installation, start-up and
service instructions
LIGHT COMMERCIAL
CONDENSING UNITS
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
I. Complete Pre-Installation Checks . . . . . . . . . . . . . . 1
II. Rig and Mount Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 3
III. Complete Refrigerant Piping Connections . . . . . . . 3
IV. Make Electrical Connections
V. Accessory Installation. . . . . . . . . . . . . . . . . . . . . . . . 4
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
I. Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
II. Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
III. Cleaning Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
. . . . . . . . . . . . . . . . 4
538J
Sizes 018-060
Cancels: New II 538J-18-1
1/15/02
I. COMPLETE PRE-INSTALLATION CHECKS
A. Unpack Unit
Move unit to final location. Remove unit packaging being
careful not to damage service valves or grilles.
B. Inspect Shipment
File claim with shipping company if shipment is damaged or
incomplete. Check unit nameplate to ensure unit matches
job requirements.
C. Consider System Requirements
Consult local b uilding codes and NEC for special installation
requirements.
Allow sufficient space for air flow clearance, wiring, refrigerant piping, and servicing unit. See Fig. 1 and 2. Unit can be
mounted on a level pad directly on base legs or mounted on
raised pads at support points. See Fig. 2 for center of gravity.
SAFETY CONSIDERATIONS
Installing and servicing air-conditioning equipment can be
hazardous due to system pressure and electrical components. Only trained and qualified service personnel should
install or service air-conditioning equipment.
Untrained personnel may perform basic maintenance such
as cleaning an d rep l ac ing f ilt er s. All oth er ope ra tio n s sho ul d
be performed by trained service personnel. When working on
air-conditioning equipment, observe safety precautions in
literature, and on tags and labels attached to unit.
Follow all safety codes. Wear safety glasses and work gloves.
Use quenching cloth for brazing operations. Have a fire extinguisher available. Read these instructions thoroughly. Consult local building codes and National Electrical Cod e (NEC,
U.S.A. Standard) for special installation requirements.
INSTALLATION
WARNING: Before installing or servicing system,
always turn off main power to system. There may be
more than one disconnect switch. Turn off accessory
heater power if applicable. Electrical shock can cause
personal injury.
C
O
O
LIN
G
Fig. 1 — Typical Condensing Unit
WEIGHT
OPERATING
15.88 130 58.9
15.88 136 61.6
19.05 161 73.0
19.05 185 83.9
22.22 222 100.5
22.22 249 112.9
8
8
4
4
8
/
/
/
5
5
3
285.8 0-0
295.3 0-0
295.3 0-0
4
8
8
/
/
/
1
5
5
168.3 0-11
171.5 0-11
171.5 0-11
8
4
4
/
/
/
5
3
3
8
/
/
/
3
7
7
295.3 0-0
403.2 0-0
8
8
/
/
5
7
171.5 0-11
209.5 0- 4 406.4 0-0
206.4 0- 3
4
4
8
/
/
/
3
1
1
352.4 0-8
347.7 0-8
16
/
8
/
7
11
Support Feet
MINIMUM MOUNTING PAD DIMENSIONS
ft-in. mm
538J
511.2 1-1 330.2 0-6
511.2 1-1 330.2 0-6
511.2 1-1 330.2 0-6
511.2 1-1 330.2 0-6
817.6 1-1
817.6 1-1
8
8
8
8
16
/
/
/
1
1
1
444.5 1-8
444.5 1-8
444.5 1-8
2
2
2
/
/
/
1
1
1
16
/
/
/
1
3
3
444.5 1-8
752.5 2-8
752.5 2-8
2
8
8
/
/
/
1
5
5
UNIT SIZE
048 and 060 2- 0 x 4-2 609.6 x 1270.0
018,024,030 and 036 1-11 x 3-6 584.2 x 1066.8
clearance on compressor end and coil side. With multi-unit application, arrange units so discharge of
one does not enter inlet of another.
coil end, and 3 ft (914.4 mm) minimum clearance on compressor end and fan side. With fan facing
wall, allow 8″ (203.2 mm) minimum clearance on fan side and coil end, and 3 ft (914.4 mm) minimum
2. Dimensions in parenthesis are in millimeters.
NOTES:
1. Required clearances: With coil facing wall, allow 6″ (156.4 mm) minimum clearance on coil side and
3. Center of gravity .
436.6 1-5
436.6 1-5
436.6 1-5
16
16
/
/
/
3
3
3
595.3 1-5
595.3 1-5
595.3 1-5
16
16
/
/
/
7
7
7
369.9 1-4 406.4 1-11
369.9 1-4 406.4 1-11
369.9 1-4 406.4 1-11
16
16
/
/
/
9
9
9
938.2 1-2
938.2 1-2
938.2 1-2
16
16
/
/
/
15
15
15
638.2 3-0
638.2 3-0
ABCD E FGHJKLM
ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm ft-in. mm lb kg
638.2 3-0
8
8
/
/
/
1
1
1
436.6 1-5
498.5 2-5
498.5 2-5
8
16
16
16
16
8
8
16
/
/
/
5
5
3
595.3 1-5
774.7 1-7
774.7 1-7
2
2
16
/
/
/
1
1
7
468.3 2- 6
468.3 2- 6
16
16
/
/
7
7
369.9 1-4 406.4 1-11
433.4 1-6
433.4 1-6
16
16
16
/
/
/
9
1
1
938.2 1-2
1131.9 1-5
1131.9 1-5
16
/
16
16
/
/
15
9
9
638.2 3-0
944.6 3-8
944.6 3-8
8
16
16
/
/
/
1
3
3
Fig. 2 — 538J018-060 — Dimensional Drawing
SIZE
UNIT
538J
024 2-1
030 2-1
036 2-1
048 3-1
018 2-1
060 3-1
—2—
II. RIG AND MOUNT UNIT
A. Mounting on Ground
Mount unit on a solid, level concrete pad. Position unit so
water or ice from roof does not fall directly i nto unit. Fieldfabricated stacking kits can be used when units are to be
stacked. If conditions or local codes require unit to be fastened to a pad, 6 field-supplied tiedown bolts should be used
and fastened through slots provided in unit mounting feet.
B. Mounting on Roof
Mount unit on level platform or frame at least 6 in. above
roof surface. Isolate unit and tubing from structure.
C. Rigging
CAUTION: Be sure unit panels are securely in
place prior to rigging.
Keep unit upright. Lift unit using sling. Use cardboard or
padding under sling, and spreader bars to prevent sling
damage to unit. See Fig. 3. See Fig. 2 for center of gravity reference. Install unit so coil does not face into prevailing
winds. If this is not possible and constant winds above
25 mph are expected, use field-fabricat ed wind baffle.
NOTE: Accessory wind baffles should be used on all units
with accessory low-ambient control.
Field-fabricat ed snow stan d may be used to rai se unit when
operation will be required during the winter. Units may also
be wall mounted using the accessory wall mounting kit.
III. COMPLETE REFRIGERATION PIPING CONNECTIONS
Outdoor units may be connected to indoor units using fieldsupplied tubing of refrigerant grade and condition. See
Tables 1A and 1B for correct line sizes. Do not use less than
10 ft (3 m) of interconnecting tubing.
CAUTION: DO NOT BURY MORE THAN 36 IN.
(922 mm) OF REFRIGERANT PIPE IN THE
GROUND. If any section of pipe is buried, there must
be a 6 in. (154 m) ver tic al r ise to the valv e con nec tion s
on the outdoor unit. If more than the recommended
length is buried, refrigerant m ay migra te to the coole r,
buried section duri ng extended periods of system shutdown. This causes refrigerant slugging and could damage compressor at start-up.
Fig. 3 — Lifting Unit with Sling
A. Check AccuRater® Control
The AccuRater refrigerant control is required for cooling system capacity optimization. An AccuRater device with fieldreplaceable piston should be supplied with the indoor unit.
Refer to AccuRater metering de vice table in separate indoor
unit installation instructi ons to determine the corre ct AccuRater piston size required for the condenser/evaporator system being installed.
Note that one of 2 types of the AccuRater devices can be
used. Use Type A only if Type B is unavailable. See Fig. 4. Do
not interchange components between AccuRater device
types. Matching of outdoor unit with indoor unit may require
field replacement of piston. Replace piston, if required,
before connecting refrigerant lines. Piston replacement
instructions are included in the indoor unit installation
instructions. After system installation is complete, see
Refrigerant Charging section on page 8 to check and/or
adjust refrigerant charge.
The 538J series units may also be installed with units using
a thermostatic expansion valve (TXV). If a TXV is used, be
sure to remove the pi ston from the i ndoor coil. See i nstallation instruction s shipped with the TXV for proper posi tioning and adjustment.
When more than 50 ft (15.2 m) of interconnecting tubing and
more than 30 ft (9.1 m) of vertical lift is used, refer to Part 3
of the System Desig n Manual for design details, or contac t
your local distributor.
If either refrig era nt tu b ing or i ndoor co il is e xp ose d to a tmo spheric condit ions for long er than 5 minu tes , it must be evac uated to 1000 microns to eliminate contamination and
moisture in the system.
Run refrigerant tubes as directly as possible, avoiding
unnecessary turns and bend s. Suspend refrigerant tubes so
they do not damage insulation on vapor tube and do not
transmit vibration to the structure. Also, when passing
refrigerant tubes through the wall, seal opening so that
vibration is not transmitted to structure. Leave some slack
in refrigerant tubes between structure and outdoor unit to
absorb vibration. Refer to separate indoor unit installati on
instructions for additiona l information.
TYPE A (FIELD-INSTALLED BYPASS TYPE)
TYPE B (RECOMMENDED)
NOTE: Arrow on AccuRater body points in free-flow direction, away
from the indoor coil.
Fig. 4 — AccuRater Metering Device Components
—3—
B. Make Piping Sweat Connections
Remove plastic caps from liquid and suction service valves.
Use refrigerant gr ade tubi ng. Service val ves are closed from
the factory and ready for brazing. After wrapping the service
valve with a wet cloth, the tubing set can be brazed to the
service valve using either silver bearing or non-silver bearing brazing material. Consult local code requirements.
Refrigerant tubing and indoor coil are ready for leak testing.
NOTE: Unit is shipped with a full factory charge of R-22
refrigerant as indicated on nameplate.
Pass nitrogen or other inert gas through piping while brazing to prevent formation of copper oxide.
CAUTION: To avo id da ma ge whil e b ra zing, serv ice
valves should be wrapped in a heat-sinking material
such as a wet cloth .
CAUTION: When brazing tubing sets to the service valves, a brazing shield must be used to prevent
damage to the painted unit surface.
C. Provide Safety Relief
A fusible plug is located in unit suction line; do not cap this
plug. If local code requires addition al safety devices, insta ll
as directed.
IV. MAKE ELECTRIAL CONNECTIONS
WARNING: 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 ma y co nsist of electrical wir e
connected to the unit ground lug in control compartment, or conduit approved for electrical ground when
installed in accordance with NEC, ANSI/NFP A (Ame rican National Standards Institute/National Fire Protection Association) 70, and local electrical codes. Failure
to follow this warning could result in the installer
being liable for personal injury to others.
CAUTION: Unit failu re as a result of oper ation on
improper line voltage or excessive phase imbalance
constitutes abuse and may cause damage to electrical
components. Such operation will invalidate any applicable warranty.
A. Power Wiring
Unit is factory-w ired for voltage shown on nameplate. Provide adequate, fused disconnect switch within sight of unit,
readily accessible but out of reach of children. Provi sion for
locking the switch open (off) is advisable to prevent power
from being turn ed on w hile unit is be ing s erviced . Di sco nnect
switch, fuses, and field wiring must be in compliance with
NEC (U.S.A. Standard) and applicable local codes. Use minimum 60 C wire for field power connection.
Route power wires through opening in the unit side panel
and connect in unit control box as shown on unit label diagram and Fig. 5 and 6. Unit must be grounded.
B. Control Circuit Wiring
Control voltage is 24 v. See Fig. 5 and unit label diagram for
field-supplied wiring details. Route control wire through
opening in the unit side panel to connection in unit control
box.
NOTE: For wire runs up to 50 ft (15 m), use no. 18 AWG
(American Wire Gage) insulate d wire (35 C minimum). For
50 to 75 ft (15 to 23 m), use no. 16 AWG insulated wire. For
more than 75 ft (23 m), use no. 14 AWG insulated wire. See
Table 2 for conversion to European wire sizes.
NOTE: Oper ation of unit on imp rope r lin e vol tage c onst itute s
abuse and co uld af fect any appl ic able warran ty. See Table 3.
Do not install unit in system where voltage may fluctuate
above or below permissible limits.
See Table 3 for recommended fuse sizes. When making electrical connections, provide cle arance at unit for refrigerant
piping connections.
Use indoor unit transfo rmer a s 24-v (40-v a min imum) supply
for system as shown in Fig. 5 or use accessory transformer.
WARNING: Before performing service or maintenance, be sure the indoor unit main power switch is off
and indoor blower has completely stopped. Failure to
do so may result in electrical shock or injury from
rotating fan blades.
C. Connections to Duct-Free Fan Coil Units
The 538J units are designed for easy match-up to 619C,
619F, 619ENX018 and 619ENX024 duct-free fan coils. These
units provide 24 -v power for the outdoor u nit from the fan
coil. Connect the Y and C terminals of the indoor unit to the
blue and brown wires of the outdoor unit with 20 gage (minimum) thermostat wire.
V. ACCESSORY INSTALLATION
Install all unit a ccessories per accessory installation instructions prior to start-up.
Do not use accessory Time Guard® II device when combining
a 538J unit with 619E indoor units.
When ambient temp erature will fall be low 55 F (1 3 C), a ccessory low ambient controller (part no. 53DS900060) is
required. When accessory low ambient kit is used, unit
should also be equipped with accessory winter start kit and
field-fabricated wind baffles.
—4—
Table 1A — Physical Data (English)
UNIT 538J 018 024 030 036 048 060
NOMINAL CAPACITY (Btuh) 18,000 24,000 30,000 36,000 48,000 60,000
UNIT OPERATING WEIGHT (lb) 130 136 161 185 222 249
COMPRESSOR Hermetic
Typ e Copeland
Model ZR18KC-PFV ZR24KC-PFV ZR28KC-PFV ZR34KC-PFV ZR47KC-PFV ZR57KC-PFV
Scroll
Copeland
Scroll
Copeland
Scroll
Copeland
Scroll
Copeland
Scroll
Copeland
Scroll
Oil (oz) Initial/Recharge 25/21 25/21 38/34 42/38 42/38 56/52
OUTDOOR FAN Propeller Type, Direct Drive, Horizontal
Rpm 850 850 850 850 850 850
Diameter (in.)...No. of Blades 18...3 18...3 18...3 18...3 24...3 24...3
Fan Pitch (Deg) 25 27 27 31 24 24
Motor Hp
Nominal Airflow (Cfm) 1720 1720 1720 1720 3900 3900
OUTDOOR COIL Copper Tube, Aluminum Plate Fin
Face Area (sq ft)...No. of Rows 6.1...1 6.1...1.5 6.1...2 6.1...2 12.3...1.5 12.3...1.75
1
/
8
1
/
8
1
/
8
1
/
8
1
/
4
1
Fins per in. 20 20 20 20 20 20
CONTROLS PRESSURESTAT SETTINGS
Low Pressure
Cutout (psig) 7 ± 3
Cut-In (psig) 22 ± 5
Fusible Plug 210 F
NOTE: Line sizes are for runs up to 25 feet.
Table 1B — Physical Data (SI)
UNIT 538J 018 024 030 036 048 060
NOMINAL CAPACITY (kW) 5.3 7.0 8.8 10.5 14.1 17.6
UNIT OPERATING WEIGHT (kg) 58.9 61.6 73.0 83.9 100.6 112.9
COMPRESSOR Hermetic
Typ e Copeland
Scroll
Model ZR18KC-PFV ZR24KC-PFV ZR28KC-PFV ZR34KC-PFV ZR47KC-PFV ZR57KC-PFV
Oil (L) Initial/Recharge .74/.62 .74/.62 1.13/1.00 1.25/1.13 1.25/1.13 1.66/1.54
OUTDOOR FAN Propeller Type, Direct Drive, Horizontal
R/s 14.2 14.2 14.2 14.2 14.2 14.2
Diameter (mm)...No. of Blades 457...3 457...3 457...3 457...3 610...3 610...3
Fan Pitch (Deg) 25 27 27 31 24 24
Motor kW .13 .09 .09 .09 .19 .19
Nominal Airflow (L/s) 812 812 812 812 1840 1840
OUTDOOR COIL Copper Tube, Aluminum Plate Fin
Face Area (m
2
)...No. of Rows .57...1 .57...1.5 .57...2 .57...2 1.14...1.5 1.14...1.75
Fins per mm .8 .8 .8 .8 .8 .8
CONTROLS PRESSURESTAT SETTINGS
Low Pressure
Cutout (kPa) 48 ± 21
Cut-In (kPa) 152 ± 34
Fusible Plug 99 C
NOTE: Line sizes are for runs up to 7.6 m.
Copeland
Scroll
Copeland
Scroll
Copeland
Scroll
Copeland
Scroll
Copeland
Scroll
/
4
—5—
LEGEND
C—Contactor (12-va)
HC — Heating Control
IFM — Indoor-Fan Motor
IFR — Indoor-Fan Relay
TRANS — Transformer
Field Wiring
Factory Wiring
*The IFR and IFM are located in indoor unit on heating-cooling applications. If accessory
IFR is required for cooling-only applications, locate (IFR) in fan coil.
NOTES:
1. Refer to unit wiring label for wire colors: BRN to BLU and C to Y connections.
2. Arrangement A, B and C are for use with residential fan coils.
Fig. 5 — Typical Control Circuit Connections
NEC — National Electrical Code
TB — Terminal Board
Fig. 6 — Line Power Connections
LEGEND
(U.S.A. Standard)
— Transformer
Field Wiring
Factory Wiring
—6—
Table 2 — American/European Wire Conversions
SERVICE
AMERICAN EUROPEAN
Industry
Standard Size
18 AWG 0.82 1.0
16 AWG 1.30 1.5
14 AWG 2.08 2.5
12 AWG 3.30 4.0
10 AWG 5.25 6.0
8 AWG 6.36 10.0
6 AWG 13.29 16.0
4 AWG 21.14 25.0
3 AWG 26.65 —
2 AWG 33.61 35.0
1 AWG 42.39 50.0
1/0 AWG 53.49 —
2/0 AWG 67.42 70.0
3/0 AWG 85.00 95.0
4/0 AWG 107.19 120.0
250 kcmil 126.64 150.0
300 kcmil 151.97 —
350 kcmil 177.90 185.0
400 kcmil 202.63 240.0
500 kcmil 253.29 300.0
600 kcmil 303.95 —
LEGEND
AWG — American Wire Gage
kcmil — Thousand Circular Mils
American Conversion
(mm)
Industry Standard
Size (mm
2
)
START-UP
I. PRELIMINARY CHECKS
1. Check that all internal wiring connections are tight
and that barriers, covers, and panels are in place.
2. Make certain field electrical power source agrees
with unit nameplate rating.
3. Open all service valves.
II. LEAK TEST
Field piping and fan coil must be leak tested by the pressure
method. Use R-22 at appr oxi mat e ly 25 psi g (1 72 k Pa) backed
up with an inert gas to a total pressure not to exceed
245 psig (1690 kPa).
III. EVACUATE AND DEHYDRATE
Field piping and fan coil must be evacuated and dehydrated.
IV. CHARGE SYSTEM
Release factory charge i nto system by opening ( backseati ng)
liquid and suction line service valves. Add charge amount as
required for the total system. Refer to separate indoor unit
installation instructions for the required total system charge
when connected to the indoor unit.
V. TO START UNIT
NOTE: When using 538J unit in conjunction with 619 series
fan coils, refer to start-up instructions include d with fan coil
for correct start-up procedures.
Be sure that field disconn ect is closed. Set roo m thermostat
below ambient temperature. Operate unit for 15 minutes,
then check system refrigerant charge. See Refrigerant
Charging section on page 8.
Unit compressor starts after a 5-minute delay if equipped
with accessory Time Guar d® II device.
WARNING: Before performing recommended maintenance, be sure unit main power switch is off. F ail ure to
do so may result in electrical shock or injury from rotating fan blade.
I. OUTDOOR FAN
A reinforced wire mount holds the outdoor fan assembly in
place. See Fig. 7 for proper mounting positions.
UNIT 538J DIMENSIONS — in. (mm)
018 024-036 048-060
0.433 (11) 0.709 (18) 0.16 (4)
Fig. 7 — Condenser Fan Mounting Positions
II. HIGH-PRESSURE RELIEF VALVE
Valve is located in compressor. Relief valve opens at a
pressure differential of approximately 450 ± 50 psig (3100 ±
345 kPa) between suction (low side) and discharge (high
side) to allow pressure equalization.
III. INTERNAL CURRENT AND TEMPERATURE SENSITIVE
OVERLOAD
Control resets automatically when internal compressor
motor temperature drops to a safe level (overloads may
require up to 45 minutes to reset). When an internal overload is suspected of being open, check by using an ohmmeter
or continuity tester.
IV. PUMPDOWN PROCEDURE
The system may be pumped down in order to make repairs
on low side without losing complete refrigerant charge.
To pump down:
1. Attach pressure gage to suction service valve gage
port.
2. Fronts ea t the liq uid lin e valve.
CAUTION: The 538J unit coils hold only the
factory-designated amount of refrigerant. Additional
refrigerant may cause units to relieve pressure
through compressor internal pressure relief valve
(indicated by sudden rise of suction pressure) before
suction pressure reaches 5 psig (34 kPa). If this occurs,
shut off unit immediately, then frontseat the suction
valve and remove and reclaim excess refrigerant following accepted practice.
3. Start unit and run until suction pressure reaches
5 psig (34 kPa).
4. Shut unit off and frontseat suction valve.
5. Depressurize low side of unit and recover refrigerant
following accepted practice.
—7—
Table 3 — Electrical Data
OPERATIONAL
538J V-PH-Hz
018
024
030
036
048
060
FLA —
HACR —
LRA —
MCA —
NEC —
RLA —
*Permissible limits of the voltage range at which unit will operate
satisfactorily.
†Time-delay fuse.
NOTES:
1. Control circuit is 24 v on all units and requires an external power source.
Full Load Amps
Heating, Air Conditioning, Refrigeration
Locked Rotor Amps
Minimum Circuit Amps per NEC Section 430-24
National Electrical Code (U.S.A. Standard)
Rated Load Amps (Compressor)
208/230-1-60 187 254
LEGEND
VOLTAGE*
Min Max RLA LRA Fan FLA MCA
COMPRESSOR POWER SUPPLY
10.7 47.0 .70 14.1 25
13.2 59.0 .70 17.2 30
15.7 73.0 .70 20.3 35
15.7 93.0 .70 20.3 35
24.3 131.0 .45 31.8 50
28.6 170.0 .45 37.2 65
V. LOW PRESSURE SWITCH
This switch, mounted on the suction line, has fixed nonadjustable settings. To check pressure switch, attach pressure gage to suction service valve gage port. Slowly close
liquid shutoff valve and allow compressor to pump down. Do
not allow compre ssor to pump down below 2 psi g (14 kPa).
Compressor should shut down when suction pressure drops
to cutout pressure in Tables 1A and 1B, and should restart
when pressure builds up to cut-in pressure shown after
accessory CLO (compressor lockout) switch has been reset
and accessory Time Guard® II device has completed its timing cycle.
VI. SERVICE VALVES
The service valves in the outdoor unit come from the factory
frontseated. This means the refrigerant charge is isolated
from the line-set connection po rts. To prevent damage to the
valve, use a wet cloth or other acceptable heat sink material
on the valve befor e brazing.
The service valves must be backseated (turned counterclockwise until seated) before the service port caps can be
removed and the hoses of the gage manifold connected. In
this position, refrigerant has access from the through outdoor and indoor unit. The service valve cannot be field
repaired; only a complete valve or valve stem seal and
service port caps are available for replacement.
VII. ACCURATER® (BYPASS TYPE) DEVICE
See Fig. 4 for bypass type AccuRater device components. The
piston has a refrigerant metering hole through it. The
retainer forms a stop f or the pi sto n in the ref rige ran t by pass
mode and a sealing surface for liquid line flare connection.
To check, clean or replace piston:
1. Shut off power to unit.
2. Pump down using Pumpdown Procedure section on
page 7.
3. Remove liquid line fl are connection from AccuRater
device.
4. Pull retainer out of body, being careful not to scrat ch
flare sealing surface. If retainer does not pull out
easily, carefully use locking pliers to remove retainer.
5. Slide piston out by inserting a small soft wire, with
small kinks, through metering hole. Ensure metering
Max Fuse† or HACR-Type
Ckt Bkr Amps
2. All motors and compressors contain internal overload protection.
3. In compliance with NEC (U.S.A. Standard) requirements for multimotor
and combination load equipment (refer to NEC Articles 430 and 440), the
overcurrent protective device for the unit shall be fuse or HACR breaker.
4. Motor RLA values are established in accordance with UL (Underwriters’
Laboratories) Standard 465 (U.S.A. Standard).
hole, sealing surface around piston cones, and fluted
portion of piston are not damaged.
6. Clean piston refrigerant metering hole.
7. Replace retainer O-ring before reassembling AccuRater device (O-ring part no. 99CC501052).
VIII. REFRIGERANT CHARGING
WARNING: To prevent personal injury, wear
safety glasses and gloves when handling refrigerant.
Do not overcharge system — this can cause com pressor
flooding.
NOTE: Do not vent or depressuri ze uni t ref riger ant to a tmosphere. Remove and recover refrigeran t following practice.
A. Superheat Method (Cooling, Non-TXV)
To check and adjust charge during cooling season, use
Tables 4A-5B and the following procedure:
1. Operate unit a minimum of 15 minutes before checking charge.
2. Measure suction pressure by attaching a gage to suction valve service port.
3. Measure suction line temperature by attaching a service thermometer to unit suction line near suction
valve. Insulate thermomete r for accurate readings.
4. Measure outdoor coil inlet-air dry bulb temperature
with a second thermometer.
5. Measure indoor coil inlet-air wet bulb temperature
with a sling psychrometer.
6. Refer to Tables 4A and 4B. Find air temperature entering outdoor coil and wet-bulb temperature entering
indoor coil. At this intersection, note the superheat
temperature.
7. Refer to Tables 5A and 5B. Find superheat temperature and suction pressure and note suction line
temperature.
8. If unit has higher suction line temperature than
charted temperature, add refrigerant until charted
temperature is reached.
9. If unit has lower suction line temperature than
charted temperature, remove and recover re frigerant
until charted temperature is reached.
—8—
10. If air temperature entering outdoor coi l or pressure
at suction valve changes, charge to ne w suction line
temperature indicated on chart.
NOTE: The above procedure is independent of indoor air
quantity.
B. Subcooling Method (Cooling, TXV)
To check and adjust charge during cooling season, use
Tables 6A and 6B and the following procedure:
1. Operate unit a minimum of 15 minutes before checking charge.
2. Measure liquid line temperature near liquid line service valve, and measure liquid pressure at liquid line
service valve. Use a digital thermo meter for all temperature measurements. DO NOT use mercury or
dial-type th ermometers.
3. Refer to Tables 6A and 6B. Find temperature point at
which the required subcooling temper at ur e inte rsects
the measured liquid line pressure.
4. If the measured liquid line temperature does not
agree with the required liquid line temperature, ADD
refrigerant to lower the temperature, or REMOVE
refrigerant to raise the temperature (allow a tolerance of ± 3 F).
Table 4A — Superheat Charging Table — English
(Superheat Entering Suction Service Valve)
OUTDOOR
TEMP (F)
55
60
65
70
75
80
85
90
95
100
105
110
115
LEGEND
Wet Bulb
WB —
*Do not attempt to charge system under these conditions or refrigerant slug-
ging may occur.
50 52 54 56 58 60 62 64 66 68 70 72 74 76
INDOOR COIL ENTERING AIR (F) WB
9 12141720232629323537404245
7 10121518212427303335384043
* 6 10 13 16 19 21 24 27 30 33 36 38 41
* * 71013161921242730333639
* * * 6 9 12 15 18 21 24 28 31 34 37
**** 581215182125283135
****** 811151922263033
****** 59131620242731
******* 6101418222529
******** 81215202327
******** 5913172226
********* 611152025
********** 8141823
Table 4B — Superheat Charging Table — SI
(Superheat Entering Suction Service Valve)
OUTDOOR
TEMP (C)
13
16
18
21
24
27
29
32
35
38
41
43
46
LEGEND
Wet Bulb
WB —
*Do not attempt to charge system under these conditions or refrigerant slug-
ging may occur.
10 11 12 13 14 16 17 18 19 20 21 22 23 24
INDOOR COIL ENTERING AIR (C) WB
578911131416181921222325
467810121315171819212224
* 3 6 7 9111213151718202123
* * 4 6 7 9 11 12 13 15 17 18 20 22
* * * 3 5 7 8 10 12 13 16 17 19 21
**** 3478101214161719
****** 4681112141718
****** 357911131517
******* 36810121416
******** 478111315
******** 35791214
********* 3681114
********** 481013
Table 5A — Required Suction-Tube Temperature (F)
— English (Entering Suction Service Valve)
SUPERHEAT
TEMP (F)
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
SUCTION PRESSURE AT SERVICE PORT (psig)
61.5 64.2 67.1 70.0 73.0 76.0 79.2 82.4 85.7
35 36 39 41 43 45 47 49 51
37 39 41 43 45 47 49 51 53
39 41 43 45 47 49 51 53 55
41 43 45 47 49 51 53 55 57
43 45 47 49 51 53 55 57 59
45 47 49 51 53 55 57 59 61
47 49 51 53 55 57 59 61 63
49 51 53 55 57 59 61 63 65
51 53 55 57 59 61 63 65 67
53 55 57 59 61 63 65 67 69
55 57 59 61 63 65 67 69 71
57 59 61 63 65 67 69 71 73
59 61 63 65 67 69 71 73 75
61 63 65 67 69 71 73 75 77
63 65 67 69 71 73 75 77 79
65 67 69 71 73 75 77 79 81
67 69 71 73 75 77 79 81 83
69 71 73 75 77 79 81 83 85
71 73 75 77 79 81 83 85 87
73 75 77 79 81 83 85 87 89
75 77 79 81 83 85 87 89 91
Table 5B — Required Suction-Tube Temperature (C)
— SI (Entering Suction Service Valve)
SUPERHEAT
TEMP (C)
0
1
2
3
4
6
7
8
9
10
11
12
13
14
16
17
18
19
20
21
22
SUCTION PRESSURE AT SERVICE PORT (kPa)
424 443 463 483 503 524 546 568 591
2345678911
34567891112
456789111213
5678911121314
67891112131415
7 8 9 11 12 13 14 15 16
8 9 11 12 13 14 15 16 17
91112131415161718
11 12 13 14 15 16 17 18 19
12 13 14 15 16 17 18 19 21
13 14 15 16 17 18 19 21 22
14 15 16 17 18 19 21 22 23
15 16 17 18 19 21 22 23 24
16 17 18 19 21 22 23 24 25
17 18 19 21 22 23 24 25 26
18 19 21 22 23 24 25 26 27
19 21 22 23 24 26 26 27 28
21 22 23 24 25 26 27 28 29
22 23 24 25 26 27 28 29 31
23 24 25 26 27 28 29 31 32
24 25 26 27 28 29 31 32 33
—9—
MAINTENANCE
Clean coil annually or as required by location and outdoor
air conditions. Inspect coil monthly and clean as required.
WARNING: Before performing recommended maintenance, be sure unit main power is off. Failure to do so
may result in electrica l shock or injury from rot ating fan
blades.
I. LUBRICATION
The outdoor fan motor is factory lubricated and requires no
oil.
II. COMPRESSOR
Fins are NOT continuous through coil sections. Dirt and
debris may pass through the first section, become trapped
between the rows of fins, and restrict co ndenser ai rflow. Use
a flashlight to determine if dirt or debris has collected
between coil sections. Clean coil as follows:
1. Turn off unit power.
2. Use a garden hose or other suitable equipment to
flush coil from the outside to remove dirt. Be sure to
flush all dirt and debris from drain holes in the base
of unit. Fan motors are waterproof.
The compress or con tains fac tory oil c har ges ; rep lac e oil w hen
lost. See Tables 1A and 1B for oil recharge. Recommended oil
is Sontex 200LT for all units.
III. CLEANING COILS
Coil should be washed out with water or blown out with compressed air. Note that the blow-thru design causes dirt and
debris to build up on the inside of the coils.
Table 6A — Required Liquid Line Temperature (F) — English (At Service Valve)
REQUIRED
SUBCOOLING
(F)
0 76 79 82 85 88 91 94 97 100 103 106 109 112 115 118 121 124 127 130 133 136 139 142 145
5 71 74 77 80 83 86 89 92 95 98 101 104 107 110 113 116 119 122 125 128 131 134 137 140
10 66 69 72 75 78 81 84 87 90 93 96 99 102 105 108 111 117 120 123 126 129 129 132 135
15 61 64 67 70 73 76 79 82 85 88 91 94 97 100 103 106 109 112 115 118 121 124 127 130
20 56 59 62 65 68 71 74 77 80 83 86 89 92 95 98 101 104 107 110 113 116 119 122 125
25 51 54 57 60 63 66 69 72 75 78 81 84 87 90 93 96 99 102 105 108 111 114 117 120
134 141 148 156 163 171 179 187 196 205 214 223 233 243 253 264 274 285 297 309 321 331 346 359
LIQUID PRESSURE AT SERVICE VALVE (PSIG)
Table 6B — Required Liquid Line Temperature (C) — SI (At Service Valve)
REQUIRED
SUBCOOLING
(C)
0 24 26 28 29 31 33 34 36 38 39 41 43 44 46 48 49 51 53 54 56 58 59 61 63
2 22 24 26 27 29 31 32 34 36 37 39 41 42 44 46 47 49 51 52 54 56 57 59 61
4 20 22 24 25 27 29 30 32 34 35 37 39 40 42 44 45 47 49 50 52 54 55 57 59
6 18 20 22 23 25 27 28 30 32 33 35 37 38 40 42 43 45 47 48 50 52 53 55 57
8 16 18 20 21 23 25 26 28 30 31 33 35 36 38 40 41 43 45 46 48 50 51 53 55
10 14 16 18 19 21 23 24 26 28 29 31 33 34 36 38 39 41 43 44 46 48 49 51 53
12 12 14 16 17 19 21 22 24 26 27 29 31 32 34 36 37 39 41 42 44 46 47 49 51
14 10 12 14 15 17 19 20 22 24 25 27 29 30 32 34 35 37 39 40 42 44 45 47 49
911 969 1030 1061 1121 1186 1219 1286 1360 1397 1471 1547 1588 1671 1755 1800 1885 1976 2026 2125 2222 2264 2379 2475
LIQUID PRESSURE AT SERVICE VALVE (PSIG)
—10—
TROUBLESHOOTING
TROUBLESHOOTING CHART — COOLING CYCLE
—11—
Copyright 2002 Bryant Heating & Cooling Systems Printed in Mexico CATALOG NO. 5353-802
Loading...