FLOW AND AFFECTING

THE GAS SERVICE VALVE IS

CAUTION

POSSIBL E REFRIGER AN T LEAK!

AVOID A POSSIBLE REFRIGERANT LEAK, OPEN THE SERVICE VALVES

UNTIL THE TOP OF THE STEM IS

1/8”

FROM THE RETAINER

CAUTION

NSURE VALVES ARE OPEN AND ADDITIONAL CHARGE IS ADDED PER

CHART BEFORE APPLYING POWER

ATTENTION INSTALLER - IMPORTANT NOTICE!

Please read carefully before installing this unit.

When opening valves with retainers, open each valve only until the top of the stem is 1/8” from the retainer. To avoid loss of refrigerant, DO NOT apply pressure to the retainer. When opening valves without a retainer, remove service valve cap and insert a hex wrench into the valve stem and back out the stem by turning the hex wrench counterclockwise. Open the valve until it contacts the rolled lip of the valve body.

NOTE: Units may utilize ball valves or front seating valves. These

are not back-seating valves. It is not necessary to force the stem tightly against the rolled lip.

After the refrigerant charge has bled into the system, open the liquid service valve. The service valve cap is the secondary seal for the valves 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 1/6 of a turn to properly seat the sealing surfaces.

Do not introduce liquid refrigerant from the cylinder into the crankcase of the compressor as this may damage the compressor.

Break vacuum by fully opening liquid and gas base valve.

• For AVZC20, do not install the 24 Volt Transformer that is included with the CTK04 Thermostat in the Heat Pump Unit; it is not needed.

• Do not attach any wires to the R & C Terminals on the Heat Pump Unit, as they are not needed for inverter unit setup.

•DATA LINE TERMINALS #1 AND #2 ARE POLARITY SENSITIVE. ONLY THE DATA LINES, 1 AND 2, ARE REQUIRED BETWEEN THE INDOOR AND

OUTDOOR

UNITS.

•DATA LINE TERMINAL #1 FROM OUTDOOR UNIT MUST CONNECT TO TERMINAL #1 ON INDOOR UNIT AND DATA LINE TERMINAL #2 FROM

OUTDOOR

UNIT MUST CONNECT TO TERMINAL #2 ON INDOOR UNIT. VERIFY WIRES ARE NOT REVERSED.

•IT IS STRONGLY RECOMMENDED TO USE WIRE NUTS AT THE INDOOR UNIT WHEN CONNECTING MULTIPLE DATA LINES OR LO W VOLTAGE WIRES

TOGETHER

. IT IS NOT RECOMMENDED TO USE THE TERMINAL BLOCK TO CONNECT TWO OR MORE WIRES.

• Calculate the Liquid Line Set length and weigh in 0.6 ounces per foot of R410A refrigerant for any length over 15 feet.

• Charge by Sub-cooling. Sub-cooling should be between 7° and 9°F. Allow 10 minutes of running in Charge Mode between each amount of refrigerant added.

DIPSWITCH FAC TO RY DEFAULT SETTINGS

Switch #

OD DS1

OD DS2

* OD DS 2 s w i tch 1 and 2 bo th must be turned on during normal operation mode

1 ON CT Communication Enabl ed

2 ON CT Communication Enabl ed

1ON

2ON

Setting Purpose

Cooling Emergency Mode for Future Use * Cooling Emergency Mode for Future Use *

STEP 3. SYSTEM START-UP TEST

NOTICE

INITIAL POWER START-UP, THE OUTDOOR UNIT WILL DISPLAY CODE

E11,

SIGNALING THAT INITIAL THE COMFORTNET™ SETUP SCREEN TO ENTER APPLICATION-UNIQUE INFORMATION DETAILED INFORMATION

. SEE C

A system test is now required to check the equipment

settings and functionality. Once selected, it checks the

equipment for approximately 5 - 15 minutes. System test

may exceed 15 minutes if there is an error. Refer to

the Troubleshooting section.

Before starting the SYSTEM TEST, turn off the electric heater

or gas furnace.

1. Ensure the thermostat is installed.

SYSTEM

OMFORTNET THERMOSTAT MANUAL FOR

TEST MUST BE RUN

. F

OLLOW

2. Apply power to outdoor and indoor units.

3. Start-up.

After the application information is entered, the initial system test must be run.

NOTICE

FOR

INVERTER

TRANSFORMER

The HOME screen will be displayed showing information similar to one of the adjacent screens. Select MENU.

NOTE: Either screen may be displayed.

SYSTEM TEST must be run for all installations. System will not operate without a completed initial SYSTEM TEST.

NOTE: Ensure the thermostat is in OFF mode.

H/P

SYSTEM USING COMFORTNET, DO

NOT

INSTALL A

4. From the MENU screen, scroll down and select COMFORTNET™ USER MENU.

5. Enter Installer password. (The password is the Date Code located on the thermostat and is available by entering the EQUIPMENT STATUS menu and scrolling to the bottom.)

6. Select YES to continue.

7. From the ComfortNet USER MENU, select HEAT PUMP.

NOTE: Screen may show air handler

or furnace depending on the type of system installed.

8. Next, scroll down and select EQUIP TEST.

9. Select SYSTEM TEST.

10. Select ON to run the SYSTEM TEST. Press DONE to initiate test.

11. Allow the system test to run for its duration (5-15 minutes). EQUIP TEST SCREEN will show the system test is ON once selected. System test will operate the outdoor unit and the indoor unit through a series of startup tests. Please proceed to the next step and allow for startup tests to complete. Do not interrupt power to outdoor unit, indoor unit, or thermostat during system test.

12. Press Previous Menu button and navigate to HOME screen and allow test to finish. The display similar to the one at the right will be displayed after SYSTEM TEST completes. Test is complete only when CODE 11 notice clears from BOTH the thermostat display AND the seven segment LED display on the outdoor unit. Please wait for test to complete and for both codes to clear.

STEP 4. SET THERMOSTAT TO CHARGE MODE

Please follow the following sequence to enter CHARGE MODE.

CHARGE mode allows for charging of the system. System operates for a duration of approximately one hour while the equipment runs at full capacity. After one hour, the CHARGE MODE ends and the system resumes normal thermostat operation.

Before starting the CHARGE MODE, turn off the electric heater or gas furnace.

1. On the HOME screen, select MENU. NOTE: Set COOL or HEAT MODE to OFF before starting

CHARGE MODE.

2. From the MENU screen, select COMFORTNET™ USER MENU.

off

3. Enter Installer password. (The password is the Date Code located on the thermostat and is available by entering the EQUIPMENT STATUS menu and scrolling to the bottom).

4. Select YES to continue.

5. Select HEAT PUMP.

6. Select MAINTENANCE.

7. Select CHARGE MODE.

8. Select ON. Press DONE to initiate CHARGE mode. (System will then run for 1 hour and either return to cooling or heating mode depending on the mode thermostat is set at COOL or HEAT, or stop if the thermostat is set for FAN only mode.)

If charging is not complete after 1 hour, repeat

7. and 8. Refer to STEP 5 and STEP 6 for refrigerant charge level adjustment.

9. To terminate CHARGE MODE, select CHARGE mode screen again. Press OFF. Press DONE to terminate CHARGE MODE.

10. Once CHARGE MODE is complete and has been terminated, navigate to HOME screen. Enter normal operation with temperature offset or thermostat schedule, as desired.

STEP 5. ADJUST REFRIGERANT LEVEL

Using service equipment, add or recover refrigerant according to the calculation in Step 1. Allow system to stabilize for 10 minutes after adjusting charge level.

STEP 6. MEASURE SUBCOOLING TO VERIFY PROPER CHARGE

NOTE: Charging equipment must use dedicated PVE oil gauges

and hoses.

1. Purge gauge lines.

2. Connect service gauge manifold to base valve service ports.

3. Convert the liquid pressure to temperature using a temperature/pressure chart.

4. Temporarily install a thermometer on the liquid line at the liquid line service valve.

a. Ensure the thermometer makes adequate contact and is insulated for best possible readings.

5. Subtract the liquid line temperature from the converted liquid pressure to determine subcooling.

6. Before starting the Subcooling adjustment, make sure the outdoor ambient temperature is in a below range and the unit is operating at 100% capacity.

SUBCOOLING = (SA T. LIQUID TEMP .) - (LIQUID LINE TEMP.)

SUPERHEA T = ( SUCT. LINE TEMP .) - (S AT . SUCT. TEMP .)

e. If subcooling and superheat are high, adjust the TXV

valve to 7 to 9°F superheat, then check subcooling.

f. If subcooling is high and superheat is 7 to 9°F, remove

charge to lower the subcooling to 7 to 9°F, then check superheat.

g. If subcooling is high and superheat is low, adjust the

TXV valve to 7 to 9°F superheat and remove charge to low the subcooling to 7 to 9°F.

h. If subcooling is 7 to 9°F and superheat is low, adjust the

TXV valve to 7 to 9°F superheat and remove charge to lower the subcooling 7 to 9°F, then check the superheat.

NOTE: Not more than 0.5 lb. (8 Oz.) of refrigerant must

be added to the system in order to achieve the target subcooling. It is recommended to add 4 oz. refrigerant each time and try adjusting the TXV and let the system stabilize.

NOTICE

HECK THE SCHRADER PORTS FOR LEAKS AND TIGHTEN VALVE CORES, IF

NECESSARY

. I

NSTALL CAPS FINGER-TIGHT

NOTICE

DO NOT

THERE IS A GROSS UNDERCHARGE

ADJUST THE CHARGE BASED ON SUCTION PRESSURE UNLESS

Chargi ng Tabl e

OD Ambie nt Tem p

(degF)

Subcooling

(degF)

Note: Subcooling information is valid only while the unit is operating at 100% capacity or 100% of compressor speed in CHARGE MODE. Compressor speed is displayed under STATUS menu in the thermostat.

< 65 °F 65°F to 105°F > 105 °F

Weigh in

Charge

7°F to 9°F

Weigh in

Charge

7. The system subcooling should be 7 to 9°F. If not in that range, adjust subcooling and superheat according to the following procedure.

a. If subcooling and superheat are low, adjust TXV to 7 to

9°F superheat, then check subcooling.

NOTE: To adjust superheat, turn the valve stem clockwise

to increase and counter clockwise to decrease.

b. If subcooling is low and superheat is 7 to 9°F, add charge

to rise subcooling to 7 to 9°F, then check superheat.

c. If subcooling is low and superheat is high, add charge to

rise subcooling to 7 to 9°F, then check superheat.

d. If subcooling is 7 to 9°F and superheat is high, adjust

the TXV valve to 7 to 9°F superheat, then check subcooling.

Rain

Shield

NOTICE

THE RAIN SHIELD WAS REMOVED DURING THE INSTALLATION

PROCESS, BE SURE TO RE-INSTALL IT AFTER CHARGING THE UNIT

HEAT PUMP WITH OUTDOOR TEMPERATURE LOCKOUTS

It is recommended to set the outdoor temperature lockouts during the initial thermostat set up. This will enable the compressor to be turned off and switch heating source from refrigeration to auxiliary/secondary heating under low ambient conditions.

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