Compu-aire CELHP, CELAC, CELLU-KOOL CELHP, CELLU-KOOL CELAC Installation, Operation, Maintenance And Parts Manual

INSTALLATION

OPERATION

MAINTENANCE

AND PARTS

MANUAL

CELLU – KOOL SERIES

MODEL

CELHP HEAT PUMP 1 ½ TO 5 TON

CELAC AIR CONDITIONER 1 ½ TO 5 TON

TYPE

SIZE

COMPU – AIRE INC.

8167 BYRON RD. WHITTIER, CA 90606

PH : (562) 945 – 8971 FAX : (562) 696 - 0724

--GETTING OTHER INFORMATION AND PUBLICATIONS

These publications can help you install the air conditioner or heat pump.

You can

usually find these at your local

1 ibrary or purchase them directly from the

publisher.

Be sure to consult current edition of each standard.

National Electrical Code

-ANSI/NFPA 70

Standard For The Installation

Of

Air

Conditioning and Ventilating Systems

Standard For Warm

Air

Heating

and

Air

Conditioning Systems

Load Calculation For Residential
Winter and Summer

Air

Conditioning

Duct

Desi gn For Residential Winter and Summer

Air

Conditioning and Equipment Selection

-ANSI/NFPA 90A

-ANSI/NFPA 908

-ACCA

Manual

3

-ACCA

Manual D

FOR MORE INFORMATION, CONTACT THESE PUBLISHERS

ACCA:

AIR

CONDITIONING CONTRACTORS OF AMERICA

1513 16th Street

NW

Washington,

DC

20036

Telephone: (202) 483

-

9370 Fax: [phone]

ANSI

:

AMERICAN

NATIONAL STANDARDS INSTLTUTE

11

West Street, 13th Floor
New York, NY 10036
Telephone: (212) 642

-

4900 Fax: [phone]

ASHRAE:

AMERICAN SOCIETY OF HEATING REFRIGERATING AND

AIR

CONDITIONING ENGINEERS, INCORPORATED
1791 Tullie Circle, N.E.
Atlanta,

GA

30329-2305

Te1 ephone: [phone] Fax: [phone]

t

NFPA: NATIONAL FIRE PROTECTION ASSOCIATION

Batterymarch Park
P.

0. Box 9101

Quincy,

MA

02269-9901

Telephone: (800) 344

-

3555 Fax: [phone]

COPYRIGHT NOVEMBER

1995

COMPU-A I RE

1

I

NC,

WHITTIER, CA

90606

CELLU-

KOOL

AIR CONDITIONER

,LID

H

PUMP

AIR

OUT

ELECTRIC HEATER (OPTIONAL)

-

EVAPORATOR COIL

/

EVAPORATOR BLOWER

I.

HIGH EFFICIENCY MOTOR

H'

-'

7

HIGH

COMPRESSOR

-

'AGE CONTROL PANEL

CONDENSER COIL

-

MODEL

DESIGNATIOX

3 3

4

HASE

I=

SINGLE PHASE

3=

THREE PHASE

YSTEM CAPACITY

2= 2TON,

3=

3TON,

4=4

TON

YSTEM TYPE

AC= AIR CONDITIONER

HP= HEAT PUMP

ERTICAL WALL HUNG UNITS

SUPPLY

Am

r

INLeT

ACCESS

PmL

---.

FILTER

AND

BLOWER MOTOR

FREE

CONDENSER

AIR

INLET

Ur

C0N.DESATE

DRAIN

-

1/2'M0UNTING

HOLE

.

FREE

COOLrNG

AIR

INLET

CONDENSER

AIR

INLET

REAR VIEW

ACCESS

CONDENSING

FRONT

VIEW

MoToR

dr

FAN

6187

BTmN

Ram

vlmlmR

a-BOW6

r

FIGURE

7

COOLING

-

COIL

DAMPER

-

BLADE

OUTSIDE

AIR

COND.

AIR

CONDENSER

1

I

EXHAUST AIR

GENERAL

The

equipment covered in this manual is to be installed by tralned, experienced service and

installation

technicians.
The refrigerant system is conpletely assembled and charged.

All

internal wiring is complete.

The unit is designed for use with or without duct work. Flanges are provided for attaching the supply and
return ducts.

These instructions explain the reconmended method to install the air cooled self

-

contained unlt and the

electrical wiring connections to the unit.

These instructions and any instructions packaged with any separate equipment required to make up the entire

air conditioning system should

be

carefully read before beginning the installation. Note particularly

"

Starting Procedure" and any tags and/or labels attached to the equiplent.

While these instructions are intended as a general recormended guide, they do not supersede any national
and/or local codes in any way. Authorities having jurisdiction should be consulted before the installation
is

made. See Page 1 for information on codes and standards.

Size of unit for a proposed installation should

be

based on heat loss calculation made according to nethods

of Air Conditioning Contractors of Amer~ca (ACCA). The air duct should

be

installed in accordance wlth the

Standards of the National Fire

Protectxon Assoc~ation for the Installation of Air

Conditioning

and

Ventilating systems of Other Than Residence Type. NFPA

No.

90A, and Residence Type Warm Air Heatlng and Air

Conditioning Systems.

NFPA

No.

90B.

Where local regulations are at a variance with instruct~ons, Installer

should adhere to local codes.

DUCT

WORK

hy heat

punp

is nore critical of proper operating charge and an adequate duct system than a straight air

conditioning unit. All duct work, supply and return.

must be properly sized for

the

design air flow

requirement of the equipment. Air Conditioning Contractors of America

(ACCA) is an excellent guide to proper

sizing. A11 duct work or portions thereof not in the conditioned space should

be

properly insulated in order

to both

mnserve energy and prevent condensation or moisture damage,

Design the duct work according to

nethods given by the hir Conditioning Contractors of America

(AKA).

When

duct runs through unheated spaces, it should

be

insulated with a mininun of one inch of insulation. Use
insulation with a vapor barrier on the outside of the insulation. Flexible joints should be used to connect
the duct

work to the equipnent in order to keep the noise transnission to a ninimun.

A

Ill-inch clearance to conbustible material for the first three feet of duct attached to the outlet air

frame is required.

Ducts through the walls must

be

insulated and all joints taped or sealed to prevent air or moisture entering

the wall cavity,

CAUTION:

Some installations may not require any return air duct. A metallic return air grille is required
with installations not requiring a return air duct. The spacing between louvers on the grille
shall not

be

larger than

518

inches.

Any grille that meets the

5/8

inch louver criteria, may

be

used. It

is

recmnded that

Compu-Aire Return Air Grille Kit

be

installed when no return duct is used. Contact distributor

or factory for ordering

information. If using a return air filter grille, filters must

be

of

sufficient size to allow a maximum velocity of

400

fpm.

NOTB:

If

no return air duct is used, applicable installation codes may limit this cabinet to installation

only in a single story structure.

FILTERS

a

A 1-inch throwaway filter is supplied with each unit.

The filter slides into position

naklng it easy to

service.

This filter can

be

serviced from the outside by renoving the service dm. A 1-inch washable

filter and 2-'inch pleated

filter are ah0 available as optional accessories. The internal filter brackets

are adjustable to accommodate the 2-inch filter

by

loosening 2 screws in each bracket assembly and sliding

the brackets apart to the required width and retightening the

4

screws.

OPTIONAL

FRESH AIR INTAKE

All units are built with a fresh air inlet slots punched in the service panel.

The fresh air damper assembly is standard

equipment

with the unit because of the variety of state or local

codes

requiring fresh air capability. It is shipped already attached to each unit.

All capacity, efficiency and cost of operation information as required for

Departaent of Energy "Energygulde"

Pact Sheets is based upn the fresh air blank-off plate in place and is recommended for max~mua energy
efficiency.

The blank-off plate is available upon request from the factory and is installed in place of the fresh air
damper shipped with each unit.

CONDENSATE DRAIN

A plastic drain hose extends fron the drain pan at the top of the unit down to the unlt base, There are

openings in the unit base for the drain hose to pass through. In the event the drain hose is connected to

a

drain systea of some type, it must

be

an open or vented type system to assure proper drainage.

- -

INSTALLATION INSTRUCTIONS

WALL

MOUNTING INFORMATION

1.

Two

holes, for the supply and return air openings, must

be

cut through the wall as shown in Figure

2,

2,

On

wood-frame walls, the wall construction must

be

strong and rigid enough to carry the welght of the un~t

without transmitting any unit vibration. WARNING:

Fire hazard can result if 119-inch clearance to

conbustible materials for supply air duct is not maintained. See Figure 2,

3.

Concrete block walls must

be

thoroughly inspected to insure that they are capable of carrylnq the weight

of the installing unit.

MOUNTING

THE

UNIT

1.

These units are secured

by

wall mounting brackets which secure the unit to the outside wall surface at

bath sides. A bottom

munting bracket is provided for ease of installation, but is not required.

2.

The unit itself is suitable for

"0"

inch clearance, but the supply air duct flange and the first three

feet of supply air duct require a

minimm of l/4-inch clearance to combustible material,

If

a

combustible wall. use a

minimum of

28-1/2" x 8-112"

dimensions

for

sizing. However,

it

is generally

recommended that a

1"

clearance is used for ease of installation and maintaining the required clearance

to combustible material.

The supply air opening would then

be

30

"

x

10".

See Fiqures 2 and

2A

for

details.

Locate and nark lag bolt locations and bottom mounting bracket location,

if

desired. See Figure

2,

kunt bottom mounting bracket. if used.

Book

top rain flashing under back bend of top. Top rain flashing is shipped attached to the back of the

unit on the right side.
Position unit in opening and secure with

5/16

lag bolts: use

3/4

inch diameter flat washers on the lag

bolts.
Secure rain flashing to wall and caulk across entire length of top. See Figure

7.

For additional munting rigidity, the return air and supply air frames or collars can

be

drilled and
screwed or welded to the structural wall itself (depending upon wall construction). Be sure to observe
required clearance if combustible wall.

On

side

by

side installations, maintain a minimum of

20

inches clearance on right

side

to allow access to

control panel and heat strips and allow proper airflow to the

outdoor coil. Additional clearance

nay

be

required to meet local or national codes.

TOP OUTLET ONLY

Reme axframe angles from the back of the unit.

Coat angles with

(2)

118"

beads of silicone as shown.

Silicone

1s

shipped in the control panel, See

Figure

28.

Secure angles to the top of the unit with

(14)

screws provided.

Use of prepunched holes provided.

Do

not relocate. See Figure

28.

After installation of ductwork, seal around airframe and ductwork to provide a rain tlght seal.
It is strongly recommended, but not required, that this unit

be

installed under a soffit area Iarqe

enough to shield the top of the unit. See Figure

2C.

mE:

IT

IS

-ED

THAT

A

BEAD

OF

SILICONE CAULKING

BE

PLACED

BEHIND

TEE

SIDE

WOWING

FLANGES

AND

UNDER

TE

TO?

FLASHING

F--

FWI

AIR

SEK

WE:

I1

1s

REUIICMB]

nu1

A

BW1

a

SlllCDH

WWG

BE

m

mtlm

ME

SlE

m1H6

~s~~1ff

~AlIlIEff

IKSIMLAIIM.

FIGURE

2A

ELECTRIC

BEAT

CLEWS

SEE

NOTE

1

Side section view of supply air duct for wall naunted unit showing

1/4"

clearance to conbustible surfaces.

WARNING

A

nininus of

114"

clearance must

be

namtained between the supply air duct and conbustible naterlals.

This

is

required for the first 3 feet of ducting.

1

I

I

It

is important to insure that the

lt4"

mininun spacing is maintained at all pints.

I

/

Failure to do this could result in overheating the mnbuntible material and nay result

in

a

fire.

I

FIGURE

2B

Refer to the unit rating

plate for wire sizing

information and maximum fuse or

"

HACR Type

"

circuit breaker size.

Each outdoor unit is marked with a

"Minimum Circuit Ampacityw.

This means

that the field wiring used must

be

sized to carry that amount of current.

Depending on the

installed

KW

of electric heat, there may

be

two field power circuits required.

If this is the

case, the unit serial plate will so indicate.

All

dels are suitable only for connection with

copper wire.

Each unit and/or wiring diagram wi

11

be

marked "Use Copper Conductors On1 y". These

instructions MUST

BE

adhered

to.

Refer to the National Electrical Code (NEC) for complete

current carrying capacity data on the various insulation grades of wiring material.

All

wiring

must conform to NEC and all local codes.
The electrical data lists fuse and wire sizes

(75OC copper) for all models, including the most

comnonly used heater sizes. Also shown are the number of field power circuits required for the

various models with heaters.
The unit rating plate

1

ists a "Maximum Time Delay Relay Fuse" or "HACR Type" circuit breaker that

is to be used with the equipment. The correct size must

be

used for proper circuit protection

and also to assure that there will

be

no

nuisance tripping due

to

the momentary high starting

current of the compressor motor.

SERVICE

HINTS

1.

Caution homeowner to maintain clean air filters at all times. Also, not

to

needlessly

close off supply and return air registers. This reduces air flow through the system,

which shortens

equipnent service life as well as increasing operating costs.

2.

Switching

to

heating cycle at

75OF

or higher outside temperature may cause a nuisance

trip of the

remote

reset high pressure switch. Turn thermostat off, then on the reset

the high pressure switch.

3.

The heat pomp wall thermostats perform multiple functions.

Be

sure that all function

switches are correctly set for the desired operating mode before trying to diagnose any

reported service problems.

4.

Check all power fuses or circuit breakers to be sure they are the correct rating.

5.

Periodic cleaning of the outdoor coil to permit full and unrestricted airflow

circulation is essential.

SEQUENCE OF OPERATION

COOCIW-Circuit R-Y makes at thermostat pulling In conpressor contactor, starting the compressor and outdoor

mtor.

The

G (indoor mtor) clrcuit is automatically conpleted on any call for cooling operation or can

be

energized

by

manual fan sw~tch on subbase for constant ax circulation.

HIU1IE--A

24'4

solenoid coil on reversing valve controls heating cycle operation.

Two

thermostat options.

one allowing

"

Auto" changeover fron cycle to cycle and the other constantly energizmg solenold coll during

heating season and thus elininating pressure equalization

nolse except during defrost, are to

be

used.

On

"

Auto" option. a circuit is conpleted from R-Ul and

R-Y

on each heating "on" cycle,

energizing

reversing

valve solenoid and pulling in compressor contactor startlng compressor and outdoor notor.

R-G

also make

starting indoor blower motor. Heat Pump heating cycle now in operation.

The second option has no

"

Auto

"
changeover position. but instead energizes the revering valve solenoid constantly whenever the systen sw~tch
on subbase is placed in "Heat" position. the

"8"

ternlnal being constantly energlzed fron

R.

A thermostat

demand for heat completes

R-Y

circuit, pulling in compressor contactor starting compressor and outdoor

mtor.

R-G also make starting indoor blower motor.

PRESSURE SERVICE PORTS

High and low pressure service ports are installed on all units so that the systen

operating

pressures can

be

observed. Pressure curves can be found later in the nanual covering all nodels on both cooling and heatlng
cycles. It is imperative to match the correct pressure curve to the unit

by

nodel number.

DEFROST CYCLE

The

defrost cycle is controlled by temperature and time on the solid state heat pu~p control,

When the outdoor tenperature is in the lower

40°F

temperature range or colder, the outdoor coll tenperature

is

32°F

or below.

This

coil temperature is sensed by the coil sensor nounted near the bottom of the

outdoor coil. Once coil temperature reaches

30'F

or below. the coil sends a signal to the control logic

of

the heat

pump

control and the defrost timer will start.

After

60

(90

or

30)

minutes at

30'P

or

belov, the heat punp control will place the system in the defrost

node.
During the

defrost node, the refrigerant cycle switches back to the cooling cycle, the outdoor mtor

stops,

electric heaters are energized, and hot gas passing through the outdoor coil me1 ts any accunulator frost.

When the temperature rises to approxinately

57"P,

the coil sensor will send a signal to the heat punp

control which will return the

system to heating operations automatically.

If

some abnormal or temporary condition such as a high wind causes the heat pump to have a prolonged defrost

cycle, the heat punp control will restore the

system to heating operation automatically after 10 minutes.

TROUBLESHOOTING

SOLID

STATE

HEAT

W

COKFROC

TRWBLESHOOTING

PROCEDURE

1.

Turn on AC power supply to indoor and outdoor units.

2.

Turn thermostat blower switch to fan on--the indoor blower should start. (If it
doesn't, troubleshoot indoor unit and correct problem).

3.

Turn thermostat blower switch to auto position. Indoor blower should stop.

4.

Set system switch

to

heat or cool. Adjust thermostat to call for heat or cool--The

indoor blower, compressor, and outdoor fan should start.

NOTE:

If there was

no

power

to

24

volt transformer, the compressor and outdoor fan motor will

not start for

5

minutes. This is because of the compressor short cycle protection.

FAN

BLADE

SETTING DIMENSIONS

Shown

in the drawing below are the correct fan blade setting dimensions for proper air delivery across the

outdoor coil.

Any

service

vork

requiring renxral or adjustment in the fan andlor notor area

will

require that the

dinensions below

be

checked and blade adjusted in or out on the motor shaft accordingly.

REMOVAL

OF

THE

FAN

SHROUD

1.

Diconned: all power to unit.

2.

Reme

the

screws holding both grills--one on each side of unit--and remove grills,

3.

Reme screws holding fan shroud to condenser and batton.

(9)

screws.

I.

Unwire condenser fan motor.

5.

Slide complete motor, fan blade, and shroud asseably out the left side of the unit.

6.

Setvice motor/fan as needed.

7.

Rwerse steps to reinstall