Bryant 302B, 602B060, 602B048, 602B042, 602B036 Installation, Start-up And Service Instructions Manual

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Page 1

Installation, Start-Up, and Service Instructions

SINGLE-PACKAGE HEAT PUMP UNITS WITH PURON (R-410A) REFRIGERANT

NOTE: Read the entire instruction manual before starting the installation.

This symbol → indicates a change since the last issue.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS.....................................................1

Introduction ....................................................................................2

Receiving and Installation..............................................................2

Check Equipment......................................................................2

Provide Unit Support................................................................2

Provide Clearances....................................................................2

Rig and Place Unit....................................................................2

Select and Install Ductwork .....................................................5

Provide for Condensate Disposal.............................................6

Install Electrical Connections...................................................7

PRE-START-UP ..........................................................................10

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

Check for Refrigerant Leaks..................................................12

Start-Up Adjustments..............................................................12

Defrost Control .......................................................................19

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

Air Filter..................................................................................22

Indoor Blower and Motor.......................................................22

Outdoor Coil, Indoor Coil, and Condensate Drain Pan........22

Outdoor Fan............................................................................22

Electrical Controls and Wiring...............................................22

Refrigerant Circuit..................................................................22

Indoor Airflow........................................................................23

Metering Devices–Accurater Piston.......................................23

Pressure Switches....................................................................23

Loss of Charge Switch ...........................................................23

High-Pressure Switch..............................................................23

Copeland Scroll Compressor (Puron Refrigerant).................23

Refrigerant System..................................................................23

System Information.................................................................24

TROUBLESHOOTING ...............................................................24

Start-Up Checklist........................................................................24

NOTE TO INSTALLER — READ THESE INSTRUCTIONS CAREFULLY AND COMPLETELY before installing this unit. Also, make sure the Owner’s Manual and Service Instructions are left with the unit after installation.

SAFETY CONSIDERATIONS

Installation and servicing of air-conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified personnel should install, repair, or service air-conditioning equipment.

Untrained personnel can perform basic maintenance functions of cleaning coils and filters. All other operations should be performed by trained service personnel. When working on air-conditioning equipment, observe precautions in the literature, tags, and labels attached to the unit, and other safety precautions that may apply.

602B

Cancels: II 602B-24-1 II 602B-24-2

12-00

C99063

Fig. 1—Unit 602B

Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing operations.

WARNING: Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electric shock, or other occurrences, which could cause serious injury or death or damage your property. Consult a qualified installer or service agency for information or assistance. The qualified installer or agency must use only factory-authorized kits or accessories when modifying this product.

Recognize safety information. This is the safety-alert symbol . When you see this symbol on the product or in instructions or manuals, be alert to the potential for personal injury.

Understand the signal words — DANGER, WARNING, CAUTION, and NOTE. Danger identifies the most serious hazards, which will result in severe personal injury or death. Warning indicates a condition that could cause serious personal injury or death. Caution is used to identify unsafe practices, which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

1. The power supply (volts, phase, and hertz) must correspond to that specified on unit rating plate.

2. The electrical supply provided by the utility must be sufficient to handle load imposed by this unit.

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Page 2

3. This installation must conform with local building codes and with NEC (National Electrical Code). Refer to provincial and local plumbing or waste water codes and other applicable local codes.

WARNING: Before performing service or maintenance operations on system, turn off main power to unit. Turn off accessory heater power switch if applicable. Electrical shock could cause severe injury or death.

CAUTION: Puron (R-410A) systems operate at higher pressures than standard R-22 systems. DO not use R-22 service equipment or components on Puron (R-410A) equipment. Ensure service equipment is rated for Puron (R-410A)

INTRODUCTION

The 602B heat pump is fully self-contained and designed for outdoor installation. (See Fig. 1) Standard units are shipped in a horizontal-discharge configuration for installation on a groundlevel slab. Standard units can be converted to downflow (vertical) discharge configurations for rooftop applications.

RECEIVING AND INSTALLATION

I. CHECK EQUIPMENT A. IDENTIFY UNIT

The unit model number and serial number are stamped on the unit identification plate. Check this information against shipping papers.

B. INSPECT SHIPMENT

Inspect for shipping damage while unit is still on shipping pallet. If unit appears to be damaged or is torn loose from its anchorage, have it examined by transportation inspectors before removal. Forward claim papers directly to transportation company. Manufacturer is not responsible for any damage incurred in transit. Check all items against shipping list. Immediately notify the nearest Bryant Air Conditioning office if any item is missing. To prevent loss or damage, leave all parts in original packages until installation.

II. PROVIDE UNIT SUPPORT A. ROOF CURB

Install accessory roof curb in accordance with instructions shipped with curb. (See Fig. 5) Install insulation, cant strips, roofing, and flashing. Ductwork must be attached to curb.

IMPORTANT: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasketing material supplied with the roof curb. Improperly applied gasketing also can result in air leaks and poor unit performance.

Curb should be level to within 1/4 in. (See Fig. 6) This is necessary for unit drain to function properly. Refer to accessory roof curb installation instructions for additional information as required.

B. SLAB MOUNT

Place the unit on a solid, level concrete pad that is a minimum of 4 in. thick with 2 in. above grade. (See Fig. 7) The slab should extend approximately 2 in. beyond the casing on all 4 sides of the unit. Do not secure the unit to the slab except when required by local codes.

C. GROUND MOUNT

The unit may be installed either on a slab or placed directly on the ground if local codes permit. Place the unit on level ground prepared with gravel for condensate discharge.

III. PROVIDE CLEARANCES

The required minimum service clearances are shown in Figs. 2 and

3. Adequate ventilation and outdoor air must be provided. The outdoor fan draws air through the outdoor coil and discharges it through the top fan grill. Be sure that the fan discharge does not recirculate to the outdoor coil. Do not locate the unit in either a corner or under an overhead obstruction. The minimum clearance under a partial overhang (such as a normal house overhang) is 48 in. above the unit top. The maximum horizontal extension of a partial overhang must not exceed 48 in.

IMPORTANT: Do not restrict outdoor airflow. An air restriction at either the outdoor-air inlet or the fan discharge may be detrimental to compressor life.

Do not place the unit where water, ice, or snow from an overhang or roof will damage or flood the unit. Do not install the unit on carpeting or other combustible materials. Slab-mounted units should be at least 4 in. above the highest expected water and runoff levels. Do not use unit if it has been under water.

IV. RIG AND PLACE UNIT

Rigging and handling of this equipment can be hazardous for many reasons due to the installation location (roofs, elevated structures, etc.)

Only trained, qualified crane operators and ground support staff should handle and install this equipment.

When working with this equipment, observe precautions in the literature, on tags, stickers, and labels attached to the equipment, and any other safety precautions that might apply.

Follow all applicable safety codes. Wear safety shoes and work gloves.

A. INSPECTION

Prior to initial use, and at monthly intervals, all rigging brackets and straps should be visually inspected for any damage, evidence of wear, structural deformation, or cracks. Particular attention should be paid to excessive wear at hoist hooking points and load support areas. Brackets or straps showing any kind of wear in these areas must not be used and should be discarded.

B. INSTALLATION

1. Remove unit from shipping carton. Leave top shipping skid on the unit as a spreader bar to prevent the rigging straps from damaging the unit. If the wood skid is not available, use a spreader bar of sufficient length to protect unit from damage.

2. Position the lifting bracket assembly around the base of the unit. Be sure the strap does not twist.

3. Place each of the 4 metal lifting brackets into the handholds in the composite pan.

4. Thread lifting bracket strapping around bottom perimeter of unit as follows:

a. Open lever of tension buckle (ratchet type). b. Feed strapping through tension buckle as shown in Fig.

8. c. Pull strapping through tension buckle unit taut. d. Snap lever down to lock strap in tension buckle. To

release strapping, squeeze safety latch, lift lever, and pull webbing outward.

5. Tighten the tension buckle until it is taut. Lifting brackets must be secure in the handholds.

6. Attach field-supplied clevis or hook of sufficient strength to hole in the lifting bracket. (See Fig. 9)

7. Attach the 2 safety straps directly to the clevis or hook at the 4 rigging brackets. DO NOT attach the safety straps to the lifting brackets. (See Fig. 9)

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UNIT ELECTRICAL CHARACTERISTICS

602B024 208/230-1-60 299 135.6 35.02 (889.5) 19.0 (482.6) 18.3 (463.6) 16.0 (406.4) 602B030 208/230-1-60,208/230-3-60 320 145.2 37.02 (940.3) 20.0 (508.0) 19.3 (489.0) 17.6 (447.0) 602B036 208/230-1-60,208/230-3-60, 460-3-60 328 148.8 37.02 (940.3) 20.0 (508.0) 19.0 (482.6) 16.5 (419.1)

→

UNIT WEIGHT

lb kg X Y Z

UNIT HEIGHT

IN. (MM)

”A”

Fig. 2—602B024-036 Unit Dimensions

—3—

C00160

CENTER OF GRAVITY

IN. (MM)

Page 4

UNIT ELECTRICAL CHARACTERISTICS

602B042 208/230-1-60, 208/230-3-60, 460-3-60 350 158.8 40.98 (1040.9) 21.0 (533.4) 20.5 (520.7) 16.6 (421.6) 602B048 208/230-1-60, 208/230-3-60, 460-3-60 355 161.0 40.98 (1040.9) 20.0 (508.0) 21.3 (539.8) 18.0 (457.2) 602B060 208/230-1-60, 208/230-3-60, 460-3-60 428 194.1 42.98 (1091.7) 21.0 (533.4) 20.0 (508.0) 17.6 (447.0)

UNIT WEIGHT

lb kg X Y Z

UNIT HEIGHT

IN. (MM)

”A”

Fig. 3—602B 042-060 Unit Dimensions

—4—

C00161

CENTER OF GRAVITY

IN. (MM)

Page 5

CORNER WEIGHTS (SMALL CABINET) CORNER WEIGHTS (LARGE CABINET)

Unit 24 30 36

Total Weight 299 320 328 Total Weight 350 355 428 Corner Weight 1 63 63 64 Corner Weight 1 75 76 92 Corner Weight 2 62 74 76 Corner Weight 2 49 50 60

Model 602B

→

8. Position lifting point directly over the unit’s center of

9. Lift unit. When unit is directly over the roof curb, remove

10. After the unit is placed on the roofcurb or mounting pad,

V. SELECT AND INSTALL DUCTWORK

The design and installation of the duct system must be in accordance with the standards of the NFPA for installation of non-residence type air conditioning and ventilating systems, NFPA 90A or residence-type, NFPA 90B and/or local codes and ordinances. Select and size ductwork, supply-air registers, and return air grilles according to ASHRAE (American Society of Heating, Refrigeration, and Air Conditioning Engineers) recommendations. The unit has duct flanges on the supply- and return-air openings on the side of the unit. When designing and installing ductwork, consider the following:

Corner Weight 3 56 56 58 Corner Weight 3 95 96 116 Corner Weight 4 118 127 130 Corner Weight 4 131 133 160

gravity.

the 2 safety straps. Lower the equipment onto the roof curb.

remove the top crating. On 602B060 units only, 2 wire ties fastened to the outdoor coils and reversing valve/accumulator assembly must be cut. Remove the left and front louver panels and corner post to access wire ties. The wire tie to be cut on the left is located approximately 4 in. down the tube sheet. The wire tie to be cut on the right is located approximately 6 in. down the tube sheet.

WARNING: For vertical supply and return units, tools or parts could drop into ductwork and cause serious injury or death. Install a 90 degree turn in the return ductwork between the unit and the conditioned space. If a 90 degree elbow cannot be installed, then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space. Units with electric heaters require 90 degree elbow in supply duct.

Model 602B

Fig. 4—Corner Weights

2. Avoid abrupt duct size increases and reductions. Abrupt

IMPORTANT: Use flexible connectors between ductwork and unit to prevent transmission of vibration. Use suitable gaskets to ensure weather tight and airtight seal. When electric heat is installed, use fireproof canvas (or similar heat resistant material) connector between ductwork and unit discharge connection. If flexible duct is used, insert a sheet metal sleeve inside duct. Heat resistant duct connector (or sheet metal sleeve) must extend 24-in. from electric heater element.

3. Size ductwork for cooling air quantity (cfm). The minimum

4. Seal, insulate, and weatherproof all external ductwork. Seal,

5. Secure all ducts to building structure. Flash, weatherproof,

A. CONVERTING HORIZONTAL DISCHARGE UNITS TO DOWNFLOW (VERTICAL) DISCHARGE UNITS

C00071

Unit 42 48 60

change in duct size adversely affects air performance.

air quantity for proper electric heater operation is listed in Table 2. Heater limit switches may trip at air quantities below those recommended.

insulate and cover with a vapor barrier all ductwork passing through conditioned spaces. Follow latest Sheet Metal and Air Conditioning Contractors National Association (SMACNA) and Air Conditioning Contractors Association (ACCA) minimum installation standards for residential heating and air conditioning systems.

and vibration-isolate duct openings in wall or roof according to good construction practices.

1. All units should have field-supplied filters or accessory filter rack installed in the return-air side of the unit. Recommended sizes for filters are shown in Table 1.

1. Open all electrical disconnects before starting any service work.

2. Remove horizontal duct covers to access bottom return and supply knock out panels.

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HVAC unit

Screw

(NOTE A)

*Gasketing

outer flange

Flashing field

supplied

Roofing material

field supplied

Cant strip

field supplied

base

Gasketing

inner flange*

Wood nailer*

Roofcurb*

Insulation (field

supplied)

Duct work

field supplied

HVAC unit

Screw

(NOTE A)

*Gasketing

outer flange

Flashing field

supplied

Roofing material

field supplied

Cant strip

field supplied

base

Gasketing

inner flange*

Duct work

field supplied

Wood nailer*

Roofcurb*

Insulation (field

supplied)

Roof

*Provided with roofcurb

Roof Curb for Small Cabinet

Note A: When unit mounting screw is used,

retainer bracket must also be used.

Supply opening (B x C)

/16"

B Typ .

C Typ .

*Provided with roofcurb

Roof Curb for Large Cabinet

Note A: When unit mounting screw is used,

retainer bracket must also be used.

R/A

Gasket around

Roof

S/A

duct

Short

Insulated deck pan

Return opening

(B X C)

UNIT SIZE ODS CATALOG NUMBER

602B024-036

602B042-060

NOTES:

1. Roof curb must be set up for unit being installed.

2. Seal strip must be applied, as required, to unit being installed.

3. Dimensions in ( ) are in millimeters.

4. Roof curb is made of 16-gage steel.

5. Table lists only the dimensions, per part number, that have changed.

6. Attach ductwork to curb (flanges of duct rest on curb).

7. Insulated panels: 1-in. thick fiberglass 1 lb. density.

8. Dimensions are in inches.

9. When unit mounting screw is used (see Note A), a retainer bracket must be used as well. This bracket must also be used when required by code for hurricane or seismic conditions. This bracket is available through Micrometl.

CPRFCURB006A00 8 (203) 11(279) 161/2 (419) 28-3/4 (730) CPRFCURB007A00 14 (356) 11(279) 161/2 (419) 28-3/4 (730) CPRFCURB008A00 8 (203) 16 3/16 (411) 17 3/8 (441) 40-1/4 (1022) CPRFCURB009A00 14 (356) 16 3/16 (411) 17 3/8 (441) 40-1/4 (1022)

→

Support

Long

Support

IN. (MM)

Fig. 5—Roof Curb Dimensions

3. Use a screwdriver and hammer to remove the panels in the bottom of the base pan.

NOTE: These panels are held in place with tabs similar to an electrical knockout.

4. Reinstall the horizontal duct covers (Fig. 11) to block off the horizontal air openings.

NOTE: Avoid abrupt duct size increases and reductions. Abrupt change in duct size adversely affects air performance.

Insulated deck pan

IN. (MM)

Gasket around

outer edge

IN. (MM)

VI. PROVIDE FOR CONDENSATE DISPOSAL NOTE: Ensure that condensate-water disposal methods comply

with local codes, restrictions, and practices. The 602B units dispose of condensate through a 3/4 in. NPT

female fitting that exits on the compressor end of the unit. Condensate water can be drained directly onto the roof in rooftop installations (where permitted) or onto a gravel apron in ground level installations. Install a field-supplied condensate trap at end of

C00076

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Page 7

OPTIONAL

RETURN

Fig. 6—Unit Leveling Tolerances

MAXIMUM ALLOWABLE

DIFFERENCE (in.)

A-B B-C A-C

1/4 1/4 1/4

C99065

AIR

OPENING

OPTIONAL

SUPPLY

AIR

OPENING

condensate connection to ensure proper drainage. Make sure that the outlet of the trap is at least 1 in. lower than the drain-pan condensate connection to prevent the pan from overflowing. Prime the trap with water. When using a gravel apron, make sure it slopes away from the unit.

If the installation requires draining the condensate water away from the unit, install a field-supplied 2 -in. trap at the condensate connection to ensure proper drainage. Condensate trap is available as an accessory or is field-supplied. Make sure that the outlet of the trap is at least 1 in. lower than the unit drain-pan condensate connection to prevent the pan from overflowing. Connect a drain trough using a minimum of field-supplied 3/4-in. PVC or fieldsupplied 3/4-in. copper pipe at outlet end of the 2-in. trap. (See Fig.

12) Do not undersize the tube. Pitch the drain trough downward at a slope of at least 1 in. every 10 ft. of horizontal run. Be sure to check the drain trough for leaks. Prime the trap at the beginning of the cooling season start-up.

VII. INSTALL ELECTRICAL CONNECTIONS

WARNING: The unit cabinet must have an uninter-

rupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of an electrical wire connected to the unit ground lug in the control compartment, or conduit approved for electrical ground when installed in accordance with NEC, ANSI/NFPA American National Standards Institute/National Fire Protection Association (latest edition) (in Canada, Canadian Electrical Code CSA C22.1) and local electrical codes. Failure to adhere to this warning could result in serious injury or death.

EVAP. COIL COND. COIL

Fig. 7—Slab Mounting Detail

HANDHOLD

HOOK

FEED

Fig. 8—Threading Belt

“A”

“B”

914-137" (36"-54")

SCALE 0.250

TIGHTEN STRAPPING SECURELY WITH TENSION BUCKLE

C99096

C99067

DETAIL A

—7—

INSTALL SAFETY STRAPS TO RIGGING CLEVIS AT 4 RIGGING BRACKETS

PLACE RIGGING BRACKET ASSEMBLY IN 4 HAND HOLES AND INSTALL TIE DOWN STRAP AROUND PERIMETER OF UNIT AND THROUGH

SEE DETAIL A

SPACE IN BRACKET ASSEMBLY

C99075

UNIT MAXIMUM WEIGHT A B

Size lb kg in. mm. in. mm. 602B024 321 145.6 19.0 482.6 18.25 463.6 602B030 342 155.2 20.0 508 19.25 489 602B036 350 158.8 20.0 508 19.0 482.6 602B042 372 168.8 21.0 533.4 20.5 520.7 602B048 377 171.0 20.0 508 21.25 539.8 602B060 450 204.2 21.0 533.4 20.0 508.0

Fig. 9—Suggested Rigging

Page 8

TABLE 1—PHYSICAL DATA—UNIT 602B

UNIT SIZE 602B024 602B030 602B036 602B042 602B048 602B060

NOMINAL CAPACITY (ton) 2 2-1/2 3 3-1/2 4 5

OPERATING WEIGHT (lb.) 299 320 328 350 355 428

COMPRESSOR QUANTITY 1

TYPE SCROLL COMPRESSOR

REFRIGERANT R-410A

REFRIGERANT METERING DEVICE Accurater

Refrigerant (R-410A) Quantity (lb.) 7.0 8.9 9.3 9.5 10.6 12.4

ORIFICE ID (in.) 0.061 0.061 0.067 0.073 0.076 0.088

ORIFICE OD (in.) 0.032 (2) 0.040 (2) 0.040 (2) 0.038 (2) 0.046 (2) 0.052 (2)

OUTDOOR COIL

Rows... Fins/in.

face area (sq. ft.)

OUTDOOR FAN

Nominal Airflow (CFM)

Diameter

Motor HP (RPM)

INDOOR COIL

Rows... Fins/in.

face area (sq. ft.)

INDOOR BLOWER

Nominal Airflow (CFM)

Size (in.)

Motor (HP)

HIGH-PRESSURE SWITCH (psig)

LOSS-OF-CHARGE/LOW-PRESSURE SWITCH

RETURN-AIR FILTERS (in.)*

* Required filter sizes shown are based on the larger of the ARI (Air Conditioning and Refrigeration Institute) rated cooling airflow or the heating airflow velocity of 300 ft/minute for throwaway type or 450 ft/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08 in. wg.

Cutout

Reset (Auto)

(Liquid Line) (psig)

Cutout

Reset (Auto)

throwaway

2...17

8.5

2350

1/8 (825)

3...15

3.7

800

10x10

1/4

20x20x1 20x20x1 20x24x1 24x30x1 24x30x1 24x30x1

2...17

10.3

2350

1/8 (825)

3...15

3.7

1000

10x10

1/4

2...17

10.3

2800

1/4 (1100)

4...15

3.7

1200

10x10

1/2

1/8 (825)

610±15 420±25

20±5

45±10

2...17

13.5

2500

3...15

4.7

1400

11x10

1/2

2...17

13.5

3300

1/4 (1100)

4...15

4.7

1600

11x10

1/2

2...17

15.4

3300

1/4 (1100)

4...15

5.7

1750

11x10

TABLE 2—MINIMUM AIRFLOW FOR RELIABLE ELECTRIC HEATER OPERATION (CFM)

SIZE 602B024 602B030 602B036 602B042 602B048 602B060

AIRFLOW (CFM) 800 1000* 1200 1400 1600 2000

* The 030 size models must be run on medium or high speed when used in conjunction with 15 kw electric heat accessory

A. HIGH-VOLTAGE CONNECTIONS

CAUTION: Failure to follow these precautions could

result in damage to the unit being installed:

1. Make all electrical connections in accordance with NEC ANSI/NFPA (latest edition) and local electrical codes governing such wiring. In Canada, all electrical connections must be in accordance with CSA standard C22.1 Canadian Electrical Code Part 1 and applicable local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between field-supplied electrical disconnect switch and unit. DO NOT USE ALUMINUM WIRE.

3. Be sure that high-voltage power to unit is within operating voltage range indicated on unit rating plate. On 3-phase units, ensure phases are balanced within 2 percent. Consult local power company for correction of improper voltage and/or phase imbalance.

4. Insulate low-voltage wires for highest voltage contained within conduit when low-voltage control wires are in same conduit as high-voltage wires.

5. Do not damage internal components when drilling through any panel to mount electrical hardware, conduit, etc.

The unit must have a separate electrical service with a fieldsupplied, waterproof disconnect switch mounted at, or within sight from the unit. Refer to the unit rating plate, NEC and local codes for maximum fuse/circuit breaker size and minimum circuit amps (ampacity) for wire sizing (See Table 3 for electrical data).

The field-supplied disconnect may be mounted on the unit over the high-voltage inlet hole (See Figs. 2 and 3).

If the unit has an electric heater, a second disconnect may be required. Consult the Installation, Start-Up, and Service Instructions provided with the accessory for electrical service connections.

Operation of unit on improper line voltage constitutes abuse and may cause unit damage that could affect warranty.

B. ROUTING POWER LEADS INTO UNIT

Use only copper wire between disconnect and unit. The highvoltage leads should be in a conduit until they enter the duct panel; conduit termination at the duct panel must be watertight. Run the high-voltage leads through the power entry knockout on the power entry side panel. (See Fig. 2 and 3 for location and size) When the leads are inside the unit, run leads up the high-voltage raceway to the line wiring splice box. (See Fig. 13 through 15) For single-

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Page 9

RETURN AIR

INDOOR THERMOSTAT

TOP COVER

FROM POWER SOURCE

DISCONNECT PER NEC*

*NEC - NATIONAL ELECTRICAL CODE

C00063

Fig. 10—Typical Installation

1” MIN.

TRAP OUTLET

2” MIN.

Duct Covers

C00092

phase units, connect leads to the black and yellow wires; for

Fig. 11—602B with Duct Covers On

3-phase units, connect the leads to the black, yellow, and blue wires. (See Fig. 18)

C. CONNECTING GROUND LEAD TO GROUND LUG

Refer to Fig. 18. Connect the ground lead to the chassis using the ground lug in the wiring splice box.

D. ROUTING CONTROL POWER WIRES (24-V)

Form a drip-loop with the thermostat leads before routing them into the unit. Route the thermostat leads through grommeted, low-voltage hole provided in unit into unit control power splice box. (See Fig. 2 and 3) Connect thermostat leads to unit control power leads as shown in Fig. 17.

C99013

Fig. 12—Condensate Trap

The unit transformer supplies 24-v power for complete system including accessory electrical heater. An automatic-reset circuit breaker (See Fig. 19) is provided in the 24-v circuit; see the caution label on the transformer or Fig. 20. Transformer is factory wired for 230-v operation. If supply voltage is 208-v, rewire transformer primary as described in Special Procedures for 208-v Operation section.

E. SPECIAL PROCEDURES FOR 208-V OPERATION

1. Be sure unit disconnect switch is open.

2. Disconnect the yellow primary lead (w 110) from the transformer. See unit wiring label. (See Fig. 13 and 14)

3. Connect the yellow primary lead (w110) to the transformer terminal labeled 200-v.

Indoor blower-motor speeds may need to be changed for 208-v operation. Refer to indoor airflow and airflow adjustments section.

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Page 10

TABLE 3—ELECTRICAL DATA—602B

UNIT 602B

SIZE

024 208/230–1–60 187 253 13.5 61.0 0.9 2.0

030

036

042

048

060

V-PH-HZ

208/230–1–60 187 253 15.9 73.0 0.9 2.1

208/230–3–60 187 253 10.9 63.0 0.9 2.1

208/230–1–60 187 253 16.9 83.0 1.6 4.1

208/230–3–60 187 253 12.2 77.0 1.6 4.1

460–3–60 414 506 5.8 35.0 0.9 2.0

208/230–1–60 187 253 22.4 105.0 0.9 4.1

208/230–3–60 187 253 15.4 88.0 0.9 4.1

460–3–60 414 506 7.3 39.0 0.9 2.0

208/230–1–60 187 253 21.3 109.0 1.6 4.1

208/230–3–60 187 253 14.7 91.0 1.6 4.1

460–3–60 414 506 7.2 46.0 0.9 2.0

208/230–1–60 187 253 27.6 158.0 1.5 6.2

208/230–3–60 187 253 19.2 137.0 1.5 6.2

460–3–60 414 506 9.0 62.0 0.9 3.2

VOLTAGE

RANGE

Min Max RLA LRA Nominal Kw* FLA UNIT MCA MAX FUSE OR CKT BKR MOCP

COMPRESSOR

ODFM

FLA

IDFM

FLA

ELECTRIC HEAT SINGLE POINT POWER SUPPLY

-/-

3.8/5.0

7.5/10.0

-/-

3.8/5.0

7.5/10.0

11.3/15.0

-/-

3.8/5.0

7.5/10.0

11.3/15.0

-/-

3.8/5.0

7.5/10.0

11.3/15.0

-/-

3.8/5.0

7.5/10.0

11.3/15.0

-/-

5.0

10.0

15.0

-/-

3.8/5.0

7.5/10.0

11.3/15.0

15.0/20.0

-/-

3.8/5.0

7.5/10.0

11.3/15.0

15.0/20.0

-/-

5.0

10.0

15.0

20.0

-/-

3.8/5.0

7.5/10.0

11.3/15.0

15.0/20.0

-/-

3.8/5.0

7.5/10.0

11.3/15.0

15.0/20.0

-/-

5.0

10.0

15.0

20.0

-/-

3.8/5.0

7.5/10.0

11.3/15.0

15.0/20.0

-/-

3.8/5.0

7.5/10.0

11.3/15.0

15.0/20.0

-/-

5.0

10.0

15.0

20.0

-/-

18.1/20.8

36.1/41.7

-/-

18.1/20.8

36.1/41.7

54.2/62.5

-/-

10.4/12.0

20.8/24.1

31.3/36.1

-/-

18.1/20.8

36.1/41.7

54.2/62.5

-/-

10.4/12.0

20.8/24.1

31.3/36.1

-/-

6.0

12.0

18.0

-/-

18.1/20.8

36.1/41.7

54.2/62.5

72.2/83.3

-/-

10.4/12.0

20.8/24.1

31.3/36.1

41.6/48.0

-/-

6.0

12.0

18.0

24.1

-/-

18.1/20.8

36.1/41.7

54.2/62.5

72.2/83.3

-/-

10.4/12.0

20.8/24.1

31.3/36.1

41.6/48.0

-/-

6.0

12.0

18.0

24.1

-/-

18.1/20.8

36.1/41.7

54.2/62.5

72.2/83.3

-/-

10.4/12.0

20.8/24.1

31.3/36.1

41.6/48.0

-/-

6.0

12.0

18.0

24.1

19.8/19.8

42.3/45.8

64.9/71.9

22.9/22.9

45.4/48.9

68.0/75.0

90.6/101.0

16.6/16.6

29.7/31.7

42.7/46.7

55.7/61.7

26.8/26.8

49.4/52.9

72.0/78.9

94.5/105.0

21.0/21.0

34.0/36.0

47.0/51.0

60.0/66.1

10.2

17.7

25.2

32.7

33.0/33.0

55.6/59.0

78.1/85.1

100.7/111.1

123.3/137.2

24.3/24.3

37.3/39.3

50.3/54.3

63.3/69.4

76.2/84.2

12.0

19.5

27.1

34.6

42.1

32.3/32.3

54.9/58.4

77.5/84.4

100.0/110.5

122.6/136.5

24.1/24.1

37.1/39.1

50.1/54.1

63.2/69.2

76.0/84.0

11.9

19.4

26.9

34.5

42.0

42.2/42.2

64.8/68.2

87.3/94.3

109.9/120.3

132.5/146.4

31.7/31.7

44.7/46.7

57.8/61.8

70.8/76.8

83.7/91.7

15.4

22.9

30.4

37.9

45.4

30/30 50/50

20/20 35/35 45/50

60/-

40/40 60/60

30/30

40/40 50/60

15 20 30

35 40/40 60/60

30/30 50/50 60/60

15 25 30 35 45

40/40

30/30 45/50 60/60

15 25 30 35 45

50/50

40/40 50/60

20 30 35 40 50

70/80

100/110

-/70

80/80

100/110

70/70

90/90 110/125 125/150

70/70 80/90

110/125 125/150

70/70 80/90

80/80

100/110 110/125 150/150

70/70 80/80

90/100

—10—

Page 11

→

C00152

Fig. 13—Wiring Schematics

—11—

Page 12

Fig. 14—Wiring Schematics

C00153

→

—12—

Page 13

→

C00154

Fig. 15—Wiring Schematics

—13—

Page 14

LEGEND

FLA — Full Load Amps LRA — Locked Rotor Amps MCA — Minimum Circuit Amps MOCP — Maximum Overcurrent Protection RLA — Rated Load Amps

*Heater capacity (KW) based on heater voltage of 208v, 240v, & 480v.

If power distribution voltage to unit varies from rated heater voltage, heater KW will vary accordingly.

NOTES:

1. In compliance with NEC (National Electrical Code) requirements for multimotor and combination load equipment (refer to NEC Articles 430 and 440), the overcurrent protective device for the unit shall be Power Supply fuse. The CGA (Canadian Gas Association) units may be fuse or circuit breaker.

2. Minimum wire size is based on 60 C copper wire. If other than 60 C wire is used, or if length exceeds wire length in table, determine size from NEC.

3. Unbalanced 3-Phase Supply Voltage

Never operate a motor where a phase imbalance in supply voltage is greater than 2%.

the percentage of voltage imbalance.

Use the following formula to determine

% Voltage imbalance

= 100 x

max voltage deviation from average voltage

average voltage

Fig. 16—Electrical Data Legend

EXAMPLE: Supply voltage is 460-3-60.

AB = 452 v BC = 464 v AC = 455 v

Average Voltage =

452 + 464 + 455

1371

= 457

Determine maximum deviation from average voltage.

(AB) 457 (BC) 464 (AC) 457

452=5v 457=7v 455=2v

Maximum deviation is 7 v. Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x

457

= 1.53%

This amount of phase imbalance is satisfactory as it is below the maximum allowable 2%.

IMPORTANT: If the supply voltage phase imbalance is more than 2%, contact your local electric utility company immediately.

C99024

THERMOSTAT

AND SUBBASE

Fig. 17—Control Connections

BRN

ORN

RED

GRN

YEL

WHT

UNIT CONTROL POWER

SPLICE BOX

C99056

GROUND

LEAD

SINGLE-PHASE

L1 CONNECTIONS TO DISCONNECT PER NEC

3-PHASE CONNECTIONS

NOTE: Use copper wire only.

LEGEND NEC – National Electrical Code

Field Wiring Splice Connections

Fig. 18—Line Power Connections

GROUND LUG

(IN SLPICE BOX)

BLK

YEL

BLU

C99057

—14—

Page 15

24 V Circuit Breaker

24 V olt Compartment

Fig. 19—Control Wiring Plate

TRANSFORMER CIRCUIT CONTAINS A MANUAL RESET OVERCURRENT PROTECTOR

C99070

PRE-START-UP

WARNING: Failure to observe the following warnings

could result in serious personal injury or death:

1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system.

2. Do not operate compressor or provide any electric power to unit unless compressor terminal cover is in place and secured.

3. Do not remove compressor terminal cover until all electrical sources are disconnected.

4. Relieve and recover all refrigerant from both high- and low-pressure sides of system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals.

5. Never attempt to repair soldered connection while refrigerant system is under pressure.

6. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective goggles and proceed as follows: a. Shut off electrical power to unit. b. Relieve and reclaim all refrigerant from system

using both high- and low-pressure ports.

c. Cut component connecting tubing with tubing cutter

and remove component from unit.

d. Carefully unsweat remaining tubing stubs when

necessary. Oil can ignite when exposed to torch flame.

IT WILL NOT AUTOMATICALLY RESET DISCONNECT POWER PRIOR TO

SERVICING THIS COMPARTMENT MUST BE CLOSED

EXCEPT WHEN SERVICING

Fig. 20—Transformer Label

C99058

Use the Start-Up Checklist supplied at the end of this book and proceed as follows to inspect and prepare the unit for initial start-up:

1. Remove all access panels.

2. Read and follow instructions on all DANGER, WARNING, CAUTION, and INFORMATION labels attached to, or shipped with, unit.

3. Make the following inspections: a. Inspect for shipping and handling damages such as

broken lines, loose parts, disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections and

on unit base. Detecting oil generally indicates a refrigerant leak. Leak-test all refrigerant tubing connections using electronic leak detector, or liquid-soap solution. If a refrigerant leak is detected, see following Check for Refrigerant Leaks section.

c. Inspect all field and factory-wiring connections. Be sure

that connections are completed and tight.

d. Inspect coil fins. If damaged during shipping and han-

dling, carefully straighten fins with a fin comb.

4. Verify the following conditions: a. Make sure that outdoor-fan blade is correctly positioned

in fan orifice. b. Make sure that air filter(s) is in place. c. Make sure that condensate drain pan and trap are filled

with water to ensure proper drainage. d. Make sure that – on the 060 size, only – the 2 wire ties

fastened to the outdoor coils and reversing valve/accumulator have been removed.

e. Make sure that all tools and miscellaneous loose parts

have been removed.

5. Compressors are internally spring mounted. Do not loosen or remove compressor hold-down bolts.

—15—

Page 16

6. Each unit system has 2 Schrader-type ports, one low-side Schrader fitting located on the suction line, and one high-side Schrader fitting located on the compressor discharge line. Be sure that caps on the ports are tight.

MOTOR

1/8" MAX BETWEEN MOTORAND FAN HUB

MOTOR SHAFT

FAN GRILLE

C99009

Fig. 21—Fan Blade Clearance

START-UP

Using the Start-Up Checklist supplied at the end of this book, proceed as follows:

I. CHECK FOR REFRIGERANT LEAKS

Locate and repair refrigerant leaks and charge the unit as follows:

1. Use both high- and low-pressure ports to relieve system pressure and reclaim remaining refrigerant.

2. Repair leak following accepted practices.

NOTE: Install a bi-flow filter drier whenever the system has been opened for repair.

3. Check system for leaks using an approved method.

4. Evacuate refrigerant system and reclaim refrigerant if no additional leaks are found.

5. Charge unit with R-410A refrigerant, using a volumetriccharging cylinder or accurate scale. Refer to unit rating plate for required charge.

II. START-UP ADJUSTMENTS

Complete the required procedures given in the Pre-Start-Up section before starting the unit. Do not jumper any safety devices when operating the unit. Do not operate the unit in Cooling mode when the outdoor temperature is below 40°F (unless accessory low-ambient kit is installed). Do not rapid-cycle the compressor. Allow 5 min. between “on” cycles to prevent compressor damage.

A. CHECKING COOLING AND HEATING CONTROL OPERATION

Start and check the unit for proper control operation as follows:

1. Place room thermostat SYSTEM switch or MODE control in OFF position. Observe that blower motor starts when FAN mode is placed in FAN ON position and shuts down within 60 sec (030-060 size) or 30 sec (024 size) when FAN MODE switch is placed in AUTO position.

2. Place system switch or MODE control in HEAT position. Set control above room temperature. Observe that compressor, outdoor fan, and indoor blower motors start. Observe that heating cycle shuts down when control setting is satisfied.

3. When using an automatic changeover room thermostat, place both SYSTEM or MODE control and FAN mode switches in AUTO positions. Observe that unit operates in Cooling mode when temperature control is set to “call for Cooling” (below room temperature), and unit operates in Heating mode when temperature control is set to “call for Heating” (above room temperature).

IMPORTANT: Three-phase, scroll compressors are direction oriented. Unit must be checked to ensure proper compressor 3-phase power lead orientation. If not corrected within 5 minutes,

the internal protector will shut off the compressor. The 3-phase power leads to the unit must be reversed to correct rotation. When turning backwards, the difference between compressor suction and discharge pressures may be dramatically lower than normal.

B. CHECKING AND ADJUSTING REFRIGERANT CHARGE

The refrigerant system is fully charged with R-410A refrigerant and is tested and factory sealed.

NOTE: Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R-410A charge. The charging label and the tables shown refer to system temperatures and pressures in Cooling mode, only. A refrigerant charging label is attached to the outside of the service access door. If charge level is suspect in Heating mode, reclaim all refrigerant and charge to nameplate amount. (This information may be obtained from the physical data table also.) The charging label and the tables shown refer to system temperatures and pressures in Cooling mode only. A refrigerant charging label is attached to the outside of the service access door. If charge level is suspect in Heating mode, reclaim all refrigerant and charge to nameplate amount. (This information may be obtained from the physical data table also.)

IMPORTANT: When evaluating the refrigerant charge, an indicated adjustment to the specified factory charge must always be very minimal. If a substantial adjustment is indicated, an abnormal condition exists somewhere in the cooling system, such as insufficient airflow across either coil or both coils.

C. REFRIGERANT CHARGE

The amount of refrigerant charge is listed on the unit nameplate and/or the physical data table. Refer to the Refrigeration Service Techniques Manual, Refrigerants Section.

D. NO CHARGE

Check for leak. Use standard evacuating techniques. After evacuating system, weigh in the specified amount of refrigerant (refer to system data plate).

E. LOW CHARGE COOLING

Use Cooling Charging Charts (Figs. 25-30). Vary refrigerant until the conditions of the chart are met. Note that charging charts are different from type normally used. Charts are based on charging the units to correct superheat for the various operating conditions. Accurate pressure gauge and temperature sensing devices are required. Connect the pressure gauge to the service port on the suction line. Mount the temperature sensing device on the suction line and insulate it so that the outdoor ambient does not affect the reading. Indoor air CFM must be within the normal operating range of the unit.

F. TO USE COOLING CHARGING CHARTS

Take the outdoor ambient temperature and read the suction pressure gauge. Refer to the chart to determine what the suction temperature should be.

NOTE: If the problem causing the inaccurate readings is a refrigerant leak, refer to Check for Refrigerant Leaks section.

G. INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS

CAUTION: For heating and cooling operation, the rec-

ommended airflow is 350 to 450 cfm for each 12,000 Btuh of rated cooling capacity. For units with optional electric heat, the airflow must not be reduced below the levels stated in Table 2.

Table 4 shows both heating and cooling airflows at various external static pressures. Refer to these tables to determine the airflow for the system being installed.

—16—

Page 17

HPS

ACCUMULATOR

COMPRESSOR

LEGEND

HPS – High Pressure Switch LCS – Loss of Charge Switch

Accurater

Metering Device

Arrow indicates direction of flow

OUTDOOR COIL

Metering

Position

Bypass

Position

LCS

Fig. 22—Typical Heat Pump Operation, Heating Mode

INDOOR COIL

C00095

OUTDOOR COIL

HPS

ACCUMULATOR

COMPRESSOR

LEGEND

HPS – High Pressure Switch LCS – Loss of Charge Switch

Accurater

Metering Device

Arrow indicates direction of flow

Fig. 23—Typical Heat Pump Operation, Cooling Mode

NOTE: Be sure that all supply-and return-air grilles are open, free

from obstructions, and adjusted properly. Airflow can be changed by changing the lead connection of the

blower motor. Unit 602B three-speed motors (except sizes 030 and 048) are

factory wired for low speed operation. Units 602B 030 and 048 are factory wired for medium speed. For 208/230-v Motors:— The motor leads are color-coded as follows: 3-SPEED Black = high speed Blue = medium speed Red = low speed To change the speed of the blower motor (BM), remove the fan motor speed leg lead from the blower relay (BR). This wire is attached to IGC terminal BM for single-phase and 3-phase units. To change the speed, remove and replace with lead for desired blower motor speed. Insulate the removed lead to avoid contact with chassis parts.

INDOOR COIL

C00096

Bypass

Position

Metering

Position

LCS

For 460-v GE Motors—The motor leads are color coded as follows: 3-SPEED Black = high Violet = jumper Orange = medium Red = low

To change the speed of the blower motor (BM), remove fan motor speed lead from the blower relay (BR) and replace with the lead for the desired blower motor speed. The motor speed lead is attached to terminal BM. For low and medium speeds, black must be connected to the jumper wire. Insulate removed lead end to avoid contact with chassis parts. To select high speed on 460-v GE motors, separate the black female quick connect (QC) from the jumper lead male quick connect (QC) and connect the black lead to the BR. Insulate the jumper to avoid contact with any chassis parts.

—17—

Page 18

TABLE 4—WET COIL AIR DELIVERY

UNIT 602B 024-060 (DEDUCT 10 PERCENT FOR 208-V)*

UNIT MOTOR SPEED

Low

024

030

036

042

048

060

* Air delivery values are based on operating voltage of 230-v or 460-v, wet coil, without filter or electric heater. Deduct filter and electric heater pressure drop (see Tables

5 and 6) to obtain static pressure available for ducting.

NOTES:

1. Do not operate the unit at a cooling airflow that is less than 350 cfm for each 12,000 Btuh of rated cooling capacity. Evaporator coil frosting may occur at airflows below this point.

2. Dashes indicate portions of table that are beyond the blower motor capacity or are not recommended.

3. Deduct 10 percent for 208-v.

Med

High

Low

Med

High

Low

Med

High

Low

Med

High

Low

Med

High

Low

Med

High

Watts 275 273 271 270 -------

Cfm923844754669-------

Watts - - - 359 353 350 347 341 - - -

Cfm - - - 941 876 814 737 622 - - -

Watts ------447439431423-

Cfm------968869765659-

Watts 276 276 272 --------

Cfm963929781--------

Watts 375 377 371 362 354 350 - - - - -

Cfm 1202 1170 1079 976 884 807 - - - - -

Watts ----469449435428---

Cfm----1174 988 828 718 - - -

Watts 462 451 431 411 394 381 - - - - -

Cfm 1374 1290 1205 1116 1020 916 - - - - -

Watts 523 506 490 471 449 426 - - - - -

Cfm 1500 1408 1301 1190 1082 977 - - - - -

Watts - 645 628 610 595 584 575 - - - -

Cfm - 1474 1369 1267 1169 1069 962 - - - -

Watts 660 639 524 611 598 583 564 541 518 495 473

Cfm 1701 1659 1618 1576 1531 1481 1425 1363 1293 1223 1154

Watts -----704675645614582550

Cfm-----1701 1631 1550 1460 1361 1256

Watts -------806777749726

Cfm-------1708 1614 1521 1435

Watts 620 600 586 574 562 548 530 510 487 - -

Cfm 1662 1621 1581 1540 1496 1447 1392 1331 1263 - -

Watts 763 747 729 709 686 661 634 606 577 547 517

Cfm 1917 1868 1822 1774 1722 1662 1594 1515 1427 1330 1227

Watts - - - 852 832 809 784 757 730 704 682

Cfm - - - 1982 1914 1839 1757 1669 1577 1486 1402

Watts 597 592 578 526 460 452 445 - - - -

Cfm 2265 2190 2101 2033 1974 1869 1614 - - - -

Watts 754 730 707 687 671 658 646 630 603 558 486

Cfm 2383 2282 2202 2134 2070 2005 1935 1858 1771 1667 1576

Watts 901 876 856 836 813 785 755 723 696 681 687

Cfm 2480 2383 2301 2233 2175 2122 2066 1998 1910 1788 1619

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

EXTERNAL STATIC PRESSURE (IN. WG)

TABLE 5—FILTER PRESSURE DROP TABLE (IN. WG)

FILTER SIZE

20X20X1 0.05 0.07 0.08 0.10 0.12 0.13 0.14 0.15 ——————————— 20X24X1 ————0.09 0.10 0.11 0.13 0.14 0.15 0.16 ———————— 24X30X1 —————— —0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16 0.17 0.18

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300

III. DEFROST CONTROL A. Quiet Shift

Quiet Shift is a field-selectable defrost mode, which will eliminate occasional noise that could be heard at the start of defrost cycle and restarting of heating cycle. It is selected by placing DIP switch 3 (on defrost board) in ON position.

When Quiet Shift switch is placed in ON position, and a defrost is initiated, the following sequence of operation will occur. Reversing valve will energize, outdoor fan will turn off, compressor will turn off for 30 sec and then turn back on to complete defrost. At

CFM

the start of heating after conclusion of defrost reversing valve will de-energize, compressor will turn off for another 30 sec, and the outdoor fan will stay off for 40 sec, before starting in the Heating mode.

B. Defrost

The defrost control is a time/temperature control which includes a field-selectable time period (DIP switch 1 and 2 on the board) between defrost cycles of 30, 60, 90, or 120 minutes (factory set at 30 minutes).

—18—

Page 19

→

TABLE 6—ELECTRIC HEAT PRESSURE DROP TABLE

SMALL CABINET: 024-036CFM

500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600

5kw 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.02 0.04 0.06 0.07 10 kw 0.00 0.00 0.00 0.00 0.00 0.02 0.04 0.06 0.07 0.09 0.10 0.11 15 kw 0.00 0.00 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 20 kw 0.00 0.00 0.02 0.04 0.06 0.08 0.09 0.11 0.13 0.15 0.17 0.19

ELECTRIC HEAT PRESSURE DROP TABLE

LARGE CABINET: 042-060

CFM

1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500

5kw 0.00 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 10 kw 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 15 kw 0.00 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 20 kw 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16

Balance Point Worksheet

Based on Indoor Entering Air of 70 F and Rated CFM

Building Heat Loss, 1000BTUH

Unit Integrated Heating Capacity (x1000BTUH)

-100 1017203040475060 Outdoor Air Temp (Deg F)

Fig. 24—602B Balance Point Worksheet

To initiate a forced defrost, two options are available depending on the status of the defrost thermostat. If defrost thermostat is closed, speedup pins (J1) must be shorted by placing a flat head screw driver in between for 5 sec and releasing, to observe a complete defrost cycle. When the Quiet Shift switch is selected, compressor will be turned off for two 30 sec intervals during this complete defrost cycle, as explained previously. When Quiet Shift switch is in factory default OFF position, a normal and complete defrost cycle will be observed. If defrost thermostat is in open position, and speedup pins are shorted (with a flat head screw driver) for 5 sec and released,a short defrost cycle will be observed (actual length is dependent

024 030 036 042 048 060

C00138

upon the selected Quiet Shift position). When Quiet Shift switch is in ON position, the length of defrost is 1 minute (30 sec compressor off period followed by 30 sec of defrost with compressor operation). On return to heating operation, compressor will again turn off for an additional 30 sec and the outdoor fan for 40 sec. When the Quiet Shift is in OFF position, only a brief 30 sec cycle will be observed. If it is desirable to observe a complete defrost in warmer weather, the defrost thermostat must be closed as follows.

1. Turn off power to outdoor unit.

2. Disconnect outdoor fan motor lead from OF2 on control board. (See Fig. 19) Tape to prevent grounding.

—19—

Page 20

(024) 60 Hz COOLING CHARGING CHART

For use with units using R410a Refrigerant

-7 -1 4 10 15 21 26

180

170

160

150

140

130

120

110

SUCTION LINE PRESSURE (PSIG)

100

20 30 40 50 60 70 80

SUCTION LINE TEMPERATURE (DEG. C)

SUCTION LINE TEMPERATURE (DEG. F)

1152

1052

952

852

752

652

552

OUTDOOR TEMP

F C 125 52

115 46 105 41 95 35 85 29 75 24 65 18 55 13 45 7

SUCTION LINE PRESSURE (kPa)

50JZ500066

Fig. 25—Cooling Charging Chart, 602B 024 Units

C00082

(030) 60 Hz COOLING CHARGING CHART For Use with Units Using R410a Refrigerant

-7 -1 4 10152126

180

170

160

150

SUCTION LINE TEMPERATURE (DEG. C)

1173

1104

1035

OUTDOOR

TEMP

F C

125 52

115 46 105 41

95 35

85 29

75 24

140

966

65 18

130

897

55 13

120

SUCTION LINE PRESSURE (PSIG)

110

100

20 30 40 50 60 70 80

SUCTION LINE TEMPERATURE (DEG. F)

828

759

690

621

552

45 7

SUCTION LINE PRESSURE (KILOPASCALS)

Fig. 26—Cooling Charging Chart, 602B 030Units

50JZ500067

C00083

(036) 60 Hz COOLING CHARGING CHART For Use with Units Using R410a Refrigerant

-7 -1 4 10 15 21 26

180

170

160

SUCTION LINE TEMPERATURE (DEG. C)

OUTDOOR

TEMP

F C

1173

125 52

115 46

1104

105 41

150

140

130

120

SUCTION LINE PRESSURE (PSIG)

110

100

20 30 40 50 60 70 80

SUCTION LINE TEMPERATURE (DEG. F)

1035

95 35

85 29

966

75 24

897

65 18

828

55 13

SUCTION LINE PRESSURE (KILOPASCALS)

759

45 7

690

621

552

50JZ500068

Fig. 27—Cooling Charging Chart, 602B 036 Units

C00084

(042) 60 Hz COOLING CHARGING CHART

For use with units using R410a Refrigerant

-7-1 4 10152126

180

170

160

150

140

130

120

SUCTION LINE PRESSURE (PSIG)

110

100

20 30 40 50 60 70 80

SUCTION LINE TEMPERATURE (DEG. C)

SUCTION LINE TEMPERATURE (DEG. F)

1173

1104

1035

966

897

828

759

690

621

552

OUTDOOR TEMP

F C 125 52

115 46 105 41 95 35 85 29 75 24 65 18 55 13 45 7

SUCTION LINE PRESSURE (KILOPASCALS)

50JZ500069

Fig. 28—Cooling Charging Chart, 602B 042 Units

C00085

—20—

Page 21

(048) 60Hz COOLING CHARGING CHART

For use with units using R410a Refrigerant

-7 -1 4 10 15 21 26

180

170

160

150

140

130

120

110

SUCTION LINE PRESSURE (PSIG)

100

30 40 50 60 70 80

SUCTION LINE TEMPERATURE (DEG. C)

SUCTION LINE TEMPERATURE (DEG. F)

1173

1104

1035

966

897

828

759

690

621

552

OUTDOOR TEMP

F C 125 52

115 46 105 41 95 35 85 29 75 24 65 18 55 13 45 7

SUCTION LINE PRESSURE (KILOPASCALS)

(060) 60 Hz COOLING CHARGING CHART

For use with units using R410a Refrigerant

-7-1 4 10152126

180

170

160

150

140

130

120

SUCTION LINE PRESSURE (PSIG)

110

100

20 30 40 50 60 70 80

SUCTION LINE TEMPERATURE (DEG. C)

1173

1104

1035

966

897

828

759

690

621

552

SUCTION LINE TEMPERATURE (DEG. F)

OUTDOOR TEMP

F C 125 52

115 46

)

105 41 95 35

PASCALS O IL

85 29

75 24 65 18 55 13 45 7

SUCTION LINE PRESSURE (

50JZ500070

Fig. 29—Cooling Charging Chart, 602B 048 Units

C00086

3. Restart unit in Heating mode, allowing frost to accumulate on outdoor coil.

4. After a few minutes in Heating mode, liquid line temperature should drop below closing point of defrost thermostat (approximately 30°F).

NOTE: Unit will remain in defrost until defrost thermostat reopens at approximately 80°F coil temperature at liquid line or remainder of defrost cycle time.

5. Turn off power to outdoor and reconnect fan motor lead to OF2 on control board after above forced defrost cycle.

MAINTENANCE

To ensure continuing high performance, and to minimize the possibility of premature equipment failure, periodic maintenance must be performed on this equipment. This heat pump unit should be inspected at least once each year by a qualified service person. To troubleshoot unit, refer to Table 7. NOTE TO EQUIPMENT OWNER: Consult your local dealer about the availability of a maintenance contract.

WARNING: The ability to properly perform maintenance on this equipment requires certain expertise, mechanical skills, tools and equipment. If you do not possess these, do not attempt to perform any maintenance on this equipment, other than those procedures recommended in the User’s Manual. FAILURE TO HEED THIS WARNING COULD RESULT IN SERIOUS INJURY OR DEATH AND POSSIBLE DAMAGE TO THIS EQUIPMENT.

50JZ500071

Fig. 30—Cooling Charging Chart, 602B 060 Units

C00087

WARNING: Failure to follow these warnings could result in serious injury or death:

1. Turn off electrical power to the unit before performing any maintenance or service on this unit.

2. Use extreme caution when removing panels and parts. As with any mechanical equipment, personal injury can result from sharp edges.

3. Never place anything combustible either on, or in contact with, the unit.

CAUTION: Errors made when reconnecting wires may cause improper and dangerous operation. Label all wires prior to disconnecting when servicing.

The minimum maintenance requirements for this equipment are as follows:

1. Inspect air filter(s) each month. Clean or replace when necessary.

2. Inspect indoor coil, drain pan, and condensate drain each cooling season for cleanliness. Clean when necessary.

3. Inspect blower motor and wheel for cleanliness each cooling season. Clean when necessary.

4. Check electrical connections for tightness and controls for proper operation each cooling season. Service when necessary.

I. AIR FILTER IMPORTANT: Never operate the unit without a suitable air filter

in the return-air duct system. Always replace the filter with the same dimensional size and type as originally installed. See Table 1 for recommended filter sizes. Inspect air filter(s) at least once each month and replace (throwaway-type) or clean (cleanable-type) at least twice during each cooling season and twice during the heating season, or whenever the filter becomes clogged with dust and lint.

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Page 22

O R W

Y C

SPEEDUP

T2 C C O

DFT

T1 Y

DFT

INTERVAL TIMER

OFF

SHIFT

OF1

OF2

120

QUIET

Speedup Pins

II. INDOOR BLOWER AND MOTOR NOTE: All motors are prelubricated. Do not attempt to lubricate

these motors. For longer life, operating economy, and continuing efficiency,

clean accumulated dirt and grease from the blower wheel and motor annually.

WARNING: Disconnect and tag electrical power to the unit before cleaning and lubricating the blower motor and wheel. Failure to adhere to this warning could cause personal injury or death.

III. OUTDOOR COIL, INDOOR COIL, AND CONDENSATE DRAIN PAN

Inspect the condenser coil, evaporator coil, and condensate drain pan at least once each year.

The coils are easily cleaned when dry; therefore, inspect and clean the coils either before or after each cooling season. Remove all obstructions, including weeds and shrubs, that interfere with the airflow through the condenser coil.

Straighten bent fins with a fin comb. If coated with dirt or lint, clean the coils with a vacuum cleaner, using the soft brush attachment. Be careful not to bend the fins. If coated with oil or grease, clean the coils with a mild detergent-and-water solution. Rinse coils with clear water, using a garden hose. Be careful not to splash water on motors, insulation, wiring, or air filter(s). For best

Quiet Shift

Fig. 31—Defrost Control

CESO130076–00

Defrost interval DIP switches

A99442

results, spray condenser coil fins from inside to outside the unit. On units with an outer and inner condenser coil, be sure to clean between the coils. Be sure to flush all dirt and debris from the unit base.

Inspect the drain pan and condensate drain line when inspecting the coils. Clean the drain pan and condensate drain by removing all foreign matter from the pan. Flush the pan and drain trough with clear water. Do not splash water on the insulation, motor, wiring, or air filter(s). If the drain trough is restricted, clear it with a “plumbers snake” or similar probe device.

IV. OUTDOOR FAN

CAUTION: Keep the condenser fan free from all ob-

structions to ensure proper cooling operation. Never place articles on top of the unit. Damage to unit may result.

1. Remove 6 screws holding outdoor grille and motor to top cover.

2. Turn motor/grille assembly upside down on top cover to expose fan blade.

3. Inspect the fan blades for cracks or bends.

4. If fan needs to be removed, loosen setscrew and slide fan off motor shaft.

5. When replacing fan blade, position blade so that the hub is 1/8 in. away from the motor end (1/8 in. of motor shaft will be visible). (See Fig. 21)

—22—

Page 23

6. Ensure that setscrew engages the flat area on the motor shaft when tightening.

7. Replace grille.

V. ELECTRICAL CONTROLS AND WIRING

Inspect and check the electrical controls and wiring annually. Be sure to turn off the electrical power to the unit.

Remove access panel to locate all the electrical controls and wiring. Check all electrical connections for tightness. Tighten all screw connections. If any smoky or burned connections are noticed, disassemble the connection, clean all the parts, restrip the wire end and reassemble the connection properly and securely.

After inspecting the electrical controls and wiring, replace all the panels. Start the unit, and observe at least one complete cooling cycle to ensure proper operation. If discrepancies are observed in operating cycle, or if a suspected malfunction has occurred, check each electrical component with the proper electrical instrumentation. Refer to the unit wiring label when making these checkouts.

VI. REFRIGERANT CIRCUIT

Inspect all refrigerant tubing connections and the unit base for oil accumulation annually. Detecting oil generally indicates a refrigerant leak.

If oil is detected or if low performance is suspected, leak-test all refrigerant tubing using an electronic leak detector, or liquid-soap solution. If a refrigerant leak is detected, refer to Check for Refrigerant Leaks section.

If no refrigerant leaks are found and low performance is suspected, refer to Checking and Adjusting Refrigerant Charge section.

IX. PRESSURE SWITCHES

Pressure switches are protective devices wired into control circuit (low voltage). They shut off compressor if abnormally high or low pressures are present in the refrigeration circuit. These pressure switches are specifically designed to operate with Puron (R-410A) systems. R-22 pressure switches must not be used as replacements for the Puron (R-410A) system.

X. LOSS OF CHARGE SWITCH

This switch is located on the liquid line and protects against low suction pressures caused by such events as loss of charge, low airflow across indoor coil, dirty filters, etc. It opens on a pressure drop at about 20 psig. If system pressure is above this, switch should be closed. To check switch:

1. Turn off all power to unit.

2. Disconnect leads on switch.

3. Apply ohm meter leads across switch. You should have continuity on a good switch.

NOTE: Because these switches are attached to refrigeration system under pressure, it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists. If switch must be removed, remove and recover all system charge so that pressure gauges read 0 psi. Never open system without breaking vacuum with dry nitrogen.

XI. HIGH-PRESSURE SWITCH

The high-pressure switch is located in the discharge line and protects against excessive condenser coil pressure. It opens at 610 psig.

High pressure may be caused by a dirty outdoor coil, failed fan motor, or outdoor air recirculation.

To check switch:

1. Turn off all power to unit.

2. Disconnect leads on switch.

3. Apply ohm meter leads across switch. You should have continuity on a good switch.

XII. COPELAND SCROLL COMPRESSOR (PURON REFRIGERANT)

The compressor used in this product is specifically designed to operate with Puron (R-410A) refrigerant and cannot be interchanged.

The compressor is an electrical (as well as mechanical) device. Exercise extreme caution when working near compressors. Power should be shut off, if possible, for most troubleshooting techniques. Refrigerants present additional safety hazards.

Fig. 32—Refrigerant Circuit

VII. INDOOR AIRFLOW

The heating and/or cooling airflow does not require checking unless improper performance is suspected. If a problem exists, be

sure that all supply- and return-air grilles are open and free from obstructions, and that the air filter is clean. When necessary, refer

to Indoor Airflow and Airflow Adjustments section to check the system airflow.

VIII. METERING DEVICES–ACCURATER PISTON

This metering device is a fixed orifice and is contained in the brass hex-body in the liquid line feeding the indoor and outdoor coils.

WARNING: Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils. Failure to follow this warning can cause a fire, serious injury, or death.

C99097

The scroll compressor pumps refrigerant throughout the system by the interaction of a stationary and an orbiting scroll. The scroll compressor has no dynamic suction or discharge valves, and it is more tolerant of stresses caused by debris, liquid slugging, and flooded starts. The compressor is equipped with an anti-rotational device and an internal pressure relief port. The anti-rotational device prevents the scroll from turning backwards and replaces the need for a cycle protector. The pressure relief port is a safety device, designed to protect against extreme high pressure. The relief port has an operating range between 550 and 625 psi differential pressure.

The Copeland scroll compressor uses Mobil 3MA POE oil. This is the only oil allowed for oil recharge.

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Page 24

XIII. REFRIGERANT SYSTEM

This step covers the refrigerant system of the 602B, including the compressor oil needed, servicing systems on roofs containing synthetic materials, the filter drier and refrigerant charging.

A. Refrigerant

CAUTION: This system uses Puron (R-410A) refriger-

ant which has higher operating pressures than R-22 and other refrigerants. No other refrigerant may be used in this system. Gauge set, hoses, and recovery system must be designed to handle Puron. If you are unsure consult the equipment manufacturer. Failure to use Puron compatible servicing equipment or replacement components may result in property damage or injury.

B. Compressor Oil

The compressor in this system uses a polyolester (POE) oil, Mobil 3MA POE. This oil is extremely hygroscopic, meaning it absorbs water readily. POE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants. Take all necessary precautions to avoid exposure of the oil to the atmosphere.

C. Servicing Systems on Roofs with Synthetic Materials

POE (polyolester) compressor lubricants are known to cause long term damage to some synthetic roofing materials.

Exposure, even if immediately cleaned up, may cause embrittlement (leading to cracking) to occur in one year or more. When performing any service that may risk exposure of compressor oil to the roof, take appropriate precautions to protect roofing. Procedures which risk oil leakage include, but are not limited to, compressor replacement, repairing refrigerant leaks, replacing refrigerant components such as filter drier, pressure switch, metering device, coil, accumulator, or reversing valve.

SYNTHETIC ROOF PRECAUTIONARY PROCEDURE

1. Cover extended roof working area with an impermeable polyethylene (plastic) drip cloth or tarp. Cover an approximate 10 X 10 ft. area.

2. Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run-offs, and protect drop cloth from tears caused by tools or components.

3. Place terry cloth shop towel inside unit immediately under component(s) to be serviced and prevent lubricant run-offs through the louvered openings in the base pan.

4. Perform required service.

5. Remove and dispose of any oil contaminated material per local codes.

D. Liquid Line Filter Drier

The biflow filter drier is specifically designed to operate with Puron. Use only factory-authorized components. Filter drier must be replaced whenever the refrigerant system is opened. When removing a filter drier, use a tubing cutter to cut the drier from the system. Do not unsweat a filter drier from the system. Heat from unsweating will release moisture and contaminants from drier into system.

E. Puron (R-410A) Refrigerant Charging

Refer to unit information plate and charging chart. Some R-410A refrigerant cylinders contain a dip tube to allow liquid refrigerant to flow from cylinder in upright position. For cylinders

equipped with a dip tube, charge Puron units with cylinder in upright position and a commercial metering device in manifold hose. Charge refrigerant into suction-line.

XIV. SYSTEM INFORMATION A. Time-Delay Relay

The Time-Delay Relay (TDR) is a solid-state control, recycle delay timer which keeps indoor blower operating for 60 sec on 030-060 sizes or 30 sec on 024 size after thermostat is satisfied. This delay enables blower to remove residual cooling in coil after compression shutdown, thereby improving efficiency of system. The sequence of operation is that on closure of wall thermostat and at end of a fixed on delay of 1 sec, fan relay is energized. When thermostat is satisfied, an off delay is initiated. When fixed delay of 60 ± 5 sec or 30 ± 5 sec is completed, fan relay is de-energized and fan motor stops. If wall thermostat closes during this delay, TDR is reset and fan relay remains energized. TDR is a 24v device that operates within a range of 15v to 30v and draws about 0.5 amps. If the blower runs continuously instead of cycling off when the fan switch is set on AUTO, the TDR is probably defective and must be replaced.

B. Loss of Charge Switch

The loss of charge switch is a protective device wired into control circuit (low voltage). It shuts off the compressor if abnormally low pressures are present in the refrigeration circuit.

C. Check Defrost Thermostat

There is a liquid header with a brass distributor and feeder tube going into outdoor coil. At the end of 1 of the feeder tubes, there is a 3/8-in. OD stub tube approximately 3 in. long. (See Fig. 33) The defrost thermostat should be located on stub tube. Note that there is only 1 stub tube used with liquid header, and on most units it is the bottom circuit.

FEEDER TUBE

STUB TUBE

DEFROST THERMOSTAT

C99029

Fig. 33—Defrost Thermostat

The defrost thermostat signals heat pump that conditions are right for defrost or that conditions have changed to terminate defrost. It is a thermally actuated switch clamped to outdoor coil to sense its temperature. Normal temperature range is closed at 30° ±3°F and open at 80° ±5°F.

NOTE: The defrost thermostat must be located on the liquid side of the outdoor coil on the bottom circuit and as close to the coil as possible.

TROUBLESHOOTING

Refer to the Cooling and Heating Troubleshooting Chart (Table 7) for troubleshooting information.

START-UP CHECKLIST

Use the Start-Up checklist to ensure proper start-up procedures are followed.

—24—

Page 25

HEAT PUMP WITH PURON—QUICK REFERENCE GUIDE

Puron refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing equipment and replacement components are designed to operate with Puron. Puron refrigerant cylinders are rose colored.

• Puron refrigerant cylinders manufactured prior to March 1, 1999, have a dip tube that allows liquid to flow out of cylinder in upright position.

Cylinders manufactured March 1, 1999 and later DO NOT have a dip tube and MUST be positioned upside down to allow liquid to flow.

• Recovery cylinder service pressure rating must be 400 psig. DOT 4BA400 or DOT BW400.

• Puron systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose.

• Manifold sets should be 750 psig high-side and 200 psig low-side with 520 psig low-side retard.

• Use hoses with 750 psig service pressure rating.

• Leak detectors should be designed to detect HFC refrigerant.

• Puron, as with other HFCs, is only compatible with POE oils.

• Vacuum pumps will not remove moisture from oil.

• Only use factory specified liquid-line filter driers with rated working pressures no less than 600 psig.

• Do not install a suction-line filter drier in liquid line.

• POE oils absorb moisture rapidly. Do not expose oil to atmosphere.

• POE oils may cause damage to certain plastics and roofing materials.

• Wrap all filter driers and service valves with wet cloth when brazing.

• A Puron liquid-line filter drier is required on every unit.

• Do not use an R-22 TXV.

• Never open system to atmosphere while it is under a vacuum.

• When system must be opened for service, break vacuum with dry nitrogen and replace filter driers.

• Do not vent Puron into the atmosphere.

• Observe all warnings, cautions, and bold text.

• Do not leave Puron suction line driers in place for more than 72 hrs.

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Page 26

SYMPTOM CAUSE REMEDY

Compressor and outdoor fan will not start

Compressor will not start but condenser fan runs

Three-phase scroll compressor (size 030060 units) may be a low pressure differential

Compressor cycles (other than normally satisfying thermostat)

Compressor operates continuously

Excessive head pressure

SYMPTOM CAUSE REMEDY

Head pressure too low

Excessive suction pressure

Suction pressure too low

Compressor runs but outdoor fan does not

IFM does not run

IFM operation is intermittent

IFM–Indoor Fan Motor

TABLE 7—TROUBLESHOOTING CHART

Power Failure Call power company Fuse blown or circuit breaker tripped Replace fuse or reset circuit breaker Defective thermostat, contactor, transformer, control relay, defrost board, or high pressure or lossof-charge/low pressure switch Insufficient line voltage Determine cause and correct Incorrect or faulty wiring Check wiring diagram and rewire correctly

Thermostat setting too high

Units have a 5-minute time delay Faulty wiring or loose connections in compressor

circuit Compressor motor burned out, seized, or internal overload open Defective run capacitor, overload, or PTC (positive temperature coefficient) thermistor

One leg of 3-phase power dead

Low input voltage (20 percent low) Determine cause and correct Scroll compressor is rotating in the wrong direction

Refrigerant overcharge or undercharge Defective compressor Replace and determine cause

Insufficient line voltage Determine cause and correct Blocked outdoor coil Determine cause and correct Defective run/start capacitor, overload or start relay Defective thermostat Replace thermostat Faulty outdoor-fan motor or capacitor Replace Damaged reversing valve Determine cause and correct Restriction in refrigerant system Locate restriction and remove Dirty air filter Replace filter Unit undersized for load Decrease load or increase unit size Thermostat set too low Reset thermostat Low refrigerant charge Locate leak, repair, and recharge

Frosted coil with incorrect defrost operation

Air in system Outdoor coil dirty or restricted Clean coil or remove restriction

Dirty air filter Replace filter Dirty indoor or outdoor coil Clean coil Refrigerant overcharged Recover excess refrigerant

Air in system (Heat) Indoor air restricted or recirculating Determine cause and correct

Indoor or outdoor air restricted or air short-cycling Determine cause and correct Low refrigerant charge Check for leaks, repair and recharge

Restriction in liquid tube Remove restriction (Heat) Outdoor coil frosted (Cool) High Heat load Check for source and eliminate

Reversing valve hung up or leaking internally Replace valve Refrigerant overcharged Recover excess refrigerant (Cool) Dirty air filter Replace filter

(Heat) Outdoor coil frosted Low refrigerant charge Check for leaks, repair and recharge

Metering device or low side restricted Remove source of restriction (Cool) Insufficient coil airflow (Cool) Temperature too low in conditioned area Reset thermostat

(Cool) Outdoor ambient below 40°F Install low-ambient kit Filter-drier restricted Replace NC (normally closed) contacts on defrost board open Blower wheel not secured to shaft Properly tighten blower wheel to shaft Insufficient voltage at motor Determine cause and correct Power connectors not properly sealed Connectors should snap easily; do not force Water dripping into motor Verify proper drip loops in connector wires

Connectors not firmly sealed

Replace component

Lower thermostat setting below room temperature DO NOT bypass this compressor time delay–wait for 5 minutes until time-delay relay is deenergized

Check wiring and repair or replace Determine cause.

Replace compressor Determine cause and replace Replace fuse or reset circuit breaker. Determine

cause Correct the direction of rotation by reversing the

3-phase power leads to the unit Recover refrigerant, evacuate system, and recharge to capacities shown on nameplate

Determine cause and replace

Check defrost time settings Reset as necessary Check defrost temperature switch Replace as necessary Recover refrigerant, evacuate system, and recharge

Recover refrigerant, evacuate system, and recharge

Move timer on control board to 30 minutes between defrost cycles

Increase air quantity Check filter–replace if necessary

Check condition of relay on board Replace if necessary

Gently pull wires individually to be sure they are crimped into the housing

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Page 27

START-UP CHECKLIST

(REMOVE AND STORE IN JOB FILE)

I. PRELIMINARY INFORMATION

Model No .............................................................................................................................................................

Serial No ..............................................................................................................................................................

Date .....................................................................................................................................................................

Technician ...........................................................................................................................................................

II. PRE-START-UP

____ Verify that all packing materials have been removed from unit ____ Remove all shipping holddown bolts and brackets per installation instructions ____ Make sure that – on the 060 size, only – the two wire ties fastened to the outdoor coils and

reversing valve/accumulator have been removed ____ Verify that condensate connection is installed per installation instructions ____ Check all electrical connections and terminals for tightness ____ Check that indoor (evaporator) air filter is clean and in place ____ Verify that unit installation is level ____ Check fan wheel propeller for location in housing and setscrew tightness

III. START-UP

Supply Voltage: L1-L2 __________ L2-L3 __________ L3-L1 __________ Compressor Amps: L1 __________ L2 __________ L3 __________ Indoor Fan Amps: __________

AIR TEMPERATURE

Outdoor-Air Temperature: __________ DB Return-Air Temperature: __________ DB __________ WB Heat Pump Supply Air: __________ Electric Heater Supply Air: __________

REFRIGERANT PRESSURES AND TEMPERATURES

Refrigerant Suction __________ psig Refrigerant Discharge __________ psig Suction Line Temp*__________ Discharge Line Temp† __________ Liquid Line Temp‡ __________ ____ Verify Refrigerant charge using charging tables ____ Verify that 3-phase scroll compressor is rotating in correct direction.

* Measured at suction inlet to compressor

† Measured at discharge outlet from compressor. ‡ Measured at liquid line leaving condenser

—27—

Page 28

—28—

Printed in U.S.A. 602b Catalog No. 5360-205