Heat Controller R-410A User Manual
WARNING
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HEAT CONTROLLER
INSTALLATION INSTRUCTIONS
HIGH-EFFICIENCY CONDENSING UNITS FEATURING
EARTH-FRIENDLY R-410A REFRIGERANT
RSG - 61⁄2 & 71⁄2 TON
[ ] INDICATES METRIC CONVERSIONS
SUPERSEDES 92-42665-14-00
92-42665-14-01
TABLE OF CONTENTS
I. SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
II. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
II. CHECKING PRODUCT RECEIVED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
I
IV. EQUIPMENT PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
V. WHY USE AN AIR COOLED SPLIT SYSTEM?. . . . . . . . . . . . . . . . . . . . . . . . . . 5
VI. STANDARD UNIT FEATURES - 6
VII. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. Important Message to Owner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. Inspection and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. Order Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
D. Standard Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. General Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
E
F. Rooftop Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
G. Slab Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
VIII. REFRIGERANT PIPING DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
A. Installation of Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
B. Typical Piping Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
VIX. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
X. ELECTRICAL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
XI. POWER WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
XII. WIRE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
XIII. GROUNDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
XIV. THERMOSTAT - 6
XV. LEAK TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
XVI.R-410A REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A. Tools Required for Installing & Servicing R-410A Models . . . . . . . . . . . . . . . 14
B. Specification of R-410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
C. Quick Reference Guide for R-410A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
D. Replacement Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
E. Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
XVII. EVACUATION & CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
XVIII. SEQUENCE OF OPERATION - 6
XIX. ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
A. Anti-Short Cycle Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
B. Liquid Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
C. Liquid Line Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
D. Sight Glass / Moisture Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
XX. MISCELLANEOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
A. Charge Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-20
B. Maintenance & Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1. Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2. HPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3. LPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4. Pre-Start Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
C. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1
⁄2 & 71⁄2 TON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1
⁄2 & 71⁄2 TON . . . . . . . . . . . . . . . . . . . . . . . . . 6
1
⁄2 & 71⁄2 TON . . . . . . . . . . . . . . . . . . . . . . . . 17
➤ Installation Instructions are updated on a regular basis. This is done as product
changes occur or if new information becomes available. In this publication, an arrow (➤)
denotes changes from the previous edition or additional new material.
2
WARNING
!
IMPORTANT: ALL MANUFACTURER PRODUCTS MEET CURRENT
FEDERAL OSHA GUIDELINES FOR
SAFETY. CALIFORNIA
ROPOSITION 65 WARNINGS ARE
P
REQUIRED FOR CERTAIN PRODUCTS, WHICH ARE NOT COVERED
BY THE OSHA STANDARDS.
CALIFORNIA'S PROPOSITION 65
REQUIRES WARNINGS FOR PRODUCTS SOLD IN CALIFORNIA THAT
CONTAIN, OR PRODUCE, ANY OF
OVER 600 LISTED CHEMICALS
KNOWN TO THE STATE OF
ALIFORNIA TO CAUSE CANCER
C
OR BIRTH DEFECTS SUCH AS
FIBERGLASS INSULATION, LEAD
IN BRASS, AND COMBUSTION
PRODUCTS FROM NATURAL GAS.
ALL “NEW EQUIPMENT” SHIPPED
FOR SALE IN CALIFORNIA WILL
HAVE LABELS STATING THAT THE
PRODUCT CONTAINS AND/OR
PRODUCES PROPOSITION 65
CHEMICALS. ALTHOUGH WE HAVE
NOT CHANGED OUR PROCESSES,
HAVING THE SAME LABEL ON ALL
OUR PRODUCTS FACILITATES
MANUFACTURING AND SHIPPING.
WE CANNOT ALWAYS KNOW
“WHEN, OR IF” PRODUCTS WILL
BE SOLD IN THE CALIFORNIA
MARKET.
YOU MAY RECEIVE INQUIRIES
FROM CUSTOMERS ABOUT CHEMICALS FOUND IN, OR PRODUCED
BY, SOME OF OUR HEATING AND
AIR-CONDITIONING EQUIPMENT,
OR FOUND IN NATURAL GAS USED
WITH SOME OF OUR PRODUCTS.
LISTED BELOW ARE THOSE CHEMICALS AND SUBSTANCES COMMONLY ASSOCIATED WITH SIMILAR EQUIPMENT IN OUR INDUSTRY AND OTHER MANUFACTURERS.
• GLASS WOOL (FIBERGLASS)
INSULATION
• CARBON MONOXIDE (CO)
• FORMALDEHYDE
• BENZENE
MORE DETAILS ARE AVAILABLE
AT THE WEBSITES FOR OSHA
(OCCUPATIONAL SAFETY AND
HEALTH ADMINISTRATION), AT
WWW.OSHA.GOV
OF CALIFORNIA'S OEHHA (OFFICE
OF ENVIRONMENTAL HEALTH
HAZARD ASSESSMENT), AT
WWW.OEHHA.ORG.
EDUCATION IS IMPORTANT SINCE
THE CHEMICALS AND SUBSTANCES ON THE LIST ARE
FOUND IN OUR DAILY LIVES. MOST
CONSUMERS ARE AWARE THAT
PRODUCTS PRESENT SAFETY AND
HEALTH RISKS, WHEN IMPROPERLY USED, HANDLED AND MAINTAINED.
AND THE STATE
CONSUMER
1.0 SAFETY INFORMATION
WARNING
!
TH ESE INST RUCTIONS A RE INTENDED A S AN AID TO QUALIFIED
LIC ENSED SER VIC E P ERS ONN EL FOR PRO PER INSTALLA TIO N,
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 FIRE, ELECTRICAL SHOCK, PROPERTY DAM-
GE, PERSONAL INJURY OR DEATH.
A
WARNING
!
DISCONNECT ALL POWER TO THE UNIT BEFORE STARTING MAINTENANCE.
FAILURE TO DO SO CAN RESULT IN SEVERE ELECTRICAL SHOCK OR
DEATH.
WARNING
!
DO NOT USE OXYGEN TO PURGE LINES OR PRESSURE SYSTEM FOR
LEAK TEST. OXYGEN REACTS VIOLENTLY WITH O IL, WHICH CAN
CAUSE AN EXPLOSION RESULTING IN SEVERE PERSONAL INJURY OR
DEATH.
WARNING
!
AFTER COMPLETION OF WIRING CHECK ALL ELECTRICAL CONNECTIONS, INCLUDING FACTORY WIRING WITHIN THE UNIT, AND MAKE
SURE ALL CONNECTIONS ARE TIGHT, REPLACE AND SECURE ALL
ELECTRICAL BOX COVERS AND ACCESS DOORS BEFORE LEAVING
UNIT OR TURNING ON POWER TO CIRCUIT SUPPLY UNIT. FAILURE TO
DO SO CAN CAUSE A FIRE OR ELECTRICAL SHOCK RESULTING IN
PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
WARNING
!
THIS UNIT MUST BE PERMANENTLY GROUNDED. A GROUND LUG IS
PROVIDED NEAR THE CONTACTOR FOR A GROUND WIRE. FAILURE TO
DO SO CAN CAUSE A FIRE OR ELECTRICAL SHOCK RESULTING IN
PROPERTY DAMAGE, SEVERE PERSONAL INJURY OR DEATH.
CAUTION
!
R-410A systems operate at higher pressures than R-22 systems. Do not use
R-22 service equipment or components on R-410A equipment.
CAUTION
!
Only use evaporators approved for use on R-410A systems. Use of existing R-22
evaporators can introduce mineral oil to the R-410A refrigerant forming two different liquids and decreasing oil return to the compressor. This can result in compressor failure.
3
II. INTRODUCTION
This booklet contains the installation and operating instructions for your self-contained
air conditioner. There are a few precautions that should be taken to derive maximum
satisfaction from it. Improper installation can result in unsatisfactory operation or dangerous conditions.
Read this booklet and any instructions packaged with separate equipment required to
ake up the system prior to installation. Give this booklet to the owner and explain its
m
provisions. The owner should retain this booklet for future reference.
III. CHECKING PRODUCT RECEIVED
Upon receiving the unit, inspect it for any damage from shipment. Claims for damage,
either shipping or concealed, should be filed immediately with the shipping company.
Check the unit model number, electrical characteristics, and accessories to determine if
they are correct.
IV. EQUIPMENT PROTECTION FROM THE
ENVIRONMENT
The metal parts of this unit may be subject to rust or deterioration in adverse environmental conditions. This oxidation could shorten the equipment’s useful life. Salt spray,
fog or mist in seacoast areas, sulphur or chlorine from lawn watering systems, and various chemical contaminants from industries such as paper mills and petroleum refineries
are especially corrosive.
If the unit is to be installed in an area where contaminants are likely to be a problem, special attention should be given to the equipment location and exposure.
1. Avoid having lawn sprinkler heads spray directly on the unit cabinet.
2. In coastal areas, locate the unit on the side of the building away from the waterfront.
3. Shielding provided by a fence or shrubs may give some protection.
4. Elevating the unit off its slab or base enough to allow air circulation will help avoid
holding water against the basepan.
Regular maintenance will reduce the buildup of contaminants and help to protect
the unit’s finish.
WARNING
!
DISCONNECT ALL POWER TO THE UNIT BEFORE STARTING MAINTENANCE.
FAILURE TO DO SO CAN RESULT IN SEVERE ELECTRICAL SHOCK OR
DEATH.
1. Frequent washing of the cabinet, fan blade and coil with fresh water will remove
most of the salt or other contaminants that build up on the unit.
2. Regular cleaning and waxing of the cabinet with an automobile polish will provide
some protection.
3. A liquid cleaner may be used several times a year to remove matter that will not
wash off with water.
Several different types of protective coatings are offered in some areas. These coatings
may provide some benefit, but the effectiveness of such coating materials cannot be verified by the equipment manufacturer.
The best protection is frequent cleaning, maintenance and minimal exposure to
contaminants.
4
V. WHY USE AN AIR COOLED SPLIT SYSTEM?
• With an air cooled system, you have no water or sewer connections to make, and
no troublesome and costly water treatment problems.
• Since the condensing unit is located outside the building, and the low profile air handling unit can be installed in the drop ceiling or in the conditioned space, you will not
eed a separate equipment room which takes up valuable building space.
n
• Because of the simple design of the condensing unit, installation is quick and sim-
le, and very little maintenance is required.
p
• The size ranges offered allow you to mix or match components to meet actual job
requirements, thus eliminating the need to use oversized or undersized equipment.
Equipment sized to meet the actual load will provide better operating economy, better humidity control, and longer equipment life.
• Remote mounting of the already quiet condensing unit keeps the compressor and
condenser fan noise outside, and the vertical discharge fans carry the sound up and
away from the surrounding area.
TABLE 1
CORNER WEIGHTS (Pounds)
Unit
Model
RSG078 45 [20.41] 66 [29.91] 63 [28.6] 90 [40.8]
Total Weight
Lbs. [kg]
264
ABCD
RSG090 283
Corner Weights, Lbs. [kg]
98 [44.5]63 [28.6]75 [34.0]47 [21.3]
FIGURE 1
UNIT DIMENSIONS — 61⁄2 & 71⁄2 TON
3253⁄64"
SUCTION
LINE 1
LIQUID
LINE1⁄2"
C
43
42
⁄64"
D
1
⁄8"
21
11
24
⁄16"
3
⁄16"
11
26
287⁄16"
⁄16"
HIGH VOLTAGE - 1
B
LOW VOLTAGE -
7
⁄8" HOLE
1
⁄16"
31
A
3
⁄4" HOLE
5
VI. STANDARD UNIT FEATURES — 61⁄2 AND 71⁄2
CABINET — Galvanized steel with a durable powder coat paint finish. The cabinet front
and sides are formed into a one piece unitized design with stamped louvers to provide
protection for the condenser coils.
SERVICE ACCESS — Control box with separation between line and control voltages,
as well as compressor and other refrigerant controls are accessible through removable
op and side panels (without affecting normal operation of unit).
t
Condenser fan motors are mounted on removable top panels which bring the motors out
to you and expose entire condenser coil for cleaning.
COMPRESSOR — Hermetically sealed with internal high temperature protection and
urable insulation on motor windings. The compressor is mounted on rubber grommets
d
to reduce vibration and noise.
CONDENSER COILS — Constructed with copper tubes and aluminum fins mechanically bonded to tubes for maximum heat transfer capabilities. All coil assemblies are leak
ested.
t
REFRIGERANT CONNECTIONS — All field sweat joints are made external of the unit
and are located close to the ground for a neat looking installation.
LOW AMBIENT CONTROL — A pressure sensitive fan cycling control allows operation
of units down to to 0°F.
HIGH PRESSURE CONTROL — Manual reset control deactivates system if abnormally
high pressure occurs.
LOW PRESSURE CONTROL — Automatic reset control deactivates system if abnormally low pressure or refrigerant loss occurs.
SERVICE VALVES — Standard on liquid line and suction line. Allows outdoor section
to be isolated from indoor coil.
FILTER DRIER — Standard, field installed. Helps maintain system cleanliness.
CONDENSER FAN MOTORS — Direct-drive, PSC single-phase motors.
TRANSFORMER — Step down type, from Line to 24 volts. (Refer to Figure 2.)
CONTACTOR — (Refer to Figure 2.) The contactor is an electrical switch which oper-
ates the compressor and condenser fans. Its 24 volt coil is activated through the High
Pressure Control and Low Pressure Control on a call for cooling.
CAPACITORS — Help provide starting torque necessary to boost the condenser fan
motors to operating speed by directing their stored energy to the starter winding in step
with the running winding.
EQUIPMENT GROUND — Lug for field connection of ground wire.
TESTING — All units are run tested at the factory prior to shipment.
FIGURE 2
61⁄2 & 71⁄2 TON FEATURES
CONTROL TRANSFORMER
CAPACITOR
COMPRESSOR CONTACTOR
SCROLL
COMPRESSOR
CRANKCASE
HEATER
LOW AMBIENT
CONTROL
SUCTION
VALVE
LOW
PRESSURE
SWITCH
LIQUID
VALVE
HIGH PRESSURE
SWITCH
CONTROL
BOX
LOW VOLTAGE
CONNECTION
HIGH VOLTAGE
ENTRY
LOW VOLTAGE
ENTRY
6
TABLE 2
HYSICAL AND ELECTRICAL DATA TABLE (RSG)
P
Condensing Unit 078 090
Operating Weight (lbs.) [kg] 264 [119.8] 287 [130.2]
Shipping Weight (lbs.) [kg] 283 [128.9] 306 [138.8]
COMPRESSOR:
Quantity 11
Type Scroll
RPM 3500
CONDENSER FANS:
Quantity 11
CFM [L/s] 4700 [2218] 4700 [2218]
Diameter (in.) [mm] 24 [610] 24 [610]
Motor Horsepower (ea.) [W]
Type PSC PSC
RPM 1075 1075
CONDENSER COIL:
Quantity 11
Rows 11⁄2 2
Fins per Inch 20 22
Square Feet [m2] 22.2 [3] 22.2 [3]
Fins/Tubes Aluminum/Copper
Tube Size, O.D. (in.) [mm]
ELECTRICAL DATA TABLE (RSG)
MODEL NO. RSG 078A3 078A4 078A5 090A3 090A4 090A5
COMPRESSOR MOTOR:
Electrical Characteristics 208/230-3-60 460-3-60 575-3-60 208/230-3-60 460-3-60 575-3-60
OPERATING CURRENT:
Rated Load Amps 22.4/22.4 10.6 7.0 25/25 12.2 9.0
Locked Rotor Amps 149 75 54 164 100 78
CONDENSER FAN MOTORS:
Volts & Phase 208/230-1 460-1 575-1 208/230-1 460-1 575-1
Full Load Amps (each) 2.2 1.3 1.0 2.2 1.3 1.0
SYSTEM CHARACTERISTICS:
Unit FLA 25.0 12 8.0 28.0 14.0 10.0
Minimum Circuit Ampacity 31/31 15 11.0 34/34 17 13
Max. Fuse Size or HACR
Circuit Breaker Ampacity 50/50 25 15 50/50 25 20
Disconnect Size 60 30 30 60 30 30
1
⁄3 [249]
3
⁄8 [10]
1
⁄3 [249]
3
⁄8 [10]
NOTE: N.E.C., C.E.C. and local codes take precedence over suggested wire and fuse sizes.
[ ] Designates Metric Conversion
VII. INSTALLATION
A. IMPORTANT MESSAGE TO OWNER
The manufacturer assumes no responsibility for equipment installed in violation of any
code or regulation. The operation portion of this manual gives instructions as to the service and care of the unit. It is recommended that the installer go over the operational
portion of this manual with the owner so that there is a full understanding of the equipment and how it is intended to function.
These instructions should be read and kept for future reference. It is suggested that this
booklet be affixed to or adjacent to the indoor equipment. It is addressed to your dealer
and serviceman, but we highly recommend that you read it—paying particular attention
to the section titled “MAINTENANCE.”
B. INSPECTION AND HANDLING
Inspect exterior of unit for evidence of rough handling in shipment. If damage is found,
enter claim at once. Unpack carefully after moving unit to approximate location. Any
damage should be reported immediately to the transportation company.
Material in this shipment was inspected at the factory and released to the common carrier with no known damage.
7
C. ORDER PARTS
Condensing Unit
Control Box End Control Box End
36” min. [914 mm]
36” min. [914 mm]
24” min.
[610 mm]
24” min.
[610 mm]
Condensing Unit
When reporting shortages or damaged parts, or when ordering repair parts, give the
omplete unit model and serial numbers which are stamped on the Unit Rating Plate.
c
D. STANDARD ITEMS
The condensing unit consists of a completely assembled package which includes a com-
ressor, a condenser coil, fan, fan motors, outdoor control box, factory wiring, factory
p
tubing and fittings.
E. INSTALLATION GENERAL
NOTE: These units must be installed outdoors. No ductwork can be attached, or
other modifications made, to the discharge grille. Modifications will affect performance or operation.
The condensing unit should be installed outdoors. It should be located as near as possible to the evaporator section to keep connecting refrigerant tubing lengths to a minimum.
The unit must be installed to allow a free air flow to the condenser coils.
If several units are installed adjacent to each other, care must be taken to avoid recirculation of air from one condenser to another. In all installations, adequate space must be
provided for installation and servicing.
FIGURE 3
LEARANCES
C
8
The unit must not be connected to any duct work. Do not locate unit under a roof drip; if
necessary, install gutters, etc., to prevent water run-off from hitting the unit. To prevent
air recirculation, it is recommended that the unit not be installed under an overhang, but
if necessary allow a minimum of 60 inches above the unit for air discharge.
NOTE: To prevent the possibility of freeze damage, you can install an air proving switch
in the air handler supply duct wired in series with the compressor contactor coil (24V)
which would lock out the compressor in the event of air flow failure.
F. ROOFTOP INSTALLATION (REFER TO FIGURE 4)
If rooftop installation is required, make certain that the building construction is adequate
for the weight of the unit. (Refer to physical data chart.) Before placing the unit on the
roof, make certain that the nylon rigging slings are of sufficient length to maintain equilibrium of the unit when lifting. Under no circumstances should the unit be lifted by only one
corner for rooftop installation.
G. SLAB INSTALLATION
Condensing units should be set on a solid level foundation. When installed at ground
level, the unit should be placed on a 6 inch cement slab. If the pad is formed at the
installation site, do not pour the pad tight against the structure, otherwise vibration will
be transmitted from the unit through the pad.
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