Heat Controller RSE1318-1A, RSE1360-1A Installation And Operation Manual

Installation and

Operation Manual

H J rRSE1318/1360-1A

Split System

Condensing Units

13 SEER 1.5 TO 5 TON CONDENSING UNITS

2

TABLE OF CONTENTS

Checking Product Received . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Electrical & Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Locating Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Unit Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Factory-Preferred Tie-Down Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Refrigerant Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Replacement Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Interconnecting Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Evacuation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Start-Up and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Checking Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Checking Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Charging by Liquid Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Charging by Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Final Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-19

Trouble Shooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

CHECKING PRODUCT RECEIVED

Upon receiving unit, inspect it for any shipping damage. Claims for damage, either
apparent or concealed, should be filed immediately with the shipping company.
Check condensing unit model number, electrical characteristics and accessories to
determine if they are correct and match the original order from the local distributor.
Check system components (evaporator coil, condensing unit, evaporator blower,
etc.) to make sure they are properly matched.

3

TABLE 1

ELECTRICAL AND PHYSICAL DATA

NOTE: Factory Refrigerant Charge includes refrigerant for 15 feet of standard line set.

Electrical Data Physical Data

Cooling

Capacity

Phase-Frequency

Voltage

(Hz) (Volts)

Compressor

Rated Load

Amperes

(RLA)

Compressor

Locked Rotor

Amperes

(LRA)

Fan Motor

Full Load
Amperes

(FLA)

Minimum

Circuit
Ampacity
Amperes

Minimum
Amperes

Maximum

Amperes

Outdoor

Coil

Area

Sq. Ft.

[Sq. M]

Outdoor

Coil

No.

Rows

Outdoor

Coil
CFM
[L/s]

Refrigerant

Charge

oz.
[g]

Net

Weight

lb.

[kg]

Ship

Weight

lb.

[kg]

Fuse or HACR

Circuit Breaker

18 1-60-208/230 6.4/6.4 36 1 10/10 15/15 15/15 8.43 1 1900 67.4 150 158

[.78] [897] [1899] [68.0] [71.7]

24 1-60-208/230 9.9/9.9 54 0.6 14/14 20/20 20/20 11.06 1 1700 77.0 155 163

[1.03] [802] [2183] [70.3] [73.9]

30 1-60-208/230 10.6/10.6 61 0.8 15/15 20/20 20/20 13.72 1 2325 97.8 175 185

[1.30] [1097] [2778] [79.4] [83.0]

36 1-60-208/230 13.5/13.5 78 0.8 18/18 25/25 30/30 16.39 1 2800 108.0 200 212

[1.52] [1321] [3062] [90.7] [96.1]

42 1-60-208/230 19.2/19.2 105 0.8 25/25 30/30 40/40 16.39 1 2800 121.0 205 217

[1.52] [1321] [3430] [93.0] [98.4]

48 1-60-208/230 21.1/21.1 115 1.2 28/28 35/35 45/45 16.39 1 3300 122.8 210 222

[1.52] [1557] [3487] [95.3] [100.7]

60 1-60-208/230 25/25 150 1.2 33/33 40/40 50/50 21.85 1 3575 190.8 247 258

[2.03] [1687] [5415] [112.0] [117.0]

4

GENERAL

The information contained in this manual has been prepared to assist in the proper
installation, operation and maintenance of the air conditioning system. Improper
installation, or installation not made in accordance with these instructions, can result
in unsatisfactory operation and/or dangerous conditions, and can cause the related
warranty not to apply.

Read this manual and any instructions packaged with separate equipment required
to make up the system prior to installation. Retain this manual for future reference.

To achieve optimum efficiency and capacity, the indoor cooling coils listed in the
condensing unit specification sheet should be used.

IMPORTANT: We recommend replacement of any HVAC equipment that has been
subjected to flooding in order to avoid any risk of injury or harm.

IMPORTANT: Use all available safety precautions during the installation and servic­ing of any HVAC equipment.

APPLICATION

Before installing any air conditioning equipment, a duct analysis of the structure and
a heat gain calculation must be made. A heat gain calculation begins by measuring
all external surfaces and openings that gain heat from the surrounding air and
quantifying that heat gain. A heat gain calculation also calculates the extra heat
load caused by sunlight and by humidity removal.

There are several factors that the installers must consider:

• Outdoor unit location • Proper equipment evacuation

• System refrigerant charge • Indoor unit airflow

• Indoor unit blower speed • Supply and return air duct design and sizing

• System air balancing • Diffuser and return air grille location and sizing

LOCATING UNIT

CONDENSER LOCATION

Consult local and national building codes and ordinances for special installation
requirements. Following location information will provide longer life and simplified
servicing of the outdoor condenser.

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.

OPERATIONAL ISSUES

• IMPORTANT: Locate the condenser in a manner that will not prevent, impair or
compromise the performance of other equipment horizontally installed in prox­imity to the unit. Maintain all required minimum distances to gas and electric
meters, dryer vents, exhaust and inlet openings. In the absence of National
Codes, or manaufacturers’ recommendations, local code recommendations
and requirements will take presidence.

• Refrigerant piping and wiring should be properly sized and kept as short as
possible to avoid capacity losses and increased operating costs.

• Locate the condenser where water run off will not create a problem with the
equipment. Position the unit away from the drip edge of the roof whenever pos­sible. Units are weatherized, but can be affected by water pouring into the unit
from the junction of rooflines, without protective guttering.

!

WARNING

THE MANUFACTURER’S WAR­RANTY DOES NOT COVER ANY
DAMAGE OR DEFECT TO THE
AIR CONDITIONER CAUSED BY
THE ATTACHMENT OR USE OF
ANY COMPONENTS. ACCES­SORIES OR DEVICES (OTHER
THAN THOSE AUTHORIZED BY
THE MANUFACTURER) INTO,
ONTO OR IN CONJUNCTION
WITH THE AIR CONDITIONER.
YOU SHOULD BE AWARE THAT
THE USE OF UNAUTHORIZED
COMPONENTS, ACCESSORIES
OR DEVICES MAY ADVERSELY
AFFECT THE OPERATION
OF THE AIR CONDITIONER AND
MAY ALSO ENDANGER LIFE
AND PROPERTY. THE MANUFAC­TURER DISCLAIMS ANY
RESPONSIBILITY FOR SUCH
LOSS OR INJURY RESULTING
FROM THE USE OF SUCH
UNAUTHORIZED COMPONENTS,
ACCESSORIES OR DEVICES.

MATCH ALL COMPONENTS:

• OUTDOOR UNIT

• INDOOR COIL/METERING DEVICE

• INDOOR AIR HANDLER/FURNACE

• REFRIGERANT LINES

5

CORROSIVE ENVIRONMENT

The metal parts of this unit may be subject to rust or deterioration if exposed to a
corrosive environment. This oxidation could shorten the equipment’s useful life.
Corrosive elements include, but are not limited to, 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.

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.

• Avoid having lawn sprinkler heads spray directly on the unit cabinet.

• In coastal areas, locate the unit on the side of the building away from the water-

front.

• Shielding provided by a fence or shrubs may give some protection, but cannot

violate minimum airflow and service access clearances.

• 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 build-up of contaminants and help to protect
the unit’s finish.

• 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.

• Regular cleaning and waxing of the cabinet with an automobile polish will pro-

vide some protection.

• 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.

FOR CONDENSERS WITH SPACE LIMITATIONS

In the event that a space limitation exists, we will permit the following clearances:

Single Unit Applications: One condenser inlet air grille side may be reduced to no
less than a 6-inch clearance. Clearances below 6 inches will reduce unit capacity
and efficiency. Do not reduce the 60-inch discharge, or the 24-inch service clear­ances.

Multiple Unit Applications: When multiple condenser grille sides are aligned, a 6­inch per unit clearance is recommended, for a total of 12 inches between two units.
Two combined clearances below 12 inches will reduce capacity and efficiency. Do
not reduce the 60-inch discharge, or 24-inch service, clearances.

CUSTOMER SATISFACTION ISSUES

• The condenser should be located away from the living, sleeping and recreation-

al spaces of the owner and those spaces on adjoining property.

• To prevent noise transmission, the mounting pad for the outdoor unit should

not be connected to the structure, and should be located sufficient distance
above grade to prevent ground water from entering the unit.

!

WARNING

DISCONNECT ALL POWER TO UNIT BEFORE STARTING
MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK
RESULTING IN SEVERE PERSONAL INJURY OR DEATH.

6

UNIT MOUNTING

If elevating the condensing unit, either on a flat roof or on a slab, observe the
following guidelines.

• The base pan provided elevates the condenser coil 3/4” above the base pad.

• If elevating a unit on a flat roof, use 4” x 4” (or equivalent) stringers positioned
to distribute unit weight evenly and prevent noise and vibration.

FACTORY-PREFERRED TIE-DOWN METHOD

INSTRUCTIONS:

IMPORTANT: These instructions are intended as a guide to securing equipment for wind­load ratings of “120 MPH sustained wind load” and “3-second, 150 MPH gust.” While this
procedure is not mandatory, the Manufacturer does recommend that equipment be prop­erly secured in areas where high wind damage may occur.

STEP 1: Before installing, clear pad of any dirt or debris.

IMPORTANT: The pad must be constructed of industry-approved materials, and
must be thick enough to accommodate the concrete fastener.

STEP 2: Center basepan on pad, ensuring it is level.

STEP 3: Using metal straps as guides, mark spots on concrete where 4 holes will be

drilled (See Figure 2).

STEP 4: Drill four pilot holes in pad, ensuring that the hole is at least 1/4” deeper than the

concrete fastener being used.

STEP 5: Gauge the amount of washers needed by stacking washers and metal strap in

place, as shown in Figure 2, Detail A. Typical installation requires 6 to 7 wash­ers.

STEP 6: Insert concrete fastener into hole in metal strap, insert washers over end of fas-

tener, and then insert into hole drilled into concrete.

STEP 7: Tighten concrete fastener.

NOTE: Do not over-tighten the concrete fastener. Doing so can weaken the
integrity of the concrete fastener and cause it to break.

STEP 8: Finish unit assembly per unit’s installation instructions.

REFRIGERANT CONNECTIONS

All units are factory charged with Refrigerant 22. All models are supplied with ser­vice valves. Keep tube ends sealed until connection is to be made to prevent sys­tem contamination.

REQUIRED PARTS LIST

NOTE: ALL PARTS AVAILABLE THROUGH LOCAL HARDWARE SUPPLY

STORES

DESCRIPTION QUANTITY

1/4” x 2” Hex Washer Head Concrete Screws 4
1/8” x 1 1/2” x W (width of unit + 4”) Metal straps 2
3/8” Washers 28

7

FIGURE 1

DIMENSIONS

DIMENSIONAL DATA

AIR DISCHARGE: ALLOW

60” MINIMUM CLEARANCE.

SERVICE ACCESS

ALLOW 24” CLEARANCE

AIR INLETS

(LOUVERED
PANELS)
ALLOW 6”
MINIMUM
CLEARANCE

18, 24 30

36, 42,

48

60

Height “H” (in.) [mm]

241/

4

[616]

24

1

/

4

[616]

2715/

16

[710]

Length “L” (in.) [mm]

235/

8

[600]

275/

8

[702]

315/

8

[803]

Width “W” (in.) [mm]

235/

8

[600]

275/

8

[702]

315/

8

[803]

31

5

/

8

[803]

BASE PAN (BOTTOM VIEW)

DO NOT OBSTRUCT DRAIN HOLES

(SHADED).

13 SEER

Cooling Capacity

2"

BASERAIL

315/

8

[803]

35

15

/

16

[913]

w

A-00008

L

H

SEE DETAIL A

8

REPLACEMENT UNITS

To prevent failure of a new condensing unit, the existing evaporator tubing system
must be correctly sized and cleaned or replaced. Care must be exercised that the
expansion device is not plugged. Test the oil for acid. If positive, a suction line filter
drier is mandatory. For new and replacement units, a liquid line filter drier should be
installed and refrigerant tubing should be properly sized.

INTERCONNECTING TUBING

VAPOR AND LIQUID LINES

Keep all lines sealed until connection is made.

Refer to Line Size Information in Tables 3 through 5 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 refrigeration charge in the outdoor unit is sufficient for 15 feet of inter­connecting lines. The factory refrigeration charge in the outdoor unit is sufficient for
the unit and 15 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

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.

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

FIGURE 2

TIE-DOWN KIT ASSEMBLY

DETAIL A

9

OUTDOOR UNIT INSTALLED ABOVE INDOOR COIL

Keep the vertical separation between coils to a minimum. However, the vertical dis­tance can be as great as 120 feet with the condensing unit ABOVE the indoor coil.
Use the following guidelines when installing the unit:

1. DO NOT exceed 120 feet maximum vertical separation.

2. Expansion Valve Coil:

a. The vertical separation can be greater than the value in Table 4, but no

more than 120 feet.

b. No changes are required for expansion valve coils.

3. Always use the smallest liquid line size permitted to minimize the system

charge.

4. Table 4 may be used for sizing horizontal runs.

OUTDOOR UNIT BELOW INDOOR COIL

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

1. DO NOT exceed the vertical separations as indicated on Table 5.

2. Always use the smallest liquid line size permitted to minimize system charge.

3. Table 5 may be used for sizing horizontal runs.

TUBING INSTALLATION

Observe the following when installing correctly sized type “L” refrigerant tubing
between the condensing unit and evaporator coil:

• If a portion of the liquid line passes through a hot area where liquid refrigerant

can be heated to form vapor, insulating the liquid line is required.

• Use clean, dehydrated, sealed refrigeration grade tubing.

• Always keep tubing sealed until tubing is in place and connections are to be

made.

• Blow out the liquid and vapor lines with dry nitrogen before connecting to the

outdoor unit and indoor coil. For an air conditioning system, any debris in the
line set could end up plugging the expansion device.

• As an added precaution, a filter drier is recommended to be installed in the liq-

uid line.

• If tubing has been cut, make sure ends are deburred while holding in a position

to prevent chips from falling into tubing. Burrs such as those caused by tubing
cutters can affect performance dramatically, particularly on small liquid line
sizes.

• For best operation, keep tubing run as short as possible with a minimum num-

ber of elbows or bends.

• Locations where the tubing will be exposed to mechanical damage should be

avoided. If it is necessary to use such locations, the copper tubing should be
housed to prevent damage.

• If tubing is to be run underground, it must be run in a sealed watertight chase.

• Use care in routing tubing and do not kink or twist. Use a tubing bender on the

vapor line to prevent kinking.

• The vapor line must be insulated to prevent dripping (sweating) and prevent

performance losses. Armaflex and Rubatex are satisfactory insulations for this
purpose. Use 1/2” minimum insulation thickness, additional insulation may be
required for long runs.

• Check Table 3 for the correct vapor line size. Check Tables 4 and 5 for the cor-

rect liquid line size.

10

TUBING CONNECTIONS

Indoor evaporator coils have only a holding charge of dry nitrogen. Keep all tube
ends sealed until connections are to be made.

• Use type “L” copper refrigeration tubing. Braze the connections with accepted
industry practices.

• Be certain both refrigerant service valves at the outdoor unit are closed.

• Clean the fittings before brazing.

• Remove the cap and schrader core from service port to protect seals from heat
damage.

• Use an appropriate heatsink material around the copper stub and the service
valves before applying heat.

• IMPORTANT: Do not braze any fitting with the TEV sensing bulb attached.

• Braze the tubing between the outdoor unit and indoor coil. Flow dry nitrogen
into a service port and through the tubing while brazing.

• After brazing – use an appropriate heatsink material to cool the joint and
remove any flux residue.

LEAK TESTING

• Pressurize line set and coil through service fittings with dry nitrogen to 150 psig
maximum. Leak test all joints using liquid detergent. If a leak is found, repair
and repeat leak test procedures.

!

WARNING

DO NOT USE OXYGEN TO PURGE LINES OR PRESSURIZE SYSTEM FOR
LEAK TEST. OXYGEN REACTS VIOLENTLY WITH OIL, WHICH CAN
CAUSE AN EXPLOSION RESULTING IN SEVERE PERSONAL INJURY OR
DEATH.

TABLE 3

VAPOR LINE LENGTH SIZE AND CAPACITY MULTIPLIER

18 24 30 36 42 48 60

Opt. .98 — — .99 — .99 .99

0’ - 25’ Std. 1.00 1.00 1.00 1.00 1.00 1.00 1.00

Opt. 1.01 1.01 1.01 1.01 1.01 1.01 1.01

Opt. .96 — — .97 — .97 .97

26’ - 50’ Std. .99 .99 .98 .99 .99 1.00 .99

Opt. 1.00 1.00 1.00 1.01 1.01 1.01 1.0

Opt. .93 — — .93 — .96 .95

51’ - 100’ Std. .98 .97 .96 .98 .98 .99 .99

Opt. .99 .99 .99 1.00 1.00 1.00 1.00

Opt. — — — — — .93 .93

101’ - 150’ Std. .97 .95 .93 .97 .96 .99 .98

Opt. .98 .97 .97 .99 .99 1.00 .99

Suction Line Run Feet

NOTES:

1) Capacity Multiplier x Rated Capacity = Actual Capacity.

2) Additional Compressor oil is not required for runs up to 150 feet.

3) Oil traps in vertical runs are not required for any height up to 125 feet. See Liquid Line chart for Vertical
Separation Requirements and Limitations.

4) Actual suction line connection size is 7/8". Adapter to 1-1/8" is factory supplied.

5/8” O.D. Optional

3/4” O.D. Standard

7/8” O.D. Optional

3/4” I.D. Sweat

3/4” O.D. Optional

7/8” O.D. Standard

1-1/8” O.D. Optional

7/8” I.D. Sweat

7/8” I.D.

Sweat (4)

7/8” O.D. Optional

1-1/8” O.D. Standard

1-3/8” O.D. Optional

Suction Line

Connection Size

Cooling

Capacity

11

TABLE 4

LIQUID LINE SIZE — OUTDOOR UNIT ABOVE INDOOR COIL

NOTES:
* Standard line size. 1) This chart is applicable for condensing units. 2) Do not exceed 120 feet maximum vertical separation. 3) Always use the smallest liquid
line possible to minimum system charge. 4) Chart may be used to size horizontal runs.

TABLE 5

LIQUID LINE SIZE — OUTDOOR UNIT BELOW INDOOR COIL

NOTES:
* Standard line size. 1) This chart is applicable for condensing units. 2) This chart may also be used to size horizontal runs. 3) Do not exceed

vertical separation as indicated on the chart. 4) Always use the smallest liquid line possible to minimum system charge. 5) No changes required for flow-check
pistons or expansion valve coils.

LIQUID LINE SIZE - OUTDOOR UNIT ABOVE INDOOR COIL

TOTAL LENGTH - (ft)

25 50 75 100 125 150

25 50 70

36 42 48 54

25 50

24 34 44 54 64

25 50

19 33 47 61

11 15

25 50 70

34 40 46 52

25 50 75

32 39 46 53

25 44 53 61 70

37 39

25 48 61 72

35 38 41

1/4*

5/16

1/4*

5/16

1/4*

5/16

3/8

5/16*

3/8

5/16*

3/8

3/8*

1/2

3/8*

1/2

5/16

5/16

5/16

5/16

5/16

3/8

3/8

VERTICAL SEPARATION - (ft)

18

Line

Size
(Inch
O.D.)

Model

Liquid Line

Connection

Size (Inch

I.D.)

24

30

36

42

48

60

TOTAL LENGTH - (ft)

25 50 75 100 125 150

25 23 8

36 30 24 18

25 23

48 38 28 18 8

25 23

50 39 25 11

57

25 23 9

38 32 26 20

25 23 9

40 33 26 19

25 28 19 11 3

35 33

25 23 11 3

37 34 31

1/4*
5/16

1/4*

5/16

1/4*

5/16

3/8

5/16*

3/8

5/16*

3/8

3/8*

1/2

3/8*

1/2

5/16

5/16

5/16

5/16

5/16

3/8

3/8

VERTICAL SEPARATION - (ft)

18

Line

Size
(Inch
O.D.)

Model

Liquid Line

Connection

Size (Inch

I.D.)

24

30

36

42

48

60

12

EVACUATION PROCEDURE

Evacuation is the most important part of the entire service procedure. The life and
efficiency of the equipment is dependent upon the thoroughness exercised by the
serviceman when evacuating air and moisture from the line set and indoor coil.

Air in the system causes high condensing temperatures and pressure, resulting in
increased power input and non-verifiable performance.

Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoric
and hydrochloric acids. These attack motor windings and parts, causing break­down.

After the system has been leak checked and proven sealed, connect the vacuum
pump and evacuate system to 500 microns. The vacuum pump must be connected
to both the high and low sides of the system through adequate connections. Use
the largest size connections available since restrictive service connections may lead
to false readings because of pressure drop through the fittings.

IMPORTANT: Compressors (especially scroll type) should never be used to evacu­ate the air conditioning system because internal electrical arcing may result in a
damaged or failed compressor.

START UP AND PERFORMANCE

Even though the unit is factory charged with Refrigerant-22, the charge must be
checked to the charge table attached to the service panel and adjusted, if required.
Allow a minimum of 5 minutes running. Before analyzing charge, see the instruc­tions on the unit service panel rating plate for marking the total charge.

• The service valves are not backseating valves. To open the valves, remove the
valve cap with an adjustable wrench. Insert a 3/16” or 5/16” hex wrench into the
stem. Back out counterclockwise until it stops.

• Replace the valve cap finger tight then tighten an additional 1/8 of a turn for a
metal-to-metal seal.

CHECKING AIRFLOW

The air distribution system has the greatest effect. The duct system is totally con­trolled by the contractor. For this reason, the contractor should use only industry­recognized procedures.

The correct air quantity is critical to air conditioning systems. Proper operation, effi­ciency, compressor life, and humidity control depend on the correct balance
between indoor load and outdoor unit capacity. Excessive indoor airflow increases
the possibility of high humidity problems. Low indoor airflow reduces total capacity,
and causes coil icing. Serious harm can be done to the compressor by low airflow,
such as that caused by refrigerant flooding.

Air conditioning systems require a specified airflow. Each ton of cooling requires
between 350 and 450 cubic feet of air per minute (CFM), or 400 CFM nominally.

Duct design and construction should be carefully done. System performance can be
lowered dramatically through bad planning or workmanship.

Air supply diffusers must be selected and located carefully. They must be sized and
positioned to deliver treated air along the perimeter of the space. If they are too
small for their intended airflow, they become noisy. If they are not located properly,
they cause drafts. Return air grilles must be properly sized to carry air back to the
blower. If they are too small, they also cause noise.

The installers should balance the air distribution system to ensure proper quiet air­flow to all rooms in the home. This ensures a comfortable living space.

These simple mathematical formulas can be used to determine the CFM in a resi­dential or light commercial system.

13

Electric resistance heaters can use

CFM =

volts x amps x 3.414

1.08 x temp rise

Gas furnaces can use

CFM =

BTUH

ΔT x 1.08

An air velocity meter or airflow hood can give a more accurate reading of the sys­tem CFM.

CHECKING REFRIGERANT CHARGE

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

CHARGING BY LIQUID PRESSURE

The liquid pressure method is used for charging systems in the cooling 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 mover is delivering the cor­rect airflow for this system size. Read and record the liquid pressures at the ports
on the liquid and suction valves.

If refrigerant lines are 15 feet long, 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.

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

If the refrigerant lines utilized extend 15 feet, add 4 psi to the liquid pressure values
shown in the chart.

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

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

CHARGING BY WEIGHT

For a new installation, evacuation of interconnecting tubing and evaporator coil is
adequate; otherwise, evacuate the entire system. Use the factory charge shown in
Table 1 of these instructions or unit data plate. 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 using:

1/4” O.D. = .3 oz./ft.
5/16” O.D. = .4 oz./ft.
3/8” O.D. = .6 oz./ft.
1/2” O.D. = 1.2 oz./ft.

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.

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 venting refrigerant into the atmosphere.

ELECTRICAL WIRING

Field wiring must comply with the National Electric Code (C.E.C. in Canada) and
any applicable local code.

GROUNDING

A grounding lug is provided near the contactor for a ground wire.

POWER WIRING

It is important that proper electrical power from a commercial utility is available at
the condensing unit contactor. Voltage ranges for operation are shown in Table 7.

Power wiring must be run in a rain-tight conduit. Conduit must be run through the
connector panel below the access cover (See Figure 1) and attached to the bottom
of the control box.

Connect power wiring to contactor located in outdoor condensing unit electrical box.
(See wiring diagram attached to unit access panel.)

Check all electrical connections, including factory wiring within the unit and make
sure all connections are tight.

DO NOT connect aluminum field wire to the contactor terminals.

CONTROL WIRING

(See Figure 3)

If the low voltage control wiring is run in conduit with the power supply, Class I insu­lation is required. Class II insulation is required if run separate. Low voltage wiring
may be run through the insulated bushing provided in the 7/8 hole in the base
panel, up to and attached to the pigtails from the bottom of the control box. Conduit
can be run to the base panel if desired by removing the insulated bushing.

A thermostat and a 24 volt, 40 VA minimum transformer are required for the control
circuit of the condensing unit. The furnace or the air handler transformer may be
used if sufficient. See the wiring diagram for reference. Use 18-gauge thermostat
wire only.

14

!

WARNING

TURN OFF ELECTRIC POWER AT
THE FUSE BOX OR SERVICE
PANEL BEFORE MAKING ANY
ELECTRICAL CONNECTIONS.

ALSO, THE GROUND CONNEC­TION MUST BE COMPLETED
BEFORE MAKING LINE VOLTAGE
CONNECTIONS. FAILURE TO DO
SO CAN RESULT IN ELECTRICAL
SHOCK, SEVERE PERSONAL
INJURY OR DEATH.

!

WARNING

THE UNIT MUST BE PERMANENTLY GROUNDED. FAILURE TO DO SO
CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL
INJURY OR DEATH.

TABLE 6

VOLTAGE RANGES (60 HZ)

Operating Voltage Range at Copeland

Nameplate Voltage Maximum Load Design Conditions for

Compressors

208/230 (1 Phase) 197 - 253

15

FIELD INSTALLED ACCESSORIES

COMPRESSOR CRANKCASE HEAT (CCH)

While scroll compressors usually do not require crankcase heaters, there are
instances when a heater should be added. Refrigerant migration during the off cycle
can result in a noisy start up. Add a crankcase heater to minimize refrigerate migra­tion, and to help eliminate any start up noise or bearing “wash out.”

NOTE: The installation of a crankcase heater is recommended if the system charge
exceeds the values listed in Table 7.

All 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.)

TIME DELAY CONTROL (TDC)

The time delay (TDC) is in the low voltage control circuit. When the compressor
shuts off due to a power failure or thermostat operation, this control keeps it off at
least 5 minutes which allows the system pressure to equalize, thus not damaging
the compressor or blowing fuses on start-up.

TABLE 7

MAXIMUM SYSTEM CHARGE VALUES

FIGURE 3

CONTROL WIRING FOR GAS OR ELECTRIC HEAT

FOR TYPICAL ELECTRIC HEAT

FOR TYPICAL GAS OR OIL HEAT

Charge Limit

Model Compressor

Without

Size Model Number

Crankcase Heat

18 H21J14BABCA 7 lbs.
24 H21J19BABCA 7 lbs.
30 H21J24BABCA 7 lbs.
36 H21J30BABCA 9 lbs.
42 H23C383ABCA 8 lbs.
48 H23C423ABCA 8 lbs.
60 H23R543ABCA 12 lbs.

16

LOW AMBIENT CONTROL (LAC)

This component senses compressor head pressure and shuts the condenser fan off
when the head pressure drops to approximately 175 PSIG. This allows the unit to
build a sufficient head pressure at lower ambient in order to maintain system bal­ance and obtain improved capacity. Low ambient control should be used on all
equipment operated below 70°F ambient.

HIGH AND LOW PRESSURE CONTROLS (HPC OR LPC)

These controls keep the compressor from operating in pressure ranges which can
cause damage to the compressor. Both controls are in the low voltage control cir­cuit.

High pressure control (HPC) is a manual reset which opens near 450 PSIG.

The low pressure control (LPC) is an automatic reset which opens near 15 PSIG
and closes near 40 PSIG.

SERVICE

OPERATION

Single phase units are operated PSC (no starting components). It is important that
such systems be off for a minimum of 5 minutes before restarting to allow equaliza­tion of pressure. The thermostat should not be moved to cycle unit without waiting 5
minutes. To do so may cause the compressor to go off on an automatic overload
device or blow a fuse. Poor electrical service can also cause nuisance tripping on
overloads, trip a breaker, or cause light dimming. This generally can be corrected
by adding start components. Check with factory for recommended start compo­nents, if required. For PSC type operation, refrigerant metering must be done with
fixed orifice, cap tubes or bleed type expansion valves because of low starting
torque. If non-bleed expansion valve coils (supplied by factory) are used, start com­ponents are required.

SINGLE-POLE COMPRESSOR CONTACTOR (CC)

Single-pole contactors are used on all standard single phase units up through 5
tons. Caution must be exercised when servicing as only one leg of the power sup­ply is broken with the contactor.

17

TROUBLE SHOOTING

In diagnosing common faults in the air conditioning system, it is useful to present
the logical pattern of thought that is used by experienced technicians. The charts
which follow are not intended to be an answer to all problems, but only to guide
your thinking as you attempt to decide on your course of action. Through a series of
yes and no answers, you will follow the logical path to a likely conclusion.

Use these charts as you would a road map, if you are a beginning technician. As
you gain experience, you will learn where to establish the shortcuts. Remember
that the chart will help clarify the logical path to the problem.

ELECTRICAL CHECKS FLOW CHART

Unit Running?

NO

NO

NO

NO

NO

YES

YES

YES

YES

Thermostat Problem?

Transformer Problem?

Run Capacitor

Compressor Contactor

Hi Pressure Control

Compressor Winding Open

Grounded Capacitor

Lo Pressure Control

Compressor Time-Delay

Start Capacitor

Potential Relay

Go to

Mechanical Checks

YES

Repair and Recheck

YES

Repair and Recheck

Voltage on Compressor

Side of Contactor?

Voltage on Line

Side of Contactor?

Circuit Breakers

or Fuses Open

Compressor Winding

Grounded

Unit Wiring and

Connections

Replace Fuses

or Reset Breakers and Recheck

Unit Wiring and

Connections

Condenser Fan

Grounded

Compressor Internal

Overload Open

18

MECHANICAL CHECKS FLOW CHART

Unit Running?

YES

Low Head Pressure

Low Suction Pressure

Open IPR Valve Dirty Evaporator

Inadequate Airflow

Restricted Filter-drier

NO

Overcharge Low Ambient Temperature

Inoperative Indoor Blower

Indoor Metering

Device Stuck

Closed

Wrong Condenser Fan Rotation

Pressure problems?

Low on Charge Dirty FiltersDirty Condenser Coil

Recirculation of

Condenser Air

Inoperative Compressor

Valves

Low on Charge

Faulty Metering Device

Restriction in System

Restricted Filter-drier

Non-condensibles

Higher than Ambient

Air Entering Condenser

Go to Electrical

Checks Flow Chart

High Head Pressure

Inoperative Outdoor Fan

Broken Indoor

Blower Belt

Restriction in System

Recirculation of

Evaporator Air

Wrong Evaporator

Blower Rotation

Indoor Metering Device

Stuck Open

Inadequate Ducts

19

TABLE 9

AIR CONDITIONING SYSTEM TROUBLESHOOTING TIPS

AIR CONDITIONING SYSTEM

TROUBLESHOOTING TIPS

SUPERHEAT CALCULATION

1. Measure the suction pressure at the suction line service valve.

2. Convert the suction pressure to saturated temperature. See Table 8.

3. Measure the temperature of the suction line at the suction line service valve.

4. Compare the temperature of the suction line to the saturated temperature.

5. The difference between saturated temperature and suctin line temperature is the
superheat. Superheat normal range 12° to 15°.

SUBCOOLING CALCULATION

1. Measure the liquid pressure at the liquid line service valve.

2. Convert the liquid line pressure to saturated temperature. See Table 8.

3. Measure the liquid line temperature at the liquid line service valve.

4. Compare the liquid line temperature to the saturated temperature.

5. The difference between saturated temperature and liquid line temperature is the
subcooling. Subcooling normal range 9° to 12°.

TABLE 8

TEMPERATURE PRESSURE CHART

TEMP R-22

(Deg. F) PSIG

-150 *29.4

-140 *29.1

-130 *28.5

-120 *27.7

-110 *26.6

-100 *25.1

-90 *23.0

-80 *20.2

-70 16.6

-60 *11.9

-50 *6.1

-40 0.6

-35 2.6

-30 4.9

-25 7.5

-20 10.2

-15 13.2

-10 16.5

-5 20.1
0 24.0
5 28.3

10 32.8
15 37.8
20 43.1
25 48.8
30 54.9
35 61.5
40 68.5
45 76.1
50 84.1
55 92.6
60 101.6
65 111.3
70 121.4
75 132.2
80 143.7
85 155.7
90 168.4

95 181.8
100 196.0
105 210.8
110 226.4
115 242.8
120 260.0
125 278.1
130 297.0
135 316.7
140 337.4
145 359.1
150 381.7

DISCHARGE SUCTION

SUPERHEAT SUBCOOLING

COMPRESSOR

PRESSURE PRESSURE AMPS

Overcharge High High Low High High

Undercharge Low Low High Low Low

Liquid Restriction (Drier) Low Low High High Low

Low Evaporator Airflow Low Low Low Low Low

Dirty Condenser High High Low Low High

Low Outside Ambient Temperature Low Low High High Low

Inefficient Compressor Low High High High Low

TXV Feeler Bulb Charge Lost Low Low High High Low

Poorly Insulated Sensing Bulb High High Low Low High

SYSTEM PROBLEM

INDICATORS

20

SYMPTOM POSSIBLE CAUSE REMEDY

Unit will not run • Power off or loose electrical connection • Check for correct voltage at contactor in condensing unit

• Thermostat out of calibration-set too high • Reset

• Defective contactor • Check for 24 volts at contactor coil - replace if contacts are
open

• Blown fuses / tripped breaker • Replace fuses / reset breaker

• Transformer defective • Check wiring-replace transformer

• High pressure control open (if provided) • Reset-also see high head pressure remedy-The high pressure
control opens at 450 PSIG

Outdoor fan runs, compressor • Run or start capacitor defective • Replace

doesn’t • Start relay defective • Replace

• Loose connection • Check for correct voltage at compressor ­check & tighten all connections

• Compressor stuck, grounded or open motor winding, • Wait at least 2 hours for overload to reset.

open internal overload. If still open, replace the compressor.

• Low voltage condition • Add start kit components

Insufficient cooling • Improperly sized unit • Recalculate load

• Improper indoor airflow • Check - should be approximately 400 CFM per ton.

• Incorrect refrigerant charge • Charge per procedure attached to unit service panel

• Air, non-condensibles or moisture in system • Recover refrigerant, evacuate & recharge, add filter drier

Compressor short cycles • Incorrect voltage • At compressor terminals, voltage must be ± 10% of

nameplate marking when unit is operating.

• Defective overload protector • Replace - check for correct voltage

• Refrigerant undercharge • Add refrigerant

Registers sweat • Low indoor airflow • Increase speed of blower or reduce restriction - replace air

filter

High head-low vapor pressures • Restriction in liquid line, expansion device or filter drier • Remove or replace defective component

• Flowcheck piston size too small • Change to correct size piston

• Incorrect capillary tubes • Change coil assembly

High head-high or normal vapor • Dirty outdoor coil • Clean coil

pressure - Cooling mode • Refrigerant overcharge • Correct system charge

• Outdoor fan not running • Repair or replace

• Air or non-condensibles in system • Recover refrigerant, evacuate & recharge

Low head-high vapor pressures • Flowcheck piston size too large • Change to correct size piston

• Defective Compressor valves • Replace compressor

• Incorrect capillary tubes • Replace coil assembly

Low vapor - cool compressor - • Low indoor airflow • Increase speed of blower or reduce restriction - replace air

iced indoor coil filter

• Operating below 65°F outdoors • Add Low Ambient Kit

• Moisture in system • Recover refrigerant - evacuate & recharge - add filter drier

High vapor pressure • Excessive load • Recheck load calculation

• Defective compressor • Replace

Fluctuating head & vapor • TXV hunting • Check TXV bulb clamp - check air distribution on coil - replace

pressures TXV

• Air or non-condensibles in system • Recover refrigerant, evacuate & recharge

Gurgle or pulsing noise at • Air or non-condensibles in system • Recover refrigerant, evacuate & recharge

expansion device or liquid line

DISCONNECT ALL POWER TO UNIT BEFORE SERVICING. CONTACTOR MAY BREAK ONLY ONE SIDE. FAILURE
TO SHUT OFF POWER CAN CAUSE ELECTRICAL SHOCK RESULTING IN PERSONAL INJURY OR DEATH.

TROUBLE SHOOTING CHART

WARNING

!

21

FIGURE 4

SINGLE-PHASE WIRING DIAGRAM

01

90-101229-01

01-19-04

JHB

Design, specifications, performance data and materials subject to change without notice.

1900 Wellworth Ave., Jackson, Michigan 49203 • Ph. 517-787-2100 • Fax [phone]

THE QUALITY LEADER IN CONDITIONING AIR

09/06

www.heatcontroller.com