Heat Controller RSG24, RSG30, RSG36, RSG42, RSG48 Installation, Operation & Maintenance Manual

INSTALLATION, OPERATION

& MAINTENANCE MANUAL

Split System A/C & Heat Pump-1.5 to 5 Ton:

RSGxxS/R-1D Series

HRGxxS-1D Series

Heat Controller, Inc. • 1900 Wellworth Ave. • Jackson, MI 49203 • [phone] • www.heatcontroller.com

TABLE OF CONTENTS

Model Nomenclature ..............................................................................................................................3

1.0 SAFETY .............................................................................................................................................5

1.1 INSPECTION................................................................................................................................7

1.2 LIMITATIONS ...............................................................................................................................7

2.0 GENERAL ..........................................................................................................................................7

2.1 DIMENSIONS & CONNECTIONS SIZES .....................................................................................8

3.0 UNIT INSTALLATION ........................................................................................................................9

3.1 LOCATION ...................................................................................................................................9

3.2 GROUND INSTALLATION ...........................................................................................................9

3.3 ROOF INSTALLATION .................................................................................................................9

3.4 UNIT PLACEMENT ......................................................................................................................9

3.5 PRECAUTIONS DURING LINE INSTALLATION .........................................................................10

3.6 PRECAUTIONS DURING BRAZING OF LINES ..........................................................................11

3.7 PRECAUTIONS DURING BRAZING SERVICE VALVE...............................................................12

3.8 UNIT MOUNTING .........................................................................................................................13

3.9 FACTORY-PREFERRED TIE-DOWN METHOD ..........................................................................14

3.10 REMOVING THE TOP PANEL AND MOTOR ............................................................................15

4.0 ELECTRICAL CONNECTIONS .........................................................................................................16

4.1 GENERAL INFORMATION & GROUNDING ...............................................................................16

4.2 FIELD CONNECTIONS POWER WIRING ..................................................................................16

4.3 ELECTRICAL DATA CHARACTERISTICS ..................................................................................16

5.0 EVACUATION ....................................................................................................................................17

6.0 INTERCONNECTING TUBING ..........................................................................................................18

6.1 SUCTION AND LIQUID LINES ....................................................................................................18

6.2 MAXIMUM LENGTH OF LINES ..................................................................................................18

6.3 VERTICAL SEPARATION ...........................................................................................................18

7.0 SYSTEM OPERATION .......................................................................................................................18

7.1 COMPRESSOR CRANKCASE HEATER (CCH) ..........................................................................18

7.2 LINE SIZING.................................................................................................................................19

7.3 PROTECTION FUNCTION INTRODUCTION ..............................................................................20

7.4 DEFROST MODE INTRODUCTION ............................................................................................20

7.5 4-WAY REVERSING VALVE & ACCUMULATOR & DISCHARGE MUFFLER .............................20

8.0 CHECKING REFRIGERANT CHARGE ............................................................................................21

8.1 CHARGING BY LIQUID PRESSURE ...........................................................................................21

8.2 CHARGING BY WEIGHT ............................................................................................................21

8.3 FINAL LEAK TESTING ................................................................................................................21

9.0 OWNER INSTRUCTIONS .................................................................................................................22

9.1 MAINTENANCE ...........................................................................................................................22

10.0 WIRING DIAGRAM ..........................................................................................................................23

10.1 CONTROL WIRING FOR A/C UNIT ...........................................................................................23

10.2 CONTROL WIRING FOR H/P UNIT ...........................................................................................25

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION

WARNING

These instructions are intended as an aid to qualied licensed

service personnel for proper installation, adjustment and
operation of this unit. Read these instructions thoroughly before
attempting installation or operation. Failure to follow these
instructions may result in improper installation, adjustment,

service or maintenance possibly resulting in re, electrical

shock, property damage, personal injury or death.

Please read carefully and keep in a safe place for future reference by a serviceman.

DO NOT DESTROY THIS MANUAL

2

13SEER BASE MODELS

MODEL NOMENCLATURE

R S G 24 S - 1 D

R = Residential

S - Split

MODELS ABOVE 13SEER:

R S G 14 24 S - 1 D

D = Revision Code

1 = 208/230/1
3 = 208/230/3

R410A Refrig.

18 = 18, 000 BTU
24 = 24,000 BTU
ETC

S = Scroll
R = Rotary

R = Residential

S - Split

D = Revision Code

1 = 208/230/1
3 = 208/230/3

R410A Refrig.

14=14SEER
16=16SEER

18 = 18, 000 BTU
24 = 24,000 BTU
ETC

S = Scroll
R = Rotary

NOTE: Not all model configurations are available for sale.

Consult the factory for availability.

3

13SEER BASE MODELS

H R G 24 S - 1 D

H=Heat Pump

R=Residential
Split

R410A Refrig.

MODELS ABOVE 13SEER:

H R G 14 24 S - 1 D

D = Revision Code

1 = 208/230/1
3 = 208/230/3

18 = 18, 000 BTU
24 = 24,000 BTU
ETC

S = Scroll

H=Heat Pump

R=Residential
Split

D = Revision Code

1 = 208/230/1
3 = 208/230/3

R410A Refrig.

14=14SEER
16=16SEER

18 = 18, 000 BTU
24 = 24,000 BTU
ETC

S = Scroll

NOTE: Not all model configurations are available for sale.

Consult the factory for availability.

4

This document is customer property and is to remain with this unit.
These instructions do not cover all the different variations of systems nor does
it provide for every possible contingency to be met in connection with installa­tion.
All phases of this installation must comply with NATIONAL STATE AND LOCAL
CODES. If additional information is required please contact your local distribu­tor.

1.0 SAFETY

This is a safety alert symbol. When you see this symbol on labels or in
manuals, be alert to the potential for personal injury.

This is an attention alert symbol. When you see this symbol on labels or in
manuals, be alert to the potential for personal injury.

Understand and pay particular attention to the signal words DANGER, WARNING, or
CAUTION.

DANGER indicates an imminently hazardous situation, which, if not avoided, will result
in death or serious injury.

WARNING indicates a potentially hazardous situation, which, if not avoided, could result
in death or serious injury.

CAUTION indicates a potentially hazardous situation, which, if not avoided may result
in minor or moderate injury. It is also used to alert against unsafe practices and hazards
involving only property damage.

WARNING

Improper installation may create a condition where the operation of the product
could cause personal injury or property damage.
Improper installation, adjustment, alteration, service or maintenance can cause
injury or property damage. Refer to this manual for assistance or for additional
information, consult a qualified contractor, installer or service agency.

CAUTION

This product must be installed in strict compliance with the installation instruc­tions and any applicable local, state, and national codes including, but not
limited to building, electrical, and mechanical codes.

WARNING

FIRE OR ELECTRICAL HAZARD
Failure to follow the safety warnings exactly could result in serious injury, death
or property damage.
A fire or electrical hazard may result causing property damage, personal injury
or loss of life.

5

WARNING

Disconnected all power before serving the unit, faluire result in electrical shock.

WARNING

Grounding the unit permanently and also before making line voltage
connection-faluire to do so can result in electrical shock, personal injury, or
death.

CAUTION

The filter dryer is located under control box. The filter dtyer must be installed
externally in the liquid line or the warranty will be void.

1.1 INSPECTION

As soon as a unit is received, it should be inspected for possible damage during transit.
If damage is evident, the extent of the damage should be noted on the carrier's delivery
receipt. A separate request for inspection by the carrier's agent should be made in
writing. See Local distributor for more information.

Requirements For Installing/Servicing R410A Equipment
Gauge sets, hoses, refrigerant containers, and recovery system must be designed
to handle the POE or PVE type oils.
Manifold sets should be 800 PSIG high side and 250 PSIG low side with 550 PSIG
Iow side restart.
All hoses must have a 700 PSIG service pressure rating.
Leak detectors should be designed to detect refrigerant.
Recovery equipment (including refrigerant recovery containers) must be specifi­ cally designed to handle R410A.
Do not use an R-22 TXV.
A liquid-line filter drier is required on every unit. see the Fig.1-shipped loose for field
installation

6

NOTE

：

It will be more convenient to open
the Service valve after removing

the Underside Clapboard.

SUCTION VALVE

LIQ. LINE VALVE

LIQUID-LINE FILTER-DRIER

(shipped loose for field installation)

Fig.1 Filter-Drier installation

1.2 LIMITATIONS

The unit should be installed in accordance with all National, State and Local Safety
Codes and the limitations listed below:

1.Limitations for the indoor unit, coil and appropriate accessories must also be observed.

2.The outdoor unit must not be installed with any duct work in the air stream. The outdoor fan is
the propeller type and is not designed to operate against any additional external static
pressure.

3.The maximum and minimum conditions for operation must be observed to assure a system
that will give maximum performance with minimum service.

4.The maximum allowable line length for this product is 150 feet.

2.0 GENERAL

The outdoor units are designed to be connected to a matching indoor coil with sweat
connect lines. Sweat connect units are factory charged with refrigerant for a match­ing indoor coil plus 25 feet of field supplied lines.

Matching indoor coils are available with a thermostatic expansion valve or an orifice
for the most common usage. The orifice size and/or refrigerant charge may need to
be changed for some indoor-outdoor unit combinations, elevation differences or
total line lengths.

Before installation a load calculation must be performanced by the installer, as well
as a duct analysis. Proper sizing and coil/air handler matching are the installer’s
responsibilities to ensure compliance.

7

"L" in. [mm]

Liquid in.

Vapor in.

21-7/8[554]

3/8 3/4

23-5/8[600]

3/8 3/4

23-5/8[600]

3/8 3/4

3/8 3/4

29-1/8[740]

3/8 3/4

3/8 3/4

3/8 7/8

29-1/8[740]

3/8 7/8

2.1 DIMENSIONS & CONNECTION SIZES

SERVICE ACCESS

ALLOW 24” CLEARANCE

W

AIR DISCHARGE: ALLOW 60”
MINIMUM CLEARANCE.

AIR INLETS

LOUVERED PANELS
ALLOW 18”
MINIMUM
CLEARANCE

DETAIL A

KNOCKOUT
1-11/32” (34.5mm)

HOLE
1-3/32” (27.8mm)

DIMENSIONAL DATA

Unit Model (Btu/h)

18(cooling unit)

18(heat pump unit)

24 23-5/8[600]

30 28[710] 28[710]

36 29-1/8[740]

42 29-7/8[759] 28[710] 28[710]

48 33-3/16[843] 28[710] 28[710]

60 29-1/8[740]

POWER WIRING
SEE DETAIL A

SERVICE
FITTING

Liquid Line
Connections

FIG.2 DIMENSIONS

Dimensions (Inches)

"H" in. [mm] "W" in. [mm]

24-15/16[633]

24-15/16[633]

21-7/8[554]

23-5/8[600]

24-15/16[633]

24-15/16[633]

24-15/16[633]

33-3/16[843]

Vapor Line
Connections

CONTROL WIRING
7/8” (22.2mm)

SERVICE
FITTING

Refrigerant Connection

Service Valve Size

8

3.0 UNIT INSTALLATION

3.1 LOCATION

Before starting the installation, select and check the suitability of the location for both
the indoor and outdoor unit. Observe all limitations and clearance requirements. The
outdoor unit must have sufficient clearance for air entrance to the condenser coil, for air
discharge and for service access. See Fig.2

NOTE

For multiple unit installations, units must be spaced a minimum of 18 inches
apart. (Coil face to coil face.)

If the unit is to be installed on a hot sun exposed roof or a black-topped ground area, the
unit should be raised sufficiently above the roof or ground to avoid taking the accumu­lated layer of hot air into the outdoor unit.

Provide an adequate structural support.

3.2 GROUND INSTALLATION

The unit may be installed at ground level on a solid base that will not shift or settle, caus­ing strain on the refrigerant lines and possible leaks. Maintain the clearances shown in
Fig.2 and install the unit in a level position.

Normal operating sound levels may be objectionable if the unit is placed directly under
windows of certain rooms (bedrooms, study, etc.).
Top of unit discharge area must be unrestricted for at least 60 inches above the unit.

WARNING

The outdoor unit should not be installed in an area where mud or ice could cause
personal injury.

Elevate the unit sufficiently to prevent any blockage of the air entrances by snow in
areas where there will be snow accumulation. Check the local weather bureau for the
expected snow accumulation in your area. Isolate the unit from rain gutters to avoid any
possible wash out of the foundation.

3.3 ROOF INSTALLATION

When installing units on a roof, the structure must be capable of supporting the total
weight of the unit, including a padded frame unit, rails, etc., which should be used to
minimize the transmission of sound or vibration into the conditioned space.

3.4 UNIT PLACEMENT

1. Provide a base in the pre-determined location.

2. Remove the shipping carton and inspect for possible damage.

3. Compressor tie-down bolts should remain tightened.

4. Position the unit on the base provided.

9

CAUTION

This system uses R410A refrigerant which operates at higher pressure than
R-22. No other refrigerant may be used in this system. Gauge sets, hoses,
refrigerant containers, and recovery system must be designed to handle
R410A. If you are unsure, consult the equipment manufacturer.

The outdoor unit must be connected to the indoor coil using field supplied refrigerant
grade copper tubing that is internally clean and dry. Units should be installed only with
the tubing sizes for approved system combinations. The charge given is applicable for
total tubing lengths up to 25 feet.

NOTE

Using a larger than specified line size could result in oil return problems. Using
too small a line will result in loss of capacity and other problems caused by insuf­ficient refrigerant flow. Slope horizontal vapor lines at least 1" every 20 feet
toward the outdoor unit to facilitate proper oil return.

3.5 PRECAUTIONS DURING LINE INSTALLATION

1. Install the lines with as few bends as possible. Care must be taken not to damage
the couplings or kink the tubing. Use clean hard drawn Copper tubing where no
appreciable amount of bending around obstruction is necessary, if soft copper must
be used, care must be taken to avoid sharp bends which may cause a restriction.

2. The lines should be installed so that they will not obstruct service access to the coil,
air handling system or filter.

3. Care must also be taken to isolate the refrigerant lines to minimize noise transmis­ sion from the equipment to the structure.

4. The vapor line and liquid line must be insulated with a minimum of 1/2" foam rubber
insulation (Armafiex or equivalent). Tape and suspend the refrigerant lines as shown.
DO NOT allow tube metal-to-metal contact. See Fig. 3.

5. Use PVC piping as a conduit for all underground installations as shown in Fig. 4.
Buried lines should be kept as short as possible to minimize the build up of liquid
refrigerant in the vapor line during long periods of shutdown.

6. Pack fiberglass insulation and a sealing material such as perma gum around refrig­ erant lines where they penetrate a wall to reduce vibration and to retain some flexi­ bility.

10

Sheet Metal Hanger

Insulated Vapor Line

TO
POWER
SUPPLY

TO
INDOOR
BLOWER

Correct Incorrect

Tape

Insulated Liquid Line

Fig.3 Tubing Hanger

Fig.4 Underground Installation

WEATHERPROOF
DISCONNECT
SWITCH

24V control signal

TO
COIL

Seal opening(s) with
permagum or equivalent

NOTE:All outdoor wiring must be weather proof

Fig.5

Typical Installation

3.6 PRECAUTIONS DURING BRAZING OF LINES

All outdoor unit and evaporator coil connections are copper-to-copper and should be
brazed with a phosphorous-copper alloy material such as Silfos-5 or equivalent. DO
NOT use soft solder. The outdoor units have reusable service valves on both the liquid
and suction vapor connection. The total system refrigerant charge is retained within the
outdoor unit during shipping and installation. The reusable service valves are provided
to evacuate and charge per this instruction.
Serious service problems can be avoided by taking adequate precautions to assure an
internally clean and dry system.

11

CAUTION

Dry nitrogen should always be supplied through the tubing while it is being
brazed, because the temperature required is high enough to cause oxidation
of the copper unless an inert atmosphere is provide. The flow of dry nitrogen
should continue until the joint has cooled. Always use a pressure regulator and
safety valve to insure that only low pressure dry nitrogen is introduced into the
tubing.Only a small flow is necessary to displace air and prevent oxidation.

3.7 PRECAUTIONS DURING BRAZING SERVICE VALVE

Precautions should be taken to prevent heat damage to service valve by wrapping a wet
rag around it as shown in Fig. 6. Also, protect all painted surfaces, insulation, during
brazing. After brazing cool joint with wet rag.

Valve can be opened by removing the plunger cap and fully inserting a hex wrench into
the stem and backing out counter-clockwise until valve stem just touches the cham­fered retaining wall.

Connect the refrigerant lines using the following procedure:

1. Remove the cap and Schrader core from both the liquid and vapor service valve
service ports at the outdoor unit. Connect Iow pressure nitrogen to the liquid line
service port.

wet rag

service valve

Fig.6 Heat Protection

2. Braze the liquid line to the liquid valve at the outdoor unit. Be sure to wrap the valve
body with a wet rag. Allow the nitrogen to continue flowing. Refer to the Tabular Data
Sheet for proper liquid line sizing.

3. Carefully remove the rubber plugs from the evaporator liquid and vapor connections
at the indoor coil.

4. Braze the liquid line to the evaporator liquid connection. Nitrogen should be flowing
through the evaporator coil.

5. Slide the plastic cap away from the vapor connection at the indoor coil. Braze the
vapor line to the evaporator vapor connection. Refer to the Table 1 for proper vapor
line sizing.

6. Protect the vapor valve with a wet rag and braze the vapor line connection to the
outdoor unit. The nitrogen flow should be exiting the system from the vapor service
port connection. After this connection has cooled, remove the nitrogen source from
the liquid fitting service port.

7. Replace the Schrader core in the liquid and vapor valves.

8. Leak test all refrigerant piping connections including the service port flare caps to be
sure they are leak tight. DO NOT OVER TIGHTEN (between 40 and 60 inch -lbs.

maximum).

9. Evacuate the vapor line, evaporator and the liquid line, to 500 microns or less.

12

Table 1: Refrigerant Connections and Recommended Liquid and Suction Tube
Diameters (ln.)

UNIT LIQUID SUCTION

SIZE Tube Diameter (in.)

Tube Diameter (in.)

18 3/8 3/4

24 3/8 3/4

30 3/8 3/4

36 3/8 3/4

42 3/8

48 3/8

3/4

7/8

60 3/8 7/8

10. Replace cap on service ports. Do not remove the flare caps from the service ports
except when necessary for servicing the system.

CAUTION

Do not connect manifold gauges unless trouble is suspected. Approximately 3/4
ounce of refrigerant will be lost each time a standard manifold gauge is
connected.

11. Release the refrigerant charge into the system. Open both the liquid and vapor
valves by removing the plunger cap and with a hex wrench back out counter

-clockwise until valve stem just touches the chamfered retaining wall.

12. Replace plunger cap finger tight, then tighten an additional 1/12 turn (1/2 hex flat).
Cap must be replaced to prevent leaks.

WARNING

Never attempt to repair any brazed connections while the system is under pres­sure. Personal injury could result.

See "System Charge" section for checking and recording system charge.

3.8 UNIT MOUNTING

If elevating the heat pump, either on a flat roof or on a slab, observe the following guidelines.

1.The base pan provided elevates the heat pump 2” above the base pad.

2. If elevating a unit on a flat roof , use 4”× 4”(or equivalent) stringers
positioned to distribute unit weight evenly and prevent noise and vibration
(See fig. 7) .

NOTE:Do not block drain openings shown in fig.7.

3. If unit must be elevated because of anticipated snow fall, secure unit and
elevating stand such that unit and/or stand will not tip over or fall off.

NOTE: To tie down unit, see 3.9.

13

Drain holes

BASE PAD
(CONCRETE OR
OTHER SUITABLE
MATERIAL)

Fig.7 RECOMMENDED ELEVATED INSTALLATION

BASE PAN (BOTTOM VIEW) DO NOT
OBSTRUCT DRAIN HOLES
(SHADED)

ELEVATION ABOVE ANTICIPATED
SNOW IS NECESSARY

3.9 FACTORY-PREFERRED TIE-DOWN METHOD

Step 1: Prior to installing clear pad of debris.
IMPORTANT
Then cement pad must be made of HVAC-approved materials and must be the
proper thickness to accommodate fasteners.

Step 2: Center and level unit onto pad.

Step 3: Using L-shaped bracket (see Fig. 8, Detail B) to locate holes on concrete and drill
pilot holes which is at least 1/4” deeper than fastener being used.

IMPORTANT

Self drilling screws to base pan should not exceed 3/8” long to avoid damaging
coil.

Step 4: Using conventional practices to install brackets, tighten concrete fasteners and
self-tapping screws (See Fig.8).

NOTE

: 1. One bracket for each side. For extra stability, 2 brackets for each side.

2. Do not over-tighten the concrete fastener to avoid weakening the concrete.

IMPORTANT NOTE:

These instructions are intended to provide a method to tie-down system to cement slab
as a securing procedure for high wind areas. It is recommended to check Local Codes
for tie-down methods and protocols.

14

For W + L Dimensions See Fig. 2

L

W

#7 X 3/8” Self Tapping Screws
(Don’t Exceed 3/8” long)

DETAIL B

1/4” Χ 1-1/2” Hex Washer Head Concrete Screws
(3/16” Pilot Hole Needed. Pilot Hole Should Be1/4” Deeper
Than The Fastener Embedment)

SEE DETAIL B

Brackets:
2” width, 1/16” thickness,
height as required.
Brackets can be made
from commercially
available channel stock,
cut to size
and predrilled

Fig.8 FACTORY-PREFERRED TIE-DOWN METHOD

REQUIRED PARTS LIST

3.10 REMOVING THE TOP PANEL AND MOTOR

1/2” bolt

NOTE:

Damage will occur to condenser unit
if you remove fan bolts prior to cover removal.

Fig. 9 COVER AND FAN

When motor requires changing follow the steps below:
Step 1: Go into electrical panel, disconnect motor power lines.
IMPORTANT NOTE
Disconnect main power to unit. Severe burns and electrical shock will occur if
you do not disconnect main power.
Step 2: Remove cover (be careful of motor wires)
Step 3: Be sure to place fan cover unit on the ground as indicated in Fig. 9
IMPROTANT NOTE
Do not place or lean fan blades on ground or against surface.
Step 4: Remove fan motor by removing 5/16” bolts from cover.
Step 5: Remove fan blade from motor by removing 1/2” bolt and place fan on the ground.
Step 6: Reverse removal process to reinstall the fan and motor.

IMPROTANT NOTE

When connecting motor wires be sure to check motor direction.

5/16” bolts

15

4.0 ELECTRICAL CONNECTIONS

4.1 GENERAL INFORMATION & GROUNDING

Check the electrical supply to be sure that it meets the values specified on the unit
nameplate and wiring label.
Power wiring, control (Iow voltage) wiring, disconnect switches and over current
protection must be supplied by the installer. Wire size should be sized per require­ments.

CAUTION

All field wiring must USE COPPER CONDUCTORS ONLY and be in accordance
with Local, National Fire, Safety & Electrical Codes. This unit must be grounded
with a separate ground wire in accordance with the above codes.

The complete connection diagram and schematic wiring label is located on the inside
surface of the unit service access panel and this instruction.

4.2 FIELD CONNECTIONS POWER WIRING

1. Install the proper size weatherproof disconnect switch outdoors and within sight of
the unit.

2. Remove the screws at the side of the corner cover. Slide corner cover down and
remove from unit. See Fig. 10.

3. Run power wiring from the disconnect switch to the unit.

4. Route wires from disconnect through power wiring opening provided and into the
unit control box.

CORNER
PANEL

POWER
WIRING

CONTROL
WIRING

Fig.10 Typical Field Wiring

5. Install the proper size time-delay fuses or circuit breaker, and make the power
supply connections.

6. Energize the crankcase heater, if equipped, to save time by preheating the compres­ sor oil while the remaining installation is completed.

NOTE: When changing the motor, remove top cover first.

16

4.3 ELECTRICAL DATA CHARATERISTICS

Phase Frequency (Hz)

Voltage (Volts)

RSG18 R 1-60-208/230

RSG18 S

1-60-208/230

RSG24 S 1-60-208/230

RSG24 R 1-60-208/230

RSG30 S 1-60-208/230

RSG30 R 1-60-208/230

RSG36 1-60-208/230

RSG42 1-60-208/230

RSG48 1-60-208/230

RSG60 1-60-208/230

HRG18 S

1-60-208/230

HRG24 S 1-60-208/230

HRG30 S 1-60-208/230

HRG36 1-60-208/230

HRG42 1-60-208/230

HRG48 1-60-208/230

HRG60 1-60-208/230

RSG1460

HRG1460

RSG36

RSG48

RSG60

RSG1460

1-60-208/230

1-60-208/230

3-60-208/230

3-60-208/230

3-60-208/230

3-60-208/230

Compressor

Fan

MCA MOPModel Number

RLA LRA FLA HP

9 48 0.6 1/12 11.9

6.65 32.6 0.6 1/12 9

13.5 58.3 0.6 1/12 17.5

8.75 34.8 0.6 1/12 11.6

14.1 73 1.0 1/6 18.7

12 59.93 1.0 1/6 16

16.7 79 1 1/6 21.9

17.9 112 1.7 1/3 24.1

21.8 117 1.7 1/3 29.0

26.4 134 1.7 1/3 34.7

9 48 0.6 1/12 11.9

13.5 58.3 0.6 1/12 17.5

14.1 73 1 1/6 18.7

16.7 79 1.0 1/6 21.9

17.9 112 1.7 1/3 24.1

21.8 117 1.7 1/3 29.0

26.4 134 1.7 1/3 34.7

26.4 134 1.7 1/3 34.7

26.4 134 1.7 1/3 34.7

10.4 73 1.0 1/6 14

13.7 83.1 1.7 1/3 18.9

16 110 1.7 1/3 21.7

16 110 1.7 1/3 21.7

20

15

30

20

30

25

35

40

50

60

20

30

30

35

40

50

60

60

60

20

30

35

60

17

5.0 EVACUATION

It will be necessary to evacuate the system to 500 microns or less. If a leak is
suspected, leak test with dry nitrogen to locate the leak. Repair the leak and test again.
To verify that the system has no leaks, simply close the valve to the vacuum pump
suction to isolate the pump and hold the system under vacuum. Watch the micron
gauge for a few minutes. If the micron gauge indicates a steady and continuous rise,
it's an indication of a leak. If the gauge shows a rise, then levels off after a few minutes
and remains fairly constant, its an indication that the system is leak free but still
contains moisture and may require further evacuation if the reading is above 500
microns.

6.0 INTERCONNECTING TUBING

6.1 VAPOR AND LIQUID LINES

Keep all lines sealed until connection is made.
Make connections at the indoor coil first.
Refer to Line Size Information in Tables 2 and 3 for correct size and multipliers to be
used to determine capacity for various vapor line diameters and lengths of run. The
losses due to the lines being exposed to outdoor conditions are not included.

The factory refrigerant charge in the outdoor unit is sufficient for the unit and 25 feet
of standard size interconnecting liquid and vapor lines. For different lengths,adjust
the charge as indicated below.

1/4” ± .3 oz. per foot
5/16” ± .4 oz. per foot
3/8” ± .6 oz. per foot
1/2” ± 1.2 oz. per foot

6.2 MAXIMUM LENGTH OF LINES

The maximum length of interconnecting line is 150 feet
Always use the shortest length possible with a minimum number of bends. Additional
compressor oil is not required for any length up to 150 feet.
N

OTE: Excessively long refrigerant lines cause loss of equipment capacity.

（Just for Scroll compressor）.

6.3 VERTICAL SEPARATION

Keep the vertical separation to a minimum. Use the following g
installing the unit:

1. DO NOT exceed the vertical separations as indicated on Table 3.

2. It is recommended to use the smallest liquid line size permitted to minimize sys ­em charge which will maximize compressor reliability.

t

3. Table 3

may be used for sizing horizontal runs.

uidelines when

7.0 SYSTEM OPERATION

7.1 COMPRESSOR CRANKCASE HEATER

Refrigerant migration during the off cycle can result in a noisy start up. A crankcase
heater is suggested to minimize refrigeration mirgration, and to help eliminate any start
up noise or bearing “wash out”.
If equipped crankcase heaters are located on the lower half of the compressor shell.
Its purpose is to drive refrigerant from the compressor shell during long off cycles, thus
preventing damage to the compressor during start-up.
At initial start-up or after extended shutdown periods, make sure the heater is ener­gized for at least 12 hours before the compressor is started. (Disconnect switch on and
wall thermostat off.)

18

7.2 LINE SIZING

TABLE 2: SUCTION LINE LENGTH/SIZE VS CAPACITY MULTIPLIER(R410A)

Unit Size

Suction Line Connection Size

Suction Line Run - Feet

1 1/2 Ton 2 Ton 2 1/2 Ton 3 Ton 3 1/2 Ton 4 Ton 5 Ton

3/4" I.D. 3/4" I.D. 3/4" I.D. 3/4" I.D. 3/4" I.D. 7/8" I.D. 7/8" I.D.

5/8 Opt. 5/8 Opt. 5/8 Opt. 5/8 Opt. 5/8 Opt. 3/4 Opt. 1 1/8 Opt.

3/4* Std. 3/4* Std. 3/4* Std. 3/4* Std. 3/4* Std. 7/8* Std. 7/8* Std.

25'

50'

100'

150'

Optional 1.00 1.00 1.00 1.00 1.00 1.00 1.00

Standard 1.00 1.00 1.00 1.00 1.00 1.00 0.99

Optional 0.97 0.97 0.97 0.97 0.98 0.98 0.99

Standard 0.98 0.98 0.98 0.99 0.98 0.98 0.98

Optional 0.94 0.94 0.94 0.94 0.95 0.95 0.98

Standard 0.95 0.95 0.96 0.97 0.97 0.97 0.94

Optional 0.90 0.90 0.90 0.90 0.91 0.92 0.97

Standard 0.92 0.92 0.93 0.96 0.96 0.96 0.90

NOTES:

* Standard size
Using suction line larger than shown in chart will result in poor oil return and is not recommended.

TABLE 3 :LIQUID LINE SIZE (R-410A)

Liquid Line Size

Total Equivalent Length - Feet

System

Capacity

1 1/2 Ton 3/8"

2 Ton 3/8"

3 Ton

3 1/2 Ton

4 Ton

5 Ton

Line Size

Connection Size

(Inch I.D.)

3/8"2 1/2 Ton

3/8"

3/8"

3/8"

3/8"

Line Size

Compressor

Type

Scroll

Rotary 3/8* 25 30 30 27

Scroll

Rotary 3/8* 25 30 30 24

Scroll

Rotary 3/8* 25 30 30 22

Scroll

Scroll

Scroll

Scroll

Connection And

Line Size

(Inch I.D.)

1/4 25 40 25 9 N/A N/A

5/16 25 50 62 58 53 49

3/8* 25 50 75 72 70 68

1/4 23 N/A N/A N/A N/A N/A

5/16 25 36 29 23 16 9

3/8* 25 50 72 70 68 65

1/4 25 N/A N/A N/A N/A N/A

5/16 25 49 38 27 17 6

3/8* 25 50 68 65 62 58

5/16 25 50 37 22 7 N/A

3/8* 25 50 68 63 58 53

5/16 25 23 4 N/A N/A N/A

3/8* 25 50 43 36 30 24

3/8* 25 46 38 30 22 15

1/2 25 50 56 55 53 52

3/8* 25 50 56 44 32 20

1/2 25 50 75 81 79 76

25 50 75 100 125 150

Outdoor unit above or below indoor coil

Maximum Vertical Separation - Feet

N/A N/A

N/A N/A

N/A N/A

NOTES:
* Standard line size
N/A Application not recommended.

19

7.3 PROTECTION FUNCTION INTRODUCTION (Heat pump only)

Sensor T3 (condenser pipe temperature) and T4 (outdoor ambient temperature)

When open-circuit, compressor, outdoor fan motor and reverse valve will be OFF.
When T4 < 5 °F, compressor will stop.If the electrical heater kit is installed in the

indoor unit, the outdoor unit would provide a signal to drive up the heater.

When T4 > 10.4 °F, compressor will restart.

Discharge temperature protection (Heat pump only)

When discharge temp. > 275 °

F, compressor will stop.

When discharge temp. < 194 °F, compressor will restart.

High pressure protection (Heat pump only)

When high pressure > 638 PSIG, compressor and outdoor fan motor will stop.
When high pressure < 464 PSIG, compressor and outdoor fan motor will restart
(3 minutes time-delay necessary).

Low pressure protection (Heat pump only)

Low pressure < 21 PSIG, compressor and outdoor fan motor will stop.
Low pressure > 44 PSIG, compressor and outdoor fan motor will restart
(3 minutes delay necessary).

In stand-by status, the compressor will not start in low pressure protection.
Within 30 mins, if 4 protection cycles occurs, system will restore after power cut-down.

7.4 DEFROST MODE INTRODUCTION

Start-up conditions of defrost mode:

When JUMP switch is set to “1”(See in Fig 11), the mode will start up in either of
the two following conditions:

1. Compressor operating, when T4 is > 28.4 °F and T3 is < 32 °F last for 40 minutes;

2. Compressor operating, when T4 is < 28.4 °F and T3 is < 32 °F last for 50 minutes.
When JUMP switch is set to “0”:
Compressor operating, when T3 is < 32 °F last for 30 minutes.

Shut-down conditions of defrost mode:

The mode will shut down in either of the two following conditions:

1. The defrosted time lasting for 10 minutes;

2. T3 is ≥ 77 °F.

JUMP Switch

Fig.11 JUMP Switch Location in the PCB Board

7.5 4-WAY REVERSING VALVE & ACCUMULATOR & DISCHARGE MUFFLER

4-Way Reversing Valve:
When the wall thermostat "calls for heat", the outdoor unit will get signal "B",
the 4-way valve power on, and the unit goes to heating mode. If there is no
signal "B", the 4-way valve stands by and the unit will keep cooling mode.

Accumulator:

To protect the compressor from flood-back & migration.

Discharge Muffler:

Heat Pumps units include Compressor Discharge Muffler.

20

8.CHECKING REFRIGERANT CHARGE

Charge for all systems should be checked against the Charging Chart inside the
access panel cover.

8.CHECKING REFRIGERANT CHARGE

8.3 FINAL LEAK TESTING

After the unit has been properly evacuated and charged, a halogen leak detector
should be used to detect leaks in the system. All piping within the condensing unit,
evaporator, and interconnecting tubing should be checked for leaks. If a leak is

.

Charge for all systems should be checked against the Charging Chart inside the
access panel cover.
IMPORTANT:Do not operate the compressor without charge in system. Addition of
R-410A will raise pressures (vapor, liquid and discharge).
If adding R-410A raises both vapor pressure and temperature, the unit is over-
charged.
IMPORTANT: Use industry-approved charging methods to ensure proper system
charge.

8.1 CHARGING BY LIQUID PRESSURE

The liquid pressure method is used for charging systems in the cooling and heating
mode. The service port on the liquid (small valve) and suction (large valve) is used
for this purpose.

Verify that the outdoor unit is running and the indoor air handler is delivering the
maximum airflow for this system size. Read and record the outdoor ambient tem

-

p

erature. Read and record the liquid and suction pressures at the ports on the liquid

and suction valves.

If refrigerant lines are sized using the nameplate charge, the correct liquid pressure is
found at the intersection of the suction pressure and the outdoor ambient.

1. Remove refrigerant charge if the liquid pressure is above the chart value. The Clean Air

Act prohibits releasing (venting) refrigerant into the atmosphere.

2. Add refrigerant charge if the liquid pressure is below the chart value.

8.CHECKING REFRIGERANT CHARGE

detected, the refrigerant should be recovered before repairing the leak. The Clean Air
Act prohibits releasing venting refrigerant into the atmosphere.

8.2 CHARGING BY WEIGHT

For a new installation, evacuation of interconnecting tubing and indoor coil is
adequate; otherwise, evacuate the entire system.

Note that charge value includes
charge required for 15 ft. of standard size interconnecting liquid line. Calculate actual
charge required with installed liquid line size and length, please see 6.1 of table of

contents.

With an accurate scale (+/-1 oz.) or volumetric charging device, adjust charge
difference between that shown on the unit data plate and that calculated for the new
system Installation. if the entire system has been evacuated, add the total calculated
charge.

IMPORTANT:Do not operate the compressor without charge in system. Addition of
R-410A will raise pressures (vapor, liquid and discharge).
If adding R-410A raises both vapor pressure and temperature, the unit is over­charged.
IMPORTANT: Use industry-approved charging methods to ensure proper system
charge.

8.1 CHARGING BY LIQUID PRESSURE

The liquid pressure method is used for charging systems in the cooling and heating
mode. The service port on the liquid (small valve) and suction (large valve) is used
for this purpose.

Verify that the outdoor unit is running and the indoor air handler is delivering the
maximum airflow for this system size. Read and record the outdoor ambient tem

erature. Read and record the liquid and suction pressures at the ports on the liquid

p
and suction valves.

If refrigerant lines are sized using the nameplate charge, the correct liquid pressure is
found at the intersection of the suction pressure and the outdoor ambient.

1. Remove refrigerant charge if the liquid pressure is above the chart value. The Clean Air

Act prohibits releasing (venting) refrigerant into the atmosphere.

2. Add refrigerant charge if the liquid pressure is below the chart value.

8.2 CHARGING BY WEIGHT

For a new installation, evacuation of interconnecting tubing and indoor coil is
adequate; otherwise, evacuate the entire system.
charge required for 15 ft. of standard size interconnecting liquid line. Calculate actual
charge required with installed liquid line size and length, please see 6.1 of table of
contents.

With an accurate scale (+/-1 oz.) or volumetric charging device, adjust charge
difference between that shown on the unit data plate and that calculated for the new
system Installation. if the entire system has been evacuated, add the total calculated
charge.

8.3 FINAL LEAK TESTING

After the unit has been properly evacuated and charged, a halogen leak detector
should be used to detect leaks in the system. All piping within the condensing unit,
evaporator, and interconnecting tubing should be checked for leaks. If a leak is
detected, the refrigerant should be recovered before repairing the leak. The Clean Air
Act prohibits releasing venting refrigerant into the atmosphere.

Note that charge value includes

.

-

21

9.0 OWNER INSTRUCTIONS

Assist owner with processing Warranty cards and/or online registration. Review Owners
Guide and provide a copy to the owner and guidance on proper operation and main­teance. Instruct the owner or the operator how to start, stop and adjust temperature
setting. The installer should instruct the owner on proper operation and maintenance of
all other system components.

9.1 MAINTENANCE

. Dirt should not be allowed to accumulate on the outdoor coils or other parts in the air

1.
circuit. Clean as often as necessary to keep the unit clean. Use a brush, vacuum

cleaner attachment, or other suitable coil cleaning methods.

The outdoor fan motor is permanently lubricated and does not require periodic oiling.

2.

If the coil needs to be cleaned, it should be washed with Calgon Coilclean (mix one

3.

part Coilclean to seven parts water). Allow solution to remain on coil for 30 minutes
before rinsing with clean water. Solution should not be permitted to come in contact
with painted surfaces.

4. Refer to the furnace or air handler instructions for filter and blower motor maintenance.

5. The indoor coil and drain pan should be inspected and cleaned regularly to assure

proper drainage.

CAUTION

It is unlawful to knowingly vent, release or discharge refrigerant into the open air
during repair, service, maintenance or the final disposal of this unit. When the
system is functioning properly and the owner has been fully instructed, secure the
owner’s approval.

22

10.0 WIRING DIAGRAM

10.1 Control Wiring for A/C Unit

CAUTION

These units must be wired and installed in accordance with all National and
Local Safety Codes.

THERMOSTAT

C

R

Y

G

R ED

GREEN

BLACK

YE LLO W

BLACK

G

R

INDOOR UNIT

Fig.12 Control Wiring for A/C Systems.

CC COMPRESSOR CONTACTOR
COMP COMPRESSOR
RC 1 RUN CAPACITOR 1
RC 2 RUN CAPACITOR 2

LINE VOLTAGE
FACTORY STANDARD
FIELD INSTALLED

OPTIONAL

FACTORY

LOW

VOLTAGE
FACTORY STANDARD
FIELD INSTALLED
FACTORY OPTIONAL
USE COPPER CONDUCTORS ONLY

WARNING :
CABINET MUST BE PERMANMENTLY GROUNDED
AND ALL WIRING TO CONFORM TO I.E.C, N.E.C,
C.E.C, C.L.C, AND LOCAL CODES AS APPLICABLE

REPLACEMENT WIRE MUST BE THE SAME GAUGE

AND INSULATION TYPE AS ORIGINAL WIRE.

C

L1

A1

RC1

Y

OUTDOOR UNIT

T1

CC

A2

C

L2

BLACK

YELLOW

ORANGE

Lug Plate

L1

GND

L1
L2

TATSOMREHTOT

C
Y

Fig.13 Outdoor Unit Wiring Diagram for A/C Systems(208/230V 1P 60Hz).

23

10.2 CONTROL WIRING FOR H/P UNITS

W2

B

C

R

Y

G

THERMOSTAT

GREEN

G

INDOOR UNIT

Fig.16 Control Wiring for H/P Systems.

CC COMPRESSOR CONTACTOR
CCH

CRANKCASE HEATER

COMP

COMPRESSOR
DEFROST CONTROL

DFC

AMBIENT TEMPERATURE

T4
T3

PIPE TEMPERATURE
HPC HIGHT PRESSURE CUT-OUT CONTROL
L

PC LOW PRESSURE CUT-OUT CONTROL
OFM OUTDOOR FAN MOTOR
RC 1 RUN CAPACITOR 1
RC 2 RUN CAPACITOR 2
RV REVER
GND GROUND CHASSIS
HGS HOT GAS SENSOR

LINE VOLTAGE
FACTORY STANDARD
FIELD INSTALLED
FAC TORY

LOW
FACTORY STANDARD
FIELD INSTALLED
FACTORY OPTIONAL
USE COPPE R CONDUCTORS ONLY

WARNING :
CABINET MUST BE PERMANMENTLY
GROUNDED AND ALL WIRING TO CONFORM TO

I.E.C, N.E.C, C.E.C, C.L.C, AND LOCAL CODES AS
APPLICABLE REPLACEMENT WIRE MUST BE THE SAME
GAUGE AND INSULATION TYPE AS ORIGINAL WIRE.

SING VALVE

OPTIONAL

VOLTAGE

RED

R

WHITE

BLACK

w1

C

BLUE

B

PURPLE

D

RED

RY

BLACK

C

YELLOW

OUTDOOR UNIT

Lug Plate

21

L1

A1

ORANGE

OFM

CC

YELLOW

22

A2

T1

HPC

HGS

CCH

YELLOW

LPC

CN20

FAN

CN15

L1L2

RED

R

C

T4
T3

DFC

C

RV

RV

BLACK

C

YELLOW

Y

BLUE

B

PURPLE

D

GND

L1

L2

R

C

Y

B

W2

Fig.16 Outdoor Unit Wiring Diagram for H/P Systems(208/230V 1P 60Hz).

NOTE：

Cut off the power supply when outdoor appear "POWER PHASE FAILURE".Swich on
power supply again after 10 seconds if correct wiring connected.

25

TABLE 5: Wiring Gauge for H/P Systems.

Model(Btu/h)

Outdoor Unit
Power Line

Outdoor-Indoor
Signal Line

Thermostat
Signal Line

Line Quantity

Line Diameter
(AWG )

Line Quantity

Line Diameter
(AWG )

Line Quantity

Line Diameter
(AWG)

18000/24000 30000/36000 42000

3

33

3

12

5

55

5

18

5

55

5

18

48000/60000

1014 12

1818 18

1818 18

26

CC COMPRESSOR CONTACTOR
COMP

COMPRESSOR
TDC TIME DELAY CONTROL
T4 10K RESISTANCE.
T3 10K RESISTANCE.
OFM OUTDOOR FAN MOTOR
RC 1 OUTDOOR FAN MOTOR RUN CAPACITOR
GND GROUND CHASSIS

LINE VOLTAGE
FACTORY STANDARD
FIELD INSTALLED

OPTIONAL

FACTORY

LOW

VOLTAGE
FACTORY STANDARD
FIELD INSTALLED
FACTORY OPTIONAL
USE COPPER CONDUCTORS ONLY
WARNING
CABINET MUST BE PERMANENTLY
GROUNDED AND ALL WIRING TO CONFORM TO
I.E.C, N.E.C, C.E.C, C.L.C, AND LOCAL CODES AS APPLICABLE
REPLACEMENT WIRE MUST BE THE SAME GAUGE AND

TO THERMOSTAT

INSULATION TYPE AS ORIGINAL WIRE.

0

STEADY ON = NORMAL OPERATION

OFF = TDC FAILURE

1

1 FLASH = T3 SENSOR FAILURE

2

2 FLASH = T4 SENSOR FAILURE

3

3 FLASH = LPC OPEN

4

4 FLASH = POWER PHASE FAILURE

MANUAL DEFROST and JUMP is unavailable for AC unit.

OFM

PLUG PLATE

T1

T2

T3

CC

WHITE

CN17

C

Y-OUT

O_FAN

CN6

CN13

CN7
CN10

INFAN

MANUAL DEFROST

T4
T3

TDC

0
0

C

LED1

JUMP

R

CCH

C

D

G

YELLOW

Y

Y

B

W2
1

1

RV

LPC

CN15

L1

L2

Fig.14 Outdoor Unit Wiring Diagram for A/C Systems(208/230V 3P 60Hz).

NOTE：

Cut off the power supply when outdoor appear "POWER PHASE FAILURE".Swich on
power supply again after 10 seconds if correct wiring connected.

TABLE 4: Wiring Gauge for A/C Systems.

Model(Btu/h)

18000/24000

Input Current Fuse Amps

Outdoor Unit
Power Line

Line Quantity

Line Diameter

(AWG )

Outdoor-Indoor
Signal Line

Line Quantity

Line Diameter

(AWG )

Thermostat
Signal Line

Line Quantity

Line Diameter

(AWG)

15/20

3

2

4

30000/36000 42000

30/30

33

40

3

12

22

2

18

44

4

18

48000/60000

40/50

1014 12

1818 18

1818 18

All dimensions are in inches. They are subject to change without notice.
Certified

dimensions will be provided upon request.

24

RSG18 S/R‐1D CHARGING CHART

RSG24 S/R‐ 1D CHARGINGCHART

RSG30 S/R‐D1 CHARGINGCHART

RSG36S‐1DCHARGINGCHART

RSG42S‐1DCHARGINGCHART

T

RSG48S 1DCHARGINGCHART

RSG48S‐1DCHARGINGCHAR

RSG60S‐1DCHARGINGCHART

3/2012