INSTALLATION
& OPERATING
INSTRUCTIONS
7-1/2 & 10 TON
SPLIT SYSTEM HEAT PUMP
GOODMAN MANUFACTURING COMPANY, L.P.
2550 North Loop West, Suite 400
Houston, Texas 77092
www.goodmanmfg.com
1
12/02IO-229
I General Warnings
III Product Description
WARNING
Before servicing or installing this equipment, the electrical power
to this unit MUST be in the "OFF" position. CAUTION: more than
one disconnect may exist. Failure to observe this warning may
result in an electrical shock that can cause serious personal injury
or death.
WARNING
The unit MUST have an uninterrupted, unbroken electrical ground
to minimize the possibility of personal injury if an electrical fault
should occur. The electrical ground circuit must consist of an appropriately sized electrical wire connecting the ground lug in the
unit control box wire to the building electrical service panel. Other
methods of grounding are permitted if performed in accordance
with the "National Electric Code" (NEC)/"American National Standards Institute" (ANSI)/"National Fire Protection Association"
(NFPA) 70 and local/state codes. In Canada, electrical grounding
is to be in accordance with the Canadian Electric Code CSA C22.1.
Failure to observe this warning can result in electrical shock that
can cause serious personal injury or death.
Due to high system pressure and electrical shock potential, installing and the servicing air conditioning systems can be hazardous. ONLY TRAINED AND QUALIFIED PERSONNEL ARE PERMITTED TO INSTALL OR SERVICE THIS EQUIPMENT. Observe
ALL warnings contained in this manual and labels/tags attached to
the equipment.
When installing or servicing this equipment, safety clothing including hand and eye protection, is strongly advised. If installing this
equipment in an area that has special safety requirements (hard
hats etc.) observe these requirements. To protect the unit when
welding close to the painted surfaces, the use of a quenching cloth
is strongly advised to prevent scorching or marring of the equipment finish.
Read these instructions before performing this installation or servicing this unit. All installations must be in accordance with all
national, state, or local building codes.
II Model Identification
CPLE 090 - 3
Electrical Designation
3 - 208-230/3/60
4 - 460/3/60
Nominal Cooling Capacity
090 - 7 ½ Tons
120 - 10 Tons
Series Identification
CPLE - Louvered Series Heat Pump
When matched with the appropriate airhandler(s) or evaporator
coil(s) the CPLE090/120 heat pump complies with the minimum
efficiency requirements found in ASHRAE 90.1-1999. See the
Goodman CPLE090/120 specification sheet for the indoor model
selection recommendation.
The CPLE090/120 product operates in the same manner as most
residential heat pumps. However, unlike some residential heat
pumps, these products use a TXV in lieu of a flowrater/piston
system for refrigerant management.
The CPLE series are intended for use with a single stage room
thermostat. This thermostat is not supplied with this equipment.
Only thermostats that use 24 VAC control circuitry are to be used.
Table 1.
CPLE090 CPLE120
Net Weight (Lbs.) 365
Shipping Weight (Lbs.) 390
Refrigerant
Compressor Type
Quantity
Oil Charge Initial/Recharge 85/81 110/106
Condenser Fan Type
Fan Diameter (in)
Fan Motor Type
Fan Motor (HP)
Fan Motor (RPM)
Nominal Cond. Airflow (CFM)
Condenser Coil Material
2
Face Area (Ft
Refrigerant Connections
Suction Line Connection (in)
Liquid Line Connection(in)
High Pressure Control (PSIG)
Low Pressure Control (PSIG)
Thermal Expansion Valve 1
)
Riffled Copper Tubes / Al Fins
425 Cut-out / Manual Reset
R22
Scroll
Propeller
26
Direct Drive PSC
1100
6600
30
Sweat Type
1-3/8
5/8
7 Cut-out / 25 Cut-in
415
440
1
1
IV Ductwork Considerations
To ensure correct performance, the indoor ductwork is to be sized
to accommodate 375-425 CFM per ton of cooling with the static
pressure not to exceed .5" WC. Inadequate ductwork that restricts
airflow can result in improper cooling performance and compressor failure.
V Unit Inspection
Upon delivery, the unit is to be inspected for damage. Any damage must be reported immediately to the carrier. Do not install this
equipment if it is determined that the integrity or safety has been
compromised by freight damage.
Using the "Model Identification" section, check the equipment model
number to ensure the following:
¾ Correct Size and Model
¾ Correct Voltage
If an incorrect unit is supplied, it must NOT be installed and it is to
be returned to the supplier. The manufacturer assumes no responsibility for the installation of incorrect delivered units.
2
VI Site Selection
This unit is designed for outdoor installations only.
Prohibited Locations. Do not locate this unit in the following
locations:
Air Supply. The CPLE products are air-cooled heat pumps. To
ensure the optimum unit performance, the installation site should
provide unobstructed airflow. See Figure 1 for minimum clearances from other air-cooled condensers/heat pumps and obstructions such as walls or overhangs. Note: It is recommended that
adequate service clearances also be considered.
Figure 1.
60"
24"
12"
12"12"
¾ Inside a building
¾ Directly under a vent termination from a gas appliance
¾ Within 3 feet of a clothes dryer vent
¾ Where water may rise into the unit
VII Typical Installations
The typical locations for the CPLE unit are slab mounted and roof
mounted. For unit weight data, see the "Product Description" section of this manual.
Slab Mounting. The slab MUST be capable of supporting the weight
of the unit. The slab should be a minimum of 6" wider than the unit
in all directions. If required, the slab should be elevated to protect
the unit from water damage due to flooding. Before installing the
unit onto a slab, the wooden shipping skid MUST be removed.
Roof Mounting. Give careful consideration to the load carrying
capability of the roof. If possible, locate the unit where walls or
partitions can offer additional support. If doubt exists regarding
the integrity of the roof or its supporting structure, consult a structural engineer.
VIII Rigging
Refrigerant System Requirements. The selected site should be
no greater than 50’ below or 70’ above the evaporator section.
For optimum performance, the minimum length interconnecting
tubing is preferred. When possible minimize the amount of bends
and turns.
Wiring and Tubing Protection. Electrical wiring and refrigerant
tubing is to be protected from damage due to incidental contact
such as being walked upon.
Vibration and Sound Control. The CPLE series is engineered to
produce the minimum sound and vibration. To minimize the
possibility of either sound or vibration issues, the CPLE condenser
is to be securely mounted to a surface that is:
¾ Solid
¾ Greatest practical mass
¾ Ridged
¾ Minimum radiating surface
WARNING
All panels MUST be in position and secured before lifting this
equipment.
Figure 2.
When possible the slab for a ground level unit should not be
connected to the wall or the building.
When lifting the unit, use spreader bars (field supplied). This practice will minimize the possibility of lifting cable/straps damage. Also,
to protect the cabinet louvers, the use of protective material such
as plywood behind the cables/straps is recommended.
3
Arrange the straps to form a central suspension point (see Figure
2 for details). When raising and setting the unit, observe all
safety rules. When the unit is in position, the wooden shipping
skid, all protection and lifting materials are to be removed.
IX Unit Corner Weight
The following table and sketch are to be used for determining
the unit corner weight. The unit net weight and shipping weight
is provided in the “Product Description” section, Page 2, of this
manual.
Piping Size Use a carefully estimated length of refrigerant tubing
(distance between condenser and evaporator). Apply the
following table to determine the tubing diameter:
Table 3.
MODEL
CPLE090
CPLE120
L = Liquid Line S = Suction Line * = Full Rating Line Size
0' - 24' *25' - 49'
Outside Diameter Line Size (in.)
LSLSLSLS
5/8 1-1/8 5/8 1-3/8 5/8 1-3/8 5/8 1-3/8
5/8 1-3/8 5/8 1-5/8 5/8 1-5/8 5/8 1-5/8
50' - 74' 75' - 99'
Figure 3.
35.500"
D
A
C
35.500"
B
Corner CP LE090 CPLE120
A 95 Lbs. 110 Lbs.
B 95 Lbs. 110 Lbs.
C 80 Lbs. 85 Lbs.
D 95 Lbs. 110 Lbs.
Table 2.
X Refrigerant Tubing
41.500"
Suction Line Insulation. All suction lines are to be insulated with
a recognized tubing insulation that is a minimum of 3/8" thick.
Solder. Solder should consist of a minimum of 2% silver.
Hangers and Isolation. All refrigerant lines are to be isolated from
the structure and supported with hangers. See Figure 4 below for
details.
Figure 4.
Inverted Suction Line Loop. When the condenser is located at
the same level or above the evaporator section, an inverted loop
is to be employed on the suction line. This practice will prevent
liquid refrigerant from migrating into the compressor during
shutdown. See Figure 5.
WARNING
To avoid overheating of the service valves, protect the valve
with a wet rag or similar approved thermal heat trap. Failure to
observe this practice can result in damage to the valve.
As previously noted, protective clothing and eye protection
should be used when making any welded connection.
Preparing the Tubing. All cut ends are to be round, burr free
and cleaned. Failure to follow this practice increases the
chances for refrigerant leaks.
Post Brazing. Quench all welded joints with water or a wet rag.
Figure 5.
F
Oil Return. To facilitate oil return to the compressor, a horizontal suction line should be pitched (1/2" per 10’) toward the
condensing unit.
4
Figure 6.
T
/
Figure 6.
PITCH SUCTION INE
CONDENSING UNIT 1
EVERY 10' OF LINE
the unit control box wire to the building electrical service panel.
Other methods of grounding are permitted if performed in
accordance with the “National Electric Code” (NEC)/”American
National Standards Institute” (ANSI)/”National Fire Protection
Association” (NFPA) 70 and local/state codes. In Canada,
electrical grounding is to be in accordance with the Canadian
Electric Code CSA C22.1. Failure to observe this warning can
result in electrical shock that can cause serious personal injury
or death.
Condenser Above the Evaporator When the condenser is
located 4’ or greater above the evaporator section, suction line
oil trap is to be used at the base of the riser. An additional oil
trap is to be added for each 20’ of vertical riser. See Figure 7
below
Figure 7.
Filter Drier and Sight Glass. A bi-flow liquid line filter drier is factory
installed. A Sight Glass/Moisture indicator is provided with the
unit. This is to be field installed on the liquid line as close as
practical to the service valve.
Holding Charge. The CPLE series is factory shipped with a 2 lb.
R-22 holding charge. When welding, introduce an inert gas (i.e.
nitrogen) through the tubing to prevent the formation of copper
oxide inside the tubing.
Evaporator Coil TXV. For improved refrigerant management, the
evaporator coil is to be equipped with a thermal expansion valve
(TXV).
Liquid Line Solenoid. It is recommended that a field supplied
liquid line solenoid be added to the liquid line as close as possible
to the evaporator coil. The solenoid is to be wired to close when
the compressor stops to prevent refrigerant migration in the “OFF”
cycle.
Evacuation and Charging. See the “Evacuation and Charging”
section Page 7 of this manual for these instructions.
XI Electrical Wiring
WARNING
Before servicing or installing this equipment, the electrical power
to this unit MUST be in the “OFF” position. CAUTION: more than
one disconnect may exist. Failure to observe this warning may
result in an electrical shock that can cause personal injury.
The unit MUST have an uninterrupted, unbroken electrical ground
to minimize the possibility of personal injury if an electrical fault
should occur. The electrical ground circuit may consist of an
appropriately sized electrical wire connecting the ground lug in
WARNING
To avoid the risk of fire or equipment damage use only copper
conductors.
Inspection of the Building Electrical Service. This unit is designed
for 3-phase operation. DO NOT OPERATE ON A SINGLE PHASE
POWER SUPPLY. Measure the power supply to the unit. The
supply voltage MUST be in agreement with the unit nameplate
power requirements and within the range shown below, Table 4:
Table 4.
Model
CPLE090-3 187 253
CPLE090-4 414 506
CPLE120-3 187 253
CPLE120-4 414 506
Voltage Balance The supply voltage shall be unbalance (phase
to phase) within 2%. To calculate the percentage of voltage
unbalance use the following formula:
Percentage
Voltage
Unbalance
Example
Ave. Voltage
Max. Deviation from Avg.
% Voltage Unbalance
Determine Wire Size The selection of the appropriate supply
wire size is important to the operation of the equipment. When
selecting the wire size, the following are important elements of
the decision:
¾ The wire size is sufficient to carry the Minimum Circuit
Ampacity (MCA). The unit MCA can be found on the
equipment S&R plate and the following table.
Table 5.
5
Minimum Supply Maximum Supply
Voltage Voltage
Max. Voltage Deviation From
= 100 x
Avg. Voltage
Avg. Voltage
L1 - L2 = 220V
L2 - L3 = 216V
= (220+216+213) / 3
= 649 / 3
= 220 - 216 = 4
= 100 x (4 / 216)
= 400 / 216
Model MCA
CPLE090-3 37.8
CPLE090-4 18.8
CPLE120-3 43.3
CPLE120-4 22.2
¾ The wire size is appropriately sized to allow for no more than
6
a 2% voltage drop from the building breaker/fuse panel to the
unit.
¾ Refer to the latest edition of the National Electric Code, or in
Canada the Canadian Electric Code, when determining the
correct wire size. The following table shows the current
carrying capabilities for copper conductors rated at 75
o
C with
a 2% voltage drop.
Table 6.
Max. Allowable length in Feet to Limit Voltage drop to 2%
Wire Size
(AWG)1015202530354045
14 75 50 37 NR NR NR NR NR
12 118 79 59 47 NR NR NR NR
10 188 125 95 75 63 54 NR NR
8 301 201 150 120 100 86 75 68
6 471 314 235 188 157 134 118 110
Based on NEC 199
Min. Circuit Ampacity (MCA) – CPLE Unit
As noted elsewhere in this manual, this unit must be grounded.
The electrical ground circuit must consist of an appropriately sized
electrical wire connecting to the ground lug in the unit control box
and wire to the building electrical service panel. Other methods
of grounding are permitted if performed in accordance with the
“National Electric Code” (NEC)/”American National Standards
Institute” (ANSI)/”National Fire Protection Association” (NFPA) 70
and local/state codes. In Canada, electrical grounding is to be in
accordance with the Canadian Electric Code CSA C22.1.
Low Voltage Connections The CPLE requires a 5-conductor low
voltage circuit from the room thermostat (without options). The
wires are to be no smaller than 18 AWG. The field connection for
this circuit is to be made in the unit control box using solderless
connectors such as wire nuts. See Figures 8 and 9 for a typical
low voltage hook-up.
Example
A CPLE120-3 is to be installed. The distance from the
building breaker box to the unit is 75’. Calculate the
minimum wire size assuming no more than 2% voltage drop.
MCA for CPLE120-3 = 43.3 (from S&R plate and table).
Applying previous table wire sizes less than #8 AWG cannot
be used for circuits which have a rating of 45A. The #8
wire is not suitable since the maximum length for a 45A
circuit is 68’. Solution, a #6 AWG wire is suitable up to
110’. Note: It is the contractors responsibility to follow the
NEC (USA) or CEC (Canada) when sizing the service wire
for this unit.
Service Disconnect Box. A service disconnect box is required as
per NEC.
Fuse – HACR Breakers
Protection is provided by either fuses or HACR type breakers.
Refer to the unit S&R plate and Table 7 for the maximum
overcurrent protection permitted.
Table 7.
Model *Max. Fuse
CPLE090-3 60
CPLE090-4 30
CPLE120-3 60
CPLE120-4 35
* Fuse or HACR Breaker of same value.
SINGLE STAGE LOW VOLTAGE HOOK-UP
THERMOSTAT
OW2CR
YG
CONDENSING
UNIT
CPLE090/120
YELLOW
ORANGE
RED
WHITE
AIR
HANDLER
AH090/120
GREEN
RED
BROWN
WHITE
BLUEBLUE
Figure 8.
TWO STAGES LOW VOLTAGE HOOK-UP
THERMOSTAT
Y
O
CONDENSING
UNIT
CPLE090/120
YELLOW
ORANGE
RED
WHITE
BLUE BLUE
C
W2
W1 R
G
AIR
HANDLER
AH090/120
GREEN
RED
BROWN
WHITE
Line Voltage Wiring ALL line voltage wiring is to be run through
conduit from the service disconnect box to the unit. Refer to the
NEC (in Canada CEC) for the correct size conduit based on the
wire size. The conduit is to enter the control box through the hole
provided in the bottom of the control box. Note: hole is sized for
¾” conduit. If permitted by code, flexible conduit is preferred to
minimize vibration transmission from the unit to the building.
Connect the line voltage wires to the L1, L2, and L3 terminals of
the definite purpose contactor (located in the unit control box).
Refer to the wiring diagram attached to the unit when making
these connections. Note: the unit wiring diagram is also included
at the end of this manual.
Figure 9.
6
Control Box Components See Figure 10 for the location of the
electrical components.
Figure 10.
DEFROST
CONTROL
CONTACTOR
CONDENSER FAN
DEFROST RELAY
CAPACITOR
To avoid possible explosion, use refrigerant cylinders properly:
¾ If you must heat a cylinder for faster charging, partly immerse
it in warm water. Never apply flame or steam to the cylinder.
¾ Store cylinders in a cool, dry place. Never use a cylinder as a
platform or a roller.
¾ Never add anything other than R-22 to an R-22 cylinder.
¾ Never fill a cylinder more than 80% full of liquid refrigerant.
¾ When removing refrigerant from a system, use only returnable
(not disposable) service cylinders. Check the cylinder for its
pressure rating and hydrostatic test date. Check the cylinder
for any damage, which may lead to a leak or explosion. If in
doubt, do not use the cylinder.
Leak Testing
HIGH VOLTAGE
CONNECTIONS
HIGH VOLTAGE
ENTRANCE
LOW VOLTAGE
ENTRANCE
GROUND LUG
LOW VOLTAGE
CONNECTIONS
XII Outside Thermostat
An outside thermostat kit that includes an emergency heat relay
is available as an accessory. Follow the manual provided with
the OT/EHR18-60 for installation practices.
XIII System Evacuation and Charging
WARNING
To avoid possible explosion, death, or injury, practice safe handling
of refrigerants.
While these items will not cover every conceivable situation, they
should serve as a useful guide:
WARNING
To avoid the risk of fire or explosion never use oxygen high
pressure or flammable gasses for leak testing of a refrigeration
system.
1. Be sure both hand valves on the gauge manifold are closed
relative to the center port (i.e., turned in all the way.) Attach
this gauge manifold to the service valves on the unit.
WARNING
To avoid possible explosion, the line from the nitrogen cylinder
must include a pressure regulator and a pressure relief valve.
The pressure relief valve must be set to open at no more than
150 psig.
2. Connect a cylinder of dry nitrogen to the center port on the
gauge manifold.
3. Open the hand valve a minimal amount on the line coming
from the nitrogen cylinder.
4. Open the high pressure valve on the gauge manifold.
Pressurize the refrigerant lines and the indoor coil to 150
psig (1034 kPA).
Refrigerants are heavier than air. They can “push out” the oxygen
in your lungs or in any enclosed space. To avoid possible death
or difficulty in breathing.
¾ Never sniff refrigerant.
¾ Never purge refrigerant.
If an indoor leak is suspected, thoroughly ventilate the area before
beginning work.
Liquid refrigerant can be very cold. To avoid possible frostbite or
blindness, avoid contact and wear gloves and goggles. If liquid
refrigerant does contact your skin or eyes, get medical help
immediately.
Always follow EPA regulations. Never burn refrigerant, as
poisonous gas will be produced.
WARNING
To avoid possible explosion or equipment damage do not exceed
150 psig when pressure testing.
After you reach 150 psig, close the valve on the nitrogen
cylinder. Disconnect it from the gauge manifold. If you plan to
use an electronic leak detector, add a trace of R-22 to the
system (if permitted by current EPA regulations).
5. Apply a soap solution on all connections and joints. If you
see bubbles, you have a leak. Mark these locations.
6. Use the gauge manifold to carefully release the nitrogen from
the system. If leaks were found, repair them. After repair,
repeat the above pressure test. If no leaks exist, proceed to
system evacuation.
7
SYSTEM EVACUATION
PRELIMINARY CHARGE ADJUSTMENT
1. Connect the vacuum pump, high vacuum manifold set with
high vacuum hoses, thermocouple vacuum gauge and
charging cylinder as shown. Begin with all valves fully closed.
Figure 11.
TO
RELATED
GAUGE
PORTS OF
COND. UNIT
LARGE DIAMETER
BRAIDED VACUUM
HOSES
A. LOW SIDE VALVE
B. HIGH SIDE VALVE
C. VACUUM PUMP
D. THERMOCOUPLE GAUGE
E. MANIFOLD GAUGE
F. CH ARGIN G CYLI NDER
THERMOCOUPLE
VACUUM
GAUGE
LOW SIDE
HIGH VACUUM
MANIF OLD
HIGH VACUUM PUMP
DIAL-A-CHARGE
CHARGING CYLINDER
A
HIGH SIDE
GAUGE
D
B
C
E
GAUGE
F
2. If service dill valves are used for evacuation, use a core
remover to lift the valve core. It provides greater efficiency.
3. Confirm proper pump and gauge operation. Open the shutoff
valve that leads to the high vacuum gauge manifold. Start
the pump. When the compound gauge (low side) reading
drops approximately 29 inches of vacuum, open the valve to
the thermocouple vacuum gauge and evacuate until the
gauge reads 250 microns or less.
4. Close the valve to the thermocouple vacuum gauge. This
avoids potential gauge damage from “pegging the meter”.
5. Open the high and low side valves on the gauge manifold.
Keeping the valve on the charging cylinder closed, open the
valve on the gauge manifold that leads to the cylinder.
6. Evacuate the system to about 29 inches Hg as measured by
the compound (low side) gauge.
7. Open the valve to the thermocouple vacuum gauge. Evacuate
until the gauge reads 250 microns or less.
8. Close the valve to the vacuum pump. Wait five minutes, then
check the pressure on the thermocouple vacuum gauge:
¾ If the pressure is not more than 1500 microns, the system is
leak-free and properly evacuated. Proceed to Step 9.
¾ If the pressure rises, but holds at about 5000 microns,
moisture and non-condensibles are still present. Open the
valve to the vacuum pump, and go back to Step 7.
¾ If the pressure rises above 5000 microns, a leak is present.
Go back to “Leak Testing” section above
9. Close the valve to the thermocouple vacuum gauge. Close
the valve to the vacuum pump. Shut off the pump.
IMPORTANT:
See the wiring diagram or outdoor unit specification sheet
to determine if this unit has a crankcase heater. If it does,
you must connect electrical power to the unit for four hours
before operating the compressor. Failure to do so could
result in compressor damage.
IMPORTANT:
During all installation and service work, follow all regulations of the Environmental Protection Agency. (This system uses R-22 - an HCFC [Hydrogenated Chlorofluorocarbon].) It is a violation of EPA regulations to discharge
HCFC into the atmosphere and doing so may result in
fines or other penalties.
Use a male hex head wrench (5/16" for liquid) to carefully open
the liquid valve stem on the unit. Use a service wrench or crescent wrench to open the suction ball valve. The valve is fully
°
open with a 90
turn (i.e. the stem is inline with the valve flow
direction).
The outdoor unit is factory charged with 2 lb. R-22.
IMPORTANT:
Use only refrigerant which is certified to meet ARI Standard 700. Used refrigerant may cause compressor damage, and will void the warranty. (Most portable machines
cannot clean used refrigerant well enough to meet this ARI
Standard.)
IMPORTANT:
When adding additional refrigerant to a system, add only
refrigerant vapor (not liquid) through the suction valve (low
side) on the outdoor unit. Any other practice may cause compressor damage.
FINAL CHARGE ADJUSTMENT
IMPORTANT:
Never operate the compressor with the suction valve closed
to “test the compressor’s pumping efficiency”. In some cases,
this can result in serious compressor damage and loss of
warranty coverage.
For 25’ of line set the 7-1/2 ton charge is approximately 19 lb.
For 25’ of line set the 10-ton is approximately 26 lb. of R-22.
DO NOT start with these amounts.
8
For installation greater than 25’ of line set, indoor unit airflow,
condensing unit location and number of tubing fittings will have
an impact on final unit charge amount. Start with half of the 25’
line set charge and proceed.
Turn the electrical power on, and let the system run. Wait for the
refrigerant pressures to stabilize.
EXPANSION VALVE INDOOR COILS:
NOTE: EXPANSION VALVE BULB, MUST BE IN PLACE ON
SUCTION LINE & INSULATED.
o
Outdoor Temperature Over 60
°
is above 60
F, the system is to be charged with the room thermostat
F. When the outdoor temperature
set in the “Cooling” mode and the fan operating in the “Auto”
position.
°
Outdoor Temperature Less Than 60
F. If the outdoor
temperature is less than 60°F, the unit is to be charged with the
room thermostat set in the “Heat” mode and the fan set in the
“Auto” position.
System Charging – Cooling Mode
The following describes adjusting the refrigerant charge with the
°
ambient temperature in excess of 60
F and the room thermostat
adjusted as indicated above.
1. Allow the system to operate for at least 20 minutes.
2. Attach and insulate an electronic thermometer to the hot gas
discharge line mid way between the compressor and the reversing valve. Note: The thermometer is to be well insulated
to prevent ambient influences.
3. Adjust the charge to maintain a clear sight glass.
4. Allow the compressor to operate for about 10 additional minutes and measure the hot gas discharge temperature.
5. Using an additional electronic thermometer, measure the
ambient.
6. Adjust the charge until the hot gas temperature equals 105
F + ambient (+ or – 5°F). Remove charge to increase the
temperature.
Note: When adjusting the charge, allow the compressor to
operate for about 10 minutes before taking readings.
Note: Subsequent opening and replacement of the cap will
require only 1/2 to 1 hex flat. See the table below for the
torque required for an effective seal on the valve bonnet (1/6
turn past finger tight.
°
At stabilized cooling conditions and with an outdoor temperature
°
F or higher, the system should have from 9°F to 13°F
of 60
subcooling. For a proper subcooling reading, measure the
refrigerant pressure and temperature at the outdoor unit’s liquid
line service valve. If you have less than 9°F subcooling, add charge.
If you have more than 13°F subcooling, remove charge.
While reaching the proper subcooling level, it is important to know
the discharge line temperature. This temperature should be at
°
least 80
F over ambient or unit is flooding back to compressor. If
flooding (i.e. low discharge line temperature) occurs, adjust valve
stem on expansion valve inward (clockwise viewing end of
expansion valve). This will increase the super heat.
After achieving the proper subcooling and a sufficient discharge
temperature, make small adjustment to expansion valve stem to
°
reach 8
F to 10°F of super heat. Adjusting the valve stem in
(clockwise), increases super heat. Adjusting the valve stem out
(counter clockwise), decreases superheat . If the system is
performing properly, reinstall the service port caps and the valve
bonnets. With the valve opened, the valve bonnet is the primary
seal against refrigerant leaks. Apply two drops of clean oil to the
cap threads, allowing the oil to run down to the inner cap seal
surface. Close caps finger-tight. Then tighten cap additional two
to three hex flats.
Table 8.
Tubing Size Torque (Foot-Pounds)
5/8 14
1-3/8 16
After closing the valve bonnet, perform a final refrigerant leak test
on the valves and sweat connections. Return the room thermostat to the desired settings.
XIV DEFROST CONTROL (DC)
The CPLE uses a Time/Temperature method for defrost. A thermal
sensor is attached to the condenser coil to determine the outdoor
coil temperature. The coil temperature sensor is electrically
“Normally Open” and is wired to the electronic defrost control that
is located in the control box.
Both coil temperature and compressor run time determine defrosting of the outdoor coil. Adjustments to the defrost timing selection can be changed from the 60 minute factory setting to either 30 or 90 minutes by moving the jumper on the defrost control. To initiate a defrost, the following statements must be true:
¾ The defrost sensor must be closed, and
System Charging – Heating Mode
The following method can be employed as a method to check the
system charge in the heating mode by measuring the hot gas
discharge at the compressor.
¾ The compressor run time must equal the timing selection on
the defrost board.
Note: The compressor run time is accumulative during multiple
“heating” cycles. The timer will reset to zero only when the defrost sensor returns to an open condition. If the room thermostat
is operating in the “EM HT” mode, no accumulation of compressor time is recorded.
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During defrost the following actions occur:
1. The reversing valve is energized and the heat pump
operates in the cooling mode.
2. The airhandler auxiliary heat (if equipped) is activated.
3. The condenser fan motor is shut-off.
If the defrost cycle has not terminated after ten (10) minutes the
control will override the defrost sensor and revert to a heating
mode.
The defrost control has test pins which can be useful when troubleshooting in the heating mode. These test pins accelerate the compressor run time counter. The suggested method for accessing
this feature is:
A. Run unit in heat mode.
B. Check unit for proper charge.
Note: Bands of frost indicate low refrigerant charge.
C. Shut off power to unit.
D. Disconnect outdoor fan by removing the purple lead from
the Condenser Fan Defrost Relay.
E. Restart unit and allow frost to accumulate.
Figure 12.
SHUNT
SELECTION
JUMPER
XV TROUBLE SHOOTING
F. After a few minutes the defrost thermostat should close.
To verify the position of the thermostat check for 24V
between “DFT” and “C” on the defrost board. Should the
defrost thermostat fail to close after a heavy build-up of
frost and the thermostat is less than 28
to be replaced.
G. After the thermostat has closed, short across the test pins
with the a screwdriver blade until the reversing valve
shifts. This could take up to 21 seconds depending upon
the position of the timing setting on the defrost board.
Immediately upon the action of the reversing valve,
remove the short. Note: If this short is not removed
immediately, the defrost activity will last only 2.3 seconds.
H. After defrost has terminated (up to 10 minutes) check the
defrost thermostat for 24V between “DFT” and “C”. This
reading should be 0 V (open sensor).
I. Shut off power to the unit.
J. Replace outdoor fan motor wire removed in Step D.
°
, the thermostat is
QUALIFIED INSTALLER/SERVICER ONLY
When troubleshooting, the first step should always be to check
for clean coils, clean filter(s), and proper airflow. Indoor airflow
should be 375 to 425 CFM per ton of cooling based on the size of
the outdoor unit. The most common way of establishing indoor
airflow is heating temperature rise. Indoor airflow will then be
(Heating output of equipment) / (1.1 x temp. rise). In other cases,
measurement of external static pressure is helpful. For details,
see the Installation Operator Instructions for your indoor
equipment.
CAUTION
3 Phase Scroll Compressor
The CPLE090/120 condenser is equipped with a 3-phase
scroll compressor. If the unit sounds noisy and/or the suction
and liquid pressures are almost equal, the compressor is
operating in the reverse rotation. Reverse (2) incoming
power supply leads.
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TROUBLESHOOTING ANALYSIS TABLE - COOLING
TROUBLE SHOOTING ANALYSIS TABLE
COMPLAINT PROBABLE CAUSE REMEDY
1. Purge or pump-down excessive charge.
2. Make certain that coil is not fouled in any
way, or that air is not re-circulating.
3. Purge these gases from the system.
Recharge system, if necessary.
1. Charge system until sight glass is clear of bubbles.
2. Replace compressor.
1. Open the liquid line valve.
2. Replace filter-dryer.
3. Detach the bulb from the suction line and hold
in one hand. If no liquid refrigerant goes through
the valve, replace the valve.
4. Test the unit for leaks. Add refrigerant until sight
glass is free from bubbles, after repairing leak.
5. Clean or replace filter.
6. Defrost and clean coil. Clean or replace filters.
7. Excessive liquid line drop. Check liquid line size.
8. Increase the blower speed.
1. Correct valve action or replace the valve.
2. Fasten bulb securely to suction line.
3. Replace compressor.
1. Close the disconnect switch.
2. Check the cause of failure and replace the fuse.
3. Adjust to lower temperature.
4. Turn selector switch knob to "Cool" position.
5. Replace contactor and/or relay.
6. Inspect and secure all electrical connections.
1. High Head Pressure
2. Low Head Pressure
3. Low Suction Pressure
4. High Suction Pressure
5. Compressor will not
start.
1. Excessive charge of refrigerant in system.
2. Inadequate supply of air across the
condenser coil.
3. Non-condensate gases in the system.
1. System low on refrigerant.
2. Compressor valves broken.
1. Liquid line valve closed.
2. Restricted liquid line.
3. The bulb of the thermal expansion valve
has lost its charge.
4. System low on refrigerant.
5. Dirty filters.
6. Coil frosted up.
7. Flash gas in the liquid line.
8. Quantity of air through evaporator not
adequate.
1. Expansion valve stuck open.
2. Expansion valve bulb not in contact with
suction line.
3. Suction and/or discharge valve leaking or
broken.
1. Disconnect switch open.
2. Blow fuse or fuse at disconnect switch.
3. Thermostat set too high.
4. Selector switch in "Off" position.
5. Contactor and/or relay coils burned out.
6. Loose or open electrical connection in either
the control or power circuit.
TROUBLESHOOTING ANALYSIS - HEATING
The following information is intended for qualified service companies only.
Common causes for unsatisfactory operation of heat pumps in the heating mode include:
Dirty Filters
Dirty filters or inadequate airflow through the indoor coil. Failure
to keep clean filters and adequate airflow (375-425 CFM/ton) will
cause excessive discharge pressures that may cause the highpressure switch to function.
Low Return Air Temperatures
Return ductwork temperatures that are less than 60°F will cause
low discharge pressure, low suction pressure and excessive
defrost cycling.
Undercharging
An undercharged system will cause low discharge pressure, low
suction pressure and an accumulation of frost on the lower section
of the outdoor coil.
Poor Termination of Defrost
The defrost sensor must make good contact with the outside coil
return bend or a non-termination of defrost may occur.
Reversing Valve
A reversing valve may not function correctly for the following
reasons:
1. Solenoid does not energize when voltage is present
Replace the reversing valve.
2. No voltage to the solenoid
Check the wiring.
3. The valve will not shift
a. Undercharged
Check for leaks
b. Valve body damage
Replace the reversing valve
c. Valve sticking
Replace the reversing valve
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XVI WIRING DIAGRAM
NOTE: SPECIFICATIONS AND PERFORMANCE DATA LISTED HEREIN ARE SUBJECT TO CHANGE WITHOUT NOTICE
Quality Makes the Difference!
All of our systems are designed and manufactured with the same high quality standards regardless of size of efficiency. Our
designs virtually eliminate the most frequent causes of product failure. They are simple to service and forgiving to operate. We
use the highest quality materials and components available because if a part fails then the unit fails. Finally, every unit is run
tested before it leaves the factory. That’s why we know...
There’s No Better Quality.
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