2HP13 & 2HP14 SPLIT SYSTEM HEAT PUMP INSTALLATION / START-UP INSTRUCTIONS /HOMEOWNERS INFORMATION MANUAL
These instructions must be read and understood completely before attempting installation.
Issue 0733
TABLE OF CONTENTS
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Unit Location & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Rooftop Installation & Recommendations . . . . . . . . . . . . . . . . . . . . 3
Indoor Coil Piston Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Refrigeration Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation of Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Evacuating & Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Opening Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
5 |
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
5 |
Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
6 |
Adjusting charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
6 |
Defrost System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
7 |
Single Phase Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
9 |
3 Phase Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
10 |
Homeowner's Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
15 |
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
17 |
These units are designed for use in residential and light commercial type buildings. Heat Pumps may only be installed with indoor combinations listed in the Air-Conditioning and Refrigeration Institute (ARI) Directory of Certified Products. Refer to http://www.aridirectory.org/index.html .
Inspect the unit for any damage before installation. If damage is found, notify the transportation company immediately and file a concealed damage claim.
Installation or repairs made by unqualified persons can result in hazards to you and others. Installation MUST conform with local building codes and with the National Electrical Code NFPA 70/ANSI C1-1993 or current edition and Canadian Electrical Code Part 1 CSA C22.1.
Improper installation, adjustment, alteration, service or maintenance will void the warranty. The qualified installer or agency must use factory-authorized kits or accessories when added to this products. Refer to the individual instructions included with the specific accessory kit.
NOTE
These instructions are intended as a general guide and do not supersede national, state or local codes in any way.
These instructions must be left with the property owner.
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NOTE TO INSTALLING DEALER
These instructions and warranty are to be given to the owner or displayed near the indoor air handler unit.
This product and/or the indoor unit that is matched with may contain fiberglass wool.
Disturbing the insulation during installation, maintenance, or repair will expose you to fiberglass wool dust. (Fiberglass wool is known to the State of California to cause cancer.)
Fiberglass wool may also cause respiratory, skin, and eye irritation.
To reduce exposure to this substance or for further information, consult material safety data sheets available from your distributor.
Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position. There may be more than 1 disconnect switch. Lock out and tag switch with a suitable warning label. Electrical shock can cause personal injury or death.
Safety Precautions
Follow all safety codes. Wear safety glasses and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warning or cautions attached to the unit.
1.Always wear proper personal protection equipment.
2.Always disconnect electrical power before removing panel or servicing equipment.
3.Keep hands and clothing away from moving parts.
4.Handle refrigerant with caution, refer to proper MSDS from refrigerant supplier.
5.Use care when lifting, avoid contact with sharp edges.
UNIT LOCATION & INSTALLATION
NOTE: In some cases noise in the living area has been traced to gas pulsations from improper installation of equipment.
1.Locate unit away form windows, patios, decks, etc. where unit operation sounds may disturb customer.
2.Ensure that vapor and liquid tube diameters are appropriate to capacity of unit.
3.Run refrigerant tubes as directly as possible by avoiding unnecessary turns and bends.
4.Leave some slack between structure and unit to absorb vibration.
5.When passing refrigerant tubes through the wall, seal opening with RTV or other silicon-based caulk.
6.Avoid direct tubing contact with water pipes, duct work, floor joists, wall studs, floors, walls, and any structure.
7.Do not suspend refrigerant tubing from joists and studs with a rigid wire or strap which comes in direct contact with tubing.
8.Ensure that tubing insulation is pliable and completely surrounds vapor tube.
When outdoor unit is connected to factory-approved indoor unit, outdoor unit contains system refrigerant charge for operation with indoor unit of the same size when connected by 15 ft. of field-supplied tubing. For proper unit operation, check refrigerant charge using charging information located on control box cover.
IMPORTANT: Maximum liquid-line size is 3/8 in. O.D. for all residential applications including long lines.
Outdoor Section
Zoning ordinances may govern the minimum distance the condensing unit can be installed from the property line.
Install on a Solid, Level Mounting Pad
The outdoor section is to be installed on a solid foundation. This foundation should extend a minimum of 2" (inches) beyond the sides of the outdoor section. To reduce the possibility of noise transmission, the foundation slab should NOT be in contact with or be an integral part of the building foundation.
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Elevate Unit
Accumulation of water and ice in base pan may cause equipment damage.
Elevate unit per local climate and code requirements to provide clearance above estimated snowfall level and ensure adequate drainage of unit. Use snow stand in areas where prolonged freezing temperatures are encountered.
If conditions or local codes require the unit be attached to pad or mounting frame, tie down bolts should be used and fastened through knockouts provided in unit base pan.
Roof Top Installations
Mount on level platform or frame 6 inches above roof surface. Place unit above a load-bearing wall and isolate unit and tubing set from structure. Arrange supporting members to adequately support unit and minimize transmission of vibration to building. Ensure roof structure and anchoring method is adequate for location. Consult local codes governing rooftop applications.
Roof mounted units exposed to winds above 5 mph may require wind baffles to achieve adequate defrost. A sheet metal baffle should be spaced 6-1/2" from the fall of the coil. The height should cover the face of the coil and the length should be 6" from the access panel.
NOTE: Unit must be level to within ± 2/ (± 3/8 in./ft) per compressor manufacturer specifications.
Clearance Requirements
When installing, allow sufficient space for airflow clearance, wiring, refrigerant piping, and service. For proper airflow, quiet operation and maximum efficiency. Position so water, snow, or ice from roof or eaves cannot fall directly on unit.
DO LOCATE THE UNIT:
!With proper clearances on sides and top of unit
!On a solid, level foundation or pad
!To minimize refrigerant line lengths
DO NOT LOCATE THE UNIT:
!On brick, concrete blocks or unstable surfaces
!Near clothes dryer exhaust vents
!Near sleeping area or near windows
!Under eaves where water, snow or ice can fall directly on the unit
!with clearance less than 2 ft. from a second unit
!with clearance less than 4 ft. on top of unit
Operating Ambient
The minimum outdoor operating ambient in cooling mode is 55/F, and the maximum outdoor operating ambient in cooling mode is 125/F. The maximum outdoor operating ambient in heating mode is 66/F.
Indoor Coil Piston Selection
The outdoor heat pump section must be matched to a factory approved indoor section. It is mandatory that the installer ensure that the correct piston is installed in the indoor section. If necessary remove the existing piston and replace it with the correct piston See indoor unit instructions for details of changing the piston. Contact your distributor for accessory piston kits.
Indoor (Cooling) Piston Size
13 SEER Heat Pump Indoor Piston Sizes
Unit Size |
Piston Size |
18 |
.055 |
24 |
.063 |
30 |
.068 |
36 |
.076 |
42 |
.076 |
48 |
.082 |
60 |
.098 |
The evaporator coil may use an expansion valve (TXV) in place of piston.
14 SEER Heat Pump Models
All 14 SEER heat pump models are only rated with TXV on the indoor side.
14 SEER Heat Pump Indoor TXV
Unit Size |
TXV Kit |
18 thru 36 |
TXV3 |
42 thru 48 |
TXV5 |
Refrigeration Line Sets
Use only refrigerant grade copper tubes. Split systems may be installed with up to 50 feet of line set (no more than 20 feet vertical) without special consideration (see long line set guidelines).
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Recommended Liquid & Vapor Tube Diameters (In.)
Unit Size |
|
LIQUID |
VAPOR |
||
Connection Dia. |
Tube Dia. |
Connection Dia. |
Tube Dia. |
||
018 |
3/8" |
|
3/8" |
3/4 |
3/4 |
024 |
3/8" |
|
3/8" |
3/4 |
3/4 |
030 |
3/8" |
|
3/8" |
3/4 |
3/4 |
036 |
3/8" |
|
3/8" |
3/4 |
3/4 |
042 |
3/8" |
|
3/8" |
7/8 |
7/8 |
048 |
3/8" |
|
3/8" |
7/8 |
7/8 |
060 |
3/8" |
|
3/8" |
7/8 |
*1-1/8 |
*FIELD SUPPLIED 7/8 X 1-1/8 CONNECTOR REQUIRED ON BOTH ENDS OF VAPOR TUBING.
It is important that no tubing be cut or seals broken until you are ready to actually make connections to the evaporator and to the condenser section. DO NOT remove rubber plugs or copper caps from the tube ends until ready to make connections at evaporator and condenser. Under no circumstances leave the lines open to the atmosphere for any period of time, if so unit requires additional evacuation to remove moisture.
Be extra careful with sharp bends. Tubing can "kink" very easily, and if this occurs, the entire tube length will have to be replaced. Extra care at this time will eliminate future service problems.
It is recommended that vertical suction risers not be up-sized. Proper oil return to the compressor should be maintained with suction gas velocity.
Installation of Line Sets
DO NOT fasten liquid or suction lines in direct contact with the floor or ceiling joist. Use an insulated or suspension type of hanger. Keep both lines separate, and always insulate the suction line. Long liquid line runs (30 feet or more) in an attic will require insulation. Route refrigeration line sets to minimize length.
DO NOT let refrigerant lines come in direct contact with foundation. When running refrigerant lines through the foundation or wall, openings should allow for a sound and vibration absorbing material to be placed or installed between tubing and foundation. Any gap between foundation or wall and refrigerant lines should be filled with a vibration damping material.
If ANY refrigerant tubing is buried, provide a 6 inch vertical rise at service valve. Refrigerant tubing lengths up to 36 inches may be buried without further special consideration. For lengths above 36 inches, consult your local distributor.
Before making braze connections, be sure all joints are clean. Before heat is applied for brazing, dry nitrogen should be flowing through the tubing to prevent oxidation and scale formation on the inside of the tubing.
The following is the recommended method for making braze connections at the refrigerant line connections:
1.Debur and clean refrigerant tube end with emery cloth or steel brush.
2.Insert tubing into swage fitting connection.
3.Wrap wet rags over valves to protect from heat.
4.Allow dry nitrogen to flow through refrigerant lines.
5.Braze joint, using a suitable brazing alloy for copper to copper joints.
6.Quench the joint and tubing with water using a wet rag. Leave rag on fitting body and re-wet with water to help cool area.
Leak Check
Refrigeration lines and indoor coil must be checked for leaks after brazing and before evacuation. The recommended procedure is to apply a trace amount of vapor refrigerant (approximately two ounces or 3 psig) into the line set and indoor coil, then pressurize with 150 psig of dry nitrogen. Use a refrigerant leak detector to check all joints. The system may also be checked for leaks using a halide torch or pressure and soapy solution. After completion of leak check, relieve all pressure from system before evacuation.
Evacuating And Charging Instructions
NOTE: Intentional release of CFC or HCFC refrigerant to the atmosphere violates Federal Law. It may also violate State and Local Codes. Check all Federal, State and Local Codes before proceeding.
These outdoor units are pre-charged at the factory with adequate refrigerant to handle 15 feet of refrigerant tubing.
NOTE: DO NOT use any portion of the charge for purging or leak testing. It is mandatory that a thorough evacuation of the refrigeration lines and indoor coil be performed.
The liquid line and suction line service valves have been closed after final testing at the factory. DO NOT disturb these valves until the lines have been leak checked and evacuated or the charge in the unit may be lost.
1.Connect the vacuum pump to the center hose of the manifold gauge set, the low-pressure manifold gauge to the vapor service valve and the high pressure manifold gauge to the liquid service valve.
NOTE: Unnecessary switching of hoses can be avoided and complete evacuation of all lines can be achieved by also connecting a branch hose from the manifold gauge center port to a cylinder of R- 22. Provide a separate shut-off valve to vacuum pump to avoid contaminating vacuum pump oil with refrigerant.
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2.The valves should be kept in the "front seated" (closed) position. This will allow evacuation of the refrigeration lines and the indoor coil, without disturbing the factory charge in the outdoor unit.
3.Follow the vacuum pump manufacturer's instructions. Allow the pump to operate until the system has been evacuated down to 300 microns. Allow the pump to continue running for an additional 15 minutes. Turn OFF the pump and leave the connections secured to the two (2) service valves. After 5 minutes, if the system fails to hold 500 microns or less, check all connections for tight fit and repeat the evacuation procedure.
4.Isolate the vacuum pump from the system by closing the shutoff valves on the gauge-set. Disconnect the vacuum pump.
Opening Service Valves
After evacuation of the connecting lines, remove the service valve cap and fully insert the hex wrench into the stem. A back-up wrench is required on the valve body to open the valve stem. Back-out counterclockwise until the valve stem just touches the coined edge.
Wrench sizes:
3/8 service valve: 3/16" Hex wrench 3/4 service valve: 5/16" Hex wrench 7/8 service valve: 5/16" Hex wrench
Replace service valve cap and torque to 8-11 ft-lb on 3/8" valves; 12-15 ft-lb on 3/4" valves; 15-20 ft-lb on 7/8" valves. Use backup wrench on valve body when torqueing valve cap.
Install Electrical Accessories
Refer to the instructions packaged with the accessories.
Electrical Connections
ELECTRICAL SHOCK HAZARD!
Turn OFF electric power before connecting unit, performing any maintenance or removing panels or doors. More than one disconnect may be required to turn off all power.
FAILURE TO DO SO COULD RESULT IN BODILY INJURY OR DEATH.
Be sure to check all local codes to determine that the unit is installed accordance with local requirements. Consult the National Electric Code for wire size requirements. Use 60/ C wire or higher. Always provide ground connections to the outdoor unit. Power supply must agree with rating on unit nameplate.
Provide line voltage power supply to unit from a properly sized disconnect switch. Route power and ground wires from disconnect switch to unit. Line voltage connections are made at the line side of the contactor in the control box of the outdoor unit. Follow the appropriate wiring diagram attached to inside of the access panel.
Proper circuit protection recommendations are indicated on Unit Rating Plate. Time delay fuses are required to prevent blowing due to starting current (the current in rush when equipment starts is referred to as the Locked Rotor Amps or (LRA). A fuse of this kind properly sized will give maximum equipment protection.
Use copper wire only between disconnect switch and unit.
Remove access panel to gain access to unit wiring. Extend wires from disconnect through power wiring hole provided and into unit control box. Flexible conduit is required for the swing out control box feature.
The unit cabinet must have an uninterrupted or unbroken ground to minimize personal injury if an electrical fault should occur. The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes. Failure to follow this warning can result in an electric shock, fire, or death.
Connect ground wire to ground connection in control box for safety. Connect power wiring to contactor.
High voltage power connections to 3-phase models is made to "Pig Tail" leads with field supplied splice connectors.
Control Wiring
The control voltage is 24 Vac. NEC Class I insulated 18 AWG is required for control wiring. For lengths longer than 150 feet, contact your local distributor for technical service.
Ensure the room thermostat is properly installed per instructions shipped with room thermostat. Generally the thermostat should not be exposed to sunlight, drafts or vibration and should not be mounted on exterior walls.
Low voltage control wire connections should be made to the screw connection terminal board mounted on the defrost control as shown. All low voltage control wiring must be separated from incoming power leads.
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Heat Pump Application with Electric Heat
Emergency Heat (heating heat pump)
If selector switch on thermostat is set to the emergency heat position, the heat pump will be locked out of the heating circuit, and all heating will be electric heat ( if applicable). A jumper should be placed between W and E on the thermostat so that the electric heat control will transfer to the first stage heat on the thermostat. This will allow the indoor blower to cycle on and off with the electric heat when the fan switch is in the AUTO position.
* Add Jumper on Subbase (Optional)
Start-Up Procedure
1.Check to ensure:
!Service valve and gage port caps are installed and tightened.
!Voltage supply at unit agrees with nameplate rating.
!Field wiring connections are tight and factory wiring has not been disturbed and are tight.
!Indoor fan motor is on correct speed tap.
2.Set thermostat selector switch to OFF and fan control switch to "Auto" is so equipped.
3.Close electrical disconnects to energize system.
4.Set room thermostat at desired temperature. Be sure set point is below indoor ambient temperature.
5.Set the system switch of the thermostat on COOL (or HEAT if applicable) and fan switch for continuous operation (ON) or AUTO, as desired. There will be a 5 minute short cycle compressor delay on startup. Operate unit for 15-20 minutes, then check the system refrigerant charge.
6.Adjust refrigerant charge per "Adjusting Charge" section.
Adjusting Charge
Factory charge is shown on the rating label located on the access panel.
All split system heat pumps are factory charged for 15 feet of connecting line set and matched indoor fan coil. Nameplate refrigerant charge should initially be adjusted for line set lengths other than 15 feet. For line sets shorter than 15 feet in length, remove charge. For line sets longer than 15 feet, add charge. Oil charge is sufficient for all line lengths.
Refrigeration Charge Adjustment
Liquid Line Diameter |
Oz. Per Linear Foot * |
3/8" |
.6 |
*Factory charge for series is for 15' (ft.) line sets and matched fan coil.
Before final adjustment is made to the refrigerant charge, it is imperative that proper indoor airflow be established. Airflow will be higher across a dry coil versus a wet coil. Blower charts are calculated with a dry or wet coil basis. Recommended airflow is 350-450 CFM per ton (12,000 Btuh) through a wet coil. Refer to indoor unit instructions for methods of determining air flow and blower performance.
Cooling Cycle Charge Adjustment
The optimum method for checking the charge is by weight. However the following methods may be used to confirm the proper charge:
Units with Indoor Pistons
Units installed with indoor pistons require charging with the superheat method.
The following procedure is valid when indoor airflow is within ± 20% of its rated CFM.
1.Operate unit a minimum of 10 minutes before checking charge.
2.Measure suction pressure by attaching a gage to suction valve service port. Do not use compressor suction port. Determine saturation temp from T/P chart.
3.Measure suction temperature by attaching an accurate thermistor type or electronic thermometer to suction line at service valve.
4.Calculate superheat (measured temp. — saturation temp.).
5.Measure outdoor air dry-bulb temperature with thermometer.
6.Measure indoor air (entering indoor coil) wet-bulb temperature with a sling psychrometer.
7.Compare superheat reading at service valve with the chart located on control box cover.
8.If unit has a higher suction line temperature than charted temperature, add refrigerant until charted temperature is reached.
9.If unit has a lower suction line temperature than charted temperature, reclaim refrigerant until charted temperature is reached.
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