Please read and save these instructions for future reference. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety information. Failure
to comply with instructions could result in personal injury and/or property damage!
Models MP/MPE (Packaged DX)Model MPF (Split DX)
General Safety Information
Only qualied personnel should install and maintain this
system. Personnel should have a clear understanding of
these instructions and should be aware of general safety
precautions. Improper installation can result in electric
shock, possible injury due to coming in contact with
moving parts, as well as other potential hazards. Other
considerations may be required if high winds or seismic
activity are present. If more information is needed,
contact a licensed professional engineer before moving
forward.
1. Follow all local electrical and safety codes, as well as
the National Electrical Code (NEC), the National Fire
Protection Agency (NFPA), where applicable. Follow
the Canadian Electrical Code (CEC) in Canada.
2. All moving parts must be free to rotate without striking
or rubbing any stationary objects.
3. Unit must be securely and adequately grounded.
4. Do not spin wheel faster than maximum cataloged
fan RPM. Adjustments to fan speed signicantly
affect motor load. If the fan RPM is changed, the
motor current should be checked to make sure it is
not exceeding the motor nameplate amps.
5. Verify that the power source is compatible with the
equipment.
6. Never open access doors to the unit while it is
running.
WARNING
The roof lining contains high voltage wiring. To prevent
electrocution, do not puncture the interior or exterior
panels of the roof.
DANGER
• Always disconnect power before working on or near
this equipment. Lock and tag the disconnect switch or
breaker to prevent accidental power up.
• If this unit is equipped with optional gas accessories,
turn off gas supply whenever power is disconnected.
CAUTION
This unit is equipped with a compressed refrigerant
system. If a leak in the system should occur,
immediately evacuate the area. An EPA Certified
Technician must be engaged to make repairs or
corrections. Refrigerant leaks may also cause bodily
harm.
CAUTION
When servicing the unit, the internal components may
be hot enough to cause pain or injury. Allow time for
cooling before servicing.
Optional Digital Scroll Compressor Controller ...29
Unit ......................................30
Refrigeration Circuit
Packaged ............................31-34
Split .................................35-37
Routine Maintenance
Monthly ...................................38
Semiannually ..............................38
Annually ..................................38
Units with Packaged DX, Semiannually ..........38
Maintenance Procedures
Lubrication ................................39
Dampers ..................................39
Gas Furnace ..............................39
Fan Motors ................................39
Fan Wheel and Fasteners ....................39
Internal Filter Maintenance ...................39
External Filter Maintenance ...................39
Coil Maintenance ...........................39
Maintenance Log ..................... Backcover
Receiving
PremiSys
This product may have been subject to road salt during
transit. If so, immediately wash off all visible white
reside from all exterior surfaces. Upon receiving the
product, check to ensure all line items are accounted
for by referencing the delivery receipt or packing list.
Inspect each crate or carton for shipping damage before
accepting delivery. Alert the carrier if any damage is
detected, do not refuse shipment. The customer shall
make notation of damage (or shortage of items) on the
delivery receipt and all copies of the bill of lading should
be countersigned by the delivering carrier. If damaged,
immediately contact your manufacturer’s representative.
Any physical damage to the unit after acceptance is not
the responsibility of the manufacturer.
The unit should be stored at least 3½ in. (89 mm) off
the oor. Clearance should be provided to permit air
circulation and space for inspection.
Outdoor
The unit should be placed on a level surface to prevent
water from leaking into the unit. The unit should be
elevated so that it is above water and snow levels.
Ensure sufcient support to prevent unit from settling into
soft ground. Locate parts far enough apart to permit air
circulation, sunlight, and space for periodic inspection.
To minimize water accumulation, place all unit parts on
blocking supports so that rain water will run off.
Do not cover parts with plastic lm or tarps as these
cause condensation of moisture from the air passing
through heating and cooling cycles.
Handling
Units are to be rigged and moved by the lifting brackets
provided or by the skid when a forklift is used. Location
of brackets varies by model and size. Handle in such
a manner as to keep from scratching or chipping the
coating. Damaged nish may reduce ability of unit to
resist corrosion.
Unpacking
Verify that all required parts and the correct quantity
of each item have been received. If any items are
missing, report shortages to your local representative to
arrange for obtaining missing parts. Sometimes it is not
possible that all items for the unit be shipped together
due to availability of transportation and truck space.
Conrmation of shipment(s) must be limited to only items
on the bill of lading.
Storage
Units are protected against damage during shipment. If
the unit cannot be installed and operated immediately,
precautions need to be taken to prevent deterioration of
the unit during storage. The user assumes responsibility
of the unit and accessories while in storage. The
manufacturer will not be responsible for damage during
storage. These suggestions are provided solely as a
convenience to the user.
The ideal environment for the storage of units and
accessories is indoors, above grade, in a low humidity
atmosphere which is sealed to prevent the entry of
blowing dust, rain, or snow. Units designed for outdoor
applications may be stored outdoors. All accessories
must be stored indoors in a clean, dry atmosphere.
Indoor
Maintain temperatures evenly to prevent condensation.
Remove any accumulations of dirt, water, ice, or snow
and wipe dry before moving to indoor storage. To
avoid condensation, allow cold parts to reach room
temperature. Leave coverings loose to permit air
circulation and to allow for periodic inspection.
Inspection and Maintenance
While in storage, inspect units once per month. Keep a
record of inspection and maintenance performed.
If moisture or dirt accumulations are found on parts,
the source should be located and eliminated. At each
inspection, rotate the fan wheel by hand ten to fteen
revolutions to distribute lubricant on motor. If paint
deterioration begins, consideration should be given to
touch-up or repainting. Units with special coatings may
require special techniques for touch-up or repair.
Machined parts coated with rust preventive should be
restored to good condition promptly if signs of rust occur.
Immediately remove the original rust preventive coating
with petroleum solvent and clean with lint-free cloths.
Polish any remaining rust from surface with crocus
cloth or ne emery paper and oil. Do not destroy the
continuity of the surfaces. Wipe thoroughly clean with
Tectyl® 506 (Ashland Inc.) or the equivalent. For hard to
reach internal surfaces or for occasional use, consider
using Tectyl® 511M Rust Preventive, WD-40® or the
equivalent.
Removing from Storage
As units are removed from storage to be installed in their
nal location, they should be protected and maintained in
a similar fashion until the equipment goes into operation.
Prior to installing the unit and system components,
inspect the unit assembly to make sure it is in working
order.
1. Check all fasteners, set screws on the fan, wheel,
bearings, drive, motor base, and accessories for
tightness.
2. Rotate the fan wheel(s) by hand and assure no parts
are rubbing.
A horizontally congured Dedicated Outdoor Air unit
designed for installation outdoors. The unit is designed
to replace air that is exhausted from the building and
also heat and cool, as needed. The air volume produced
by the unit is constant, but can be optionally modulated
to provide a variable air volume (VAV).
Cooling
Units have the following cooling options available:
• Packaged DX
• Split DX
Units with packaged DX are shipped fully charged with
refrigerant and are ready for operation upon arrival.
Heating
There are three different optional heat sources that can
be ordered for this unit:
• Indirect gas-red furnace with one or two sets of
heat exchangers
• Electric heat with innitely variable SCR control
• Hot water coil (Installed in furnace section)
Airow Arrangement
The unit is capable of Constant Air Volume (CAV),
Variable Air Volume (VAV), 100% Outdoor Air.
Supplemental Installation, Operation and
Maintenance Manuals
Refer to the following Manufacturer Installation,
Operation and Maintenance Manuals for additional
information:
• Indirect Gas-Fired Heat Modules
• Microprocessor Controller
• M-Net Connection
For information on Service and installation Operation
manual please refer to the manuals in the Outdoor
equipment.
Either one or two plenum-type fans. All units are
equipped with a plenum fan for Supply Air and a second
may be selected for Exhaust (Relief) Air.
Coils (Packaged)
Evaporator coil
Condenser coil
Hot Water coil (Optional)
Reheat coil (Optional)
Coils (Split)
Evaporator coil
Hot Water coil (Optional)
Reheat coil
Compressors
Each unit having packaged DX will have either one
or two refrigerant compressors. Optionally, one the
compressors may be a digital scroll type compressor.
Optional inverter scroll compressors on Split DX system
only.
Dampers
Motorized intake air damper.
Electric Heater
An SCR controlled electric heater (not shown) is
available on the units. It requires a separate power
supply and has its own control panel. See unit-specic
wiring diagram.
Filters
Two-inch thick metal mesh lters in the optional Outdoor
Weatherhood air intake, 2-inch thick pleated paper
MERV 8 (standard) or MERV 13 (optional) lters in the
airstream. Optional 4-inch thick lter bank with 2-inch
thick MERV 8 and 2-inch thick MERV 13 pleated paper
Final Filters.
Indirect Gas-Fired Furnace
The optional model PVG furnace is available on housing
sizes 1 and 2. Housing size 4 uses the optional model
PVF furnace.
Packaged DX System
Unit may be ordered with a packaged DX system.
It will include either one or two compressors, a
condenser coil(s) and evaporator coil(s) and all needed
components. Units that have packaged DX are charged
with R-410A refrigerant. Do not use tools or parts
designed for other refrigerants on these units.
Split DX System
Unit may be ordered with a split DX system for
connection to a Mitsubishi Outdoor Unit. All MPF models
are standard with split DX cooling and the energy wheel.
Final Filters
(on coil face)
Main Control
Center
Intake Air
Damper
Plenum-Type
Supply Air Blower
Indirect Gas-Fired Furnace
(optional)
Energy Wheel (MPF)
Weatherhood Filters
(metal mesh)
Plenum-Type
Exhaust Air Blower
Coils
Open view of Model MPF showing split DX cooling, fans and energy recovery wheel.
All dimensions are shown in inches. Weight shown in pounds. *Size and quantity is per airstream. **Dimension based upon
MERV 8 or 13 lters (MERV 14 lters are 4 in. thick).†Based upon a 30 / 36 in. energy wheel (16x25x2, quantity of 3 for 41 in.
energy wheel). ‡Based upon a 52 in. energy wheel (16x16x2, quantity of 8 for 58 in. energy wheel). #Based upon a 52 / 58 in.
energy wheel (16x20x2, quantity of 8 for 74 in. energy wheel). ^Above 12,000 cfm. WH = weatherhood (aluminum mesh). Model
MPE includes energy wheel (not shown).
All dimensions are shown in inches. Weight shown in pounds. *Size and quantity is per airstream. †Based upon a 30 / 36 in.
energy wheel (16x25x2, quantity of 3 for 41 in. energy wheel). ‡ Based upon a 52 in. energy wheel (16x16x2, quantity of 8 for 58
in. energy wheel). WH = weatherhood (aluminum mesh).
Packaged DX units require additional clearance
because they must have unrestricted air movement
around the condenser coil and condenser fans. Hot air
is being discharged from the condenser fans during
operation. Enough clearance must be provided to
avoid recirculation or coil starvation. When equipped
with condenser coils, the unit should never be placed
under an overhang or inside a building. A minimum of
48 inches above the condenser fans is acceptable, but
unobstructed is strongly recommended.
Minimum 48 inches clearance
Condenser Fans
Minimum 18 inches
clearance
Lifting
1. Before lifting, be sure that all shipping materials have
been removed from unit.
2. To assist in determining rigging requirements, weights
are provided in the Unit Weights & Dimensions
section of this manual.
3. Unit must be lifted by all lifting lugs provided at top of
unit.
4. Spreader bars must span the unit to prevent damage
to the cabinet by the lift cables.
5. Always test-lift the unit to check for proper balance
and rigging before hoisting to desired location.
Use spreader bars to prevent damage to cabinet.
Condenser Coil
End view of roof top unit with Packaged DX
Handling Concerns for Units with Packaged
DX
Units having packaged DX have a system that is
pressurized with refrigerant and if it is damaged, the
refrigerant could leak into the atmosphere or cause
bodily harm due to the extreme cold nature of expanding
refrigerant. Use protective equipment such as gloves
and safety glasses to minimize or prevent injury in case
of a system leak during installation.
Before Lifting - Field Power Access
Determine where high voltage and low voltage wiring is
to be brought into the cabinet. If wiring is to be brought
into the cabinet through the oor, see Alternate Supply
Entry Locations in this manual. If unit is to be installed on
a roof, cut access openings in the roof deck as needed.
6. Never lift unit by weatherhood.
7. Never lift units in windy conditions.
8. Preparation of curb and roof openings should be
completed prior to lifting unit to the roof.
9. Check to be sure that gasketing (supplied by others)
has been applied to the top of the curb prior to lifting
the unit and setting on the curb.
Roof curb details, including duct locations and
dimensions, are to be found in the roof curb assembly
instructions.
Rooftop units require curbs to be mounted rst. The
duct connections must be located so they will be clear of
structural members of the building.
1. Factory Supplied Roof Curbs
Roof curbs are Model GKD which are shipped in a
knockdown kit (includes duct adapters) and require eld
assembly (by others). Assembly instructions are included
with the curb kit.
2. Install Curb
Locate curb over roof opening and fasten in place.
Check that the diagonal dimensions are within ± 1/8
inch of each other and adjust as necessary. For proper
coil drainage and unit operation, it is important that the
installation be level. Shim the curb as required to level.
Install gasketing on top surface of curb (provided by
others).
3. Install Ductwork
Installation of all ducts should be done in accordance
with SMACNA and AMCA guidelines. Duct adapters are
provided to support ducts prior to setting the unit.
4. Set the Unit
Lift unit to a point directly above the curb and duct
openings. Guide unit while lowering to align with duct
openings. Roof curbs t inside the unit base. Make sure
the unit is properly seated on the curb and level.
Ductwork Congurations
NOTE
Downblast Discharge Ductwork - whenever
downblast discharge is used, the ductwork directly
beneath the unit must be connected with either a “T”
or an “L” configuration and the area directly beneath
the heat source must not have any openings such as
louvers or grates.
No louvers or grates
Rail Mounting and Layout
• The units may be installed on rails provided and
installed by others. Ensure that rails are designed to
handle the weight of the unit and provide proper load
distribution on building supports.
• Make sure that rail positioning does not interfere with
the openings on the unit.
• Rails should run the width of the unit and extend
beyond the unit a minimum of 12 inches on each
side.
• Set unit on rails.
W
Typical Unit with Condensing Section and
Factory-Supplied Curb Kit
L
Typical Unit Installed on Rails Supplied by Others
The roof lining contains high voltage wiring. To prevent
electrocution, do not puncture the interior or exterior
panels of the roof.
WARNING
To prevent injury or death due to electrocution or
contact with moving parts, lock disconnect switch open.
For units with a gas furnace, if you turn off the power
supply, turn off the gas.
IMPORTANT
Before connecting power to the unit, read and
understand the following instructions and wiring
diagrams. Complete wiring diagrams are attached on
the inside of the control center door(s).
IMPORTANT
All wiring should be done in accordance with the latest
edition of the National Electric Code ANSI/NFPA 70
and any local codes that may apply. In Canada, wiring
should be done in accordance with the Canadian
Electrical Code.
IMPORTANT
The equipment must be properly grounded and
bonded. Any wiring running through the unit in the
airstream must be protected by metal conduit, metal
clad cable or raceways.
CAUTION
If replacement wire is required, it must have a
temperature rating of at least 105ºC, except for an
energy cut-off or sensor lead wire which must be rated
to 150ºC.
DANGER
High voltage electrical input is needed for this
equipment. This work should be performed by a
qualified electrician.
CAUTION
Any wiring deviations may result in personal injury
or property damage. Manufacturer is not responsible
for any damage to, or failure of the unit caused by
incorrect final wiring.
WARNING
Consult your dealer when the following issues on Y
system are the key concern.
• Warm air may flow out from the indoor unit during
heating Thermo-OFF.
• Refrigerant flow sound may occur in the rooms
with low background noise such as hotel rooms,
hospital rooms, bedrooms, or conference rooms.
To avoid the above issues on Y system, changing
board settings on the indoor and outdoor units is
required.
The unit’s nameplate, located on the outside of the
control panel side, states the voltage and the unit’s
MCA. The main power lines to the unit should be sized
accordingly. Model MPF is provided with a separate
condensing unit with its own disconnect that requires a
separate power feed from the unit.
Determine the Size of Electric Heater Wiring
An optional electric heater may require a separate power
supply. The power connection should be made to the
factory-provided electric heater disconnect and must be
compatible with the ratings on the nameplate, supply
power voltage, phase and amperage. Consult ANSI/
NFPA 70 and CSA C22.1 for proper conductor sizing.
Provide the Opening(s) for the Electrical
Connections
Electrical openings vary by unit size and arrangement
and are eld-supplied.
Connect the Power Supplies
Connect the main power lines and electric heater power
lines to the disconnect switches or terminal blocks and main
grounding lug(s). Torque eld connections to manufacturer’s
recommendations.
Wire the Optional Convenience Outlet
The convenience outlet requires a separate 115V power
supply circuit. The circuit must include short circuit
protection which may need to be supplied by others.
Connect Field-Wired Low Voltage
Components
Most factory-supplied electrical components are
prewired. To determine what electrical accessories
require additional eld-wiring, refer to the unit-specic
wiring diagram located on the inside of the control center
access door.
Control wires should not be run inside the same conduit
as that carrying the supply power. Make sure that eld-
supplied conduit does not interfere with access panel
operation. All low voltage wiring should be run in conduit
wherever it may be exposed to the weather.
The low voltage control circuit is 24 VAC and control
wiring should not exceed 0.75 ohms. If wire resistance
exceeds 0.75 ohms, an industrial-style, plug-in relay
should be added to the unit control center and wired in
place of the remote switch (typically between terminal
blocks R and G on the terminal strip. The relay must
be rated for at least 5 amps and have a 24 VAC coil.
Failure to comply with these guidelines may cause
motor starters to “chatter” or not pull in which can cause
contactor failures and/or motor failures.
Field-Provided Disconnect
If eld-installing an additional disconnect switch, it
is recommended that there is at least four feet of
service room between the switch and system access
panels. When providing or replacing fuses in a fusible
disconnect, use dual element time delay fuses and size
according to the rating plate.
Recommended Electrical and Gas Supply
PremiSys
Entry Locations
Manufacturer recommends that electrical service and
gas supply be brought into the cabinet through the end
wall, as shown below. There are three penetrations into
the cabinet that are required; one for high voltage supply
wiring, one for low voltage control wiring and one for
either gas supply or high voltage supply wiring for an
electric heater.
Disconnect Switch for electric heater.
Present only if electric heat is selected.
Terminate heater supply wiring here.
Optional Main Disconnect Switch
(Terminate high voltage supply wiring
here or at power distribution block).
RECOMMENDED LOCATION
for low voltage control wiring.
Indirect-Gas Piping Installation
Optional Gas Piping
Units with indirect gas-red furnaces require eld-
supplied and installed gas supply piping. The unit gas
connection is 3⁄4 inch NPT. The maximum allowable gas
pressure is 14 in. wg.
From Gas Supply
Gas Cock
Bleeder Valve or
1/8 in Plugged Tap
Ground
Joint
Union
8 in. Trap
Gas to
Controls
RECOMMENDED LOCATION:
Factory-provided opening for gas
supply. If electric heat is ordered,
use this location for high voltage
supply wiring for heater.
RECOMMENDED LOCATION
for field-supplied high voltage
supply wiring.
Recommended Gas and Electric Supply Entry Locations
Alternate Supply Entry Locations
Each installation is unique and as a result, alternate
entry locations may be eld-located. Before using any
alternate entry location, verify the suitability of the
location and ensure the use of an alternate location does
not interfere with unit wiring, components or functionality.
WARNING
Never drill holes in the roof of the unit! There is high
voltage wiring located between the inner and outer
roof panels. Damage to the wiring could cause severe
bodily harm or death.
Typical Gas Supply Piping Connection
Gas Connections
If this unit is equipped with an indirect gas-red furnace,
connection to an appropriate gas supply line will be
required. For complete information on installation
procedures for the optional gas furnace, refer the
PVF/PVG Indirect Gas-Fired Heat Module Installation,
Operation, and Maintenance Manual.
Factory-installed cooling components are mounted in the
coil section of the unit. The coil section is downstream of
the energy wheel on the supply air side of the unit.
Optional hot water coil is located downstream of the
supply fan on all models. Water piping can be routed
through the base of this unit if desired.
Piping vestibule is available for all models.
Water Coils
1. Piping should be in accordance with accepted
industry standards. Pipework should be supported
independently of the coils. When installing couplings,
do not apply undue stress to the connection
extending through the unit. Use a backup pipe
wrench to avoid breaking the weld between coil
connection and header.
2. Connect the water supply to the bottom connection
on the air leaving side and the water return to the
top connection on the air entering side. Connecting
the supply and/or return in any other manner will
result in very poor performance. Be sure to replace
factory-installed grommets around coil connections
if removed for piping. Failure to replace grommets
will result in water leakage into the unit and altered
performance.
3. Water coils are not normally recommended for use
with entering air temperatures below 40° F. No
control system can be depended on to be 100% safe
against freeze-up with water coils. Glycol solutions
or brines are the only safe media for operation of
water coils with low entering air conditions. If glycol
or brine solutions are not used, coils must be drained
when freezing conditions are expected. If required,
vent and drain connections must be field-piped,
external to the unit.
4. Pipe sizes for the system must be selected on the
basis of the head (pressure) available from the
circulation pump. The velocity should not exceed
6 feet per second and the friction loss should be
approximately 3 feet of water column per 100 feet
of pipe.
Condensate Drain Trap
This unit is equipped with a stainless steel condensate
pan with a stainless steel connection. It is important that
the drain connection be tted with a “P” trap to ensure
proper drainage of condensate while maintaining internal
static pressures and to prevent migration of sewer gas
back into the unit.
A “P” trap assembly (kit) is
supplied with each unit and
is to be assembled and
installed as local conditions
require and according to the
assembly instructions
provided with the “P” trap.
If local and area codes permit,
the condensate may be drained
back onto the roof, but a drip pad should be provided
beneath the outlet. If local and area codes require
a permanent drain line, it should be fabricated and
installed in accordance with Best Practices and all
codes.
In some climates, it will be necessary to provide freeze
protection for the “P” trap and drain line. The “P” trap
should be kept lled with water or glycol solution at all
times and it should be protected from freezing to protect
the “P” trap from damage. If severe weather conditions
occur, it may be necessary to fabricate a “P” trap and
drain line of metal and install a heat tape to prevent
freezing.
Refrigerant pipe for CITY MULTI® shall be made of
phosphorus deoxidized copper, and has two types.
• Type-O: Soft copper pipe (annealed copper pipe),
can be easily bent with human’s hands.
• Type-1⁄2H pipe: Hard copper pipe (straight pipe),
being stronger than Type-O pipe of the same radical
thickness.
The maximum operation pressure of R410A air
conditioner is 4.30 MPa [624psi]. The refrigerant piping
should ensure the safety under the maximum operation
pressure. Follow the recommended pipe size in the table
below or you shall follow the local industrial standard.
Pipes of radial thickness 0.7mm or less shall not be
used.
Copper Pipe Size and Radial Thickness for
R410A CITY MULTI®
Size
(mm)
O.D.
ø6.35ø1⁄40.8[32]1 or 2
ø9.52ø3⁄80.8[32]1 or 2
ø12.7ø1⁄20.8[32]1 or 2
ø15.88ø5⁄81.0[40]1 or 2
ø19.05ø3⁄41.2[48]1 or 2
ø22.2ø7⁄81.0[40]2
ø25.4ø11.0[40]2
ø28.58ø11⁄81.0[40]2
ø31.75ø11⁄41.1[44]2
ø34.93ø13⁄81.2[48]2
ø41.28ø15⁄81.4[56]2
*Pipe Type:
1=ACR-Annealed
2=ACR-Drawn Temper
**The gures in the radial thickness column are based on the Japanese
standards and provided only as a reference. Use pipes the meet the local
standards.
Size
(in.)
O.D.
**Radial
Thickness
(mm)
**Radial
Thickness
(in.)
*Pipe
Type
Piping Design
Refrigerant Line Sizes
DOAS UnitRefrigerant Line Connections
(in.)
MPF-1-**-**-96-11⁄2 liquid11⁄8 suction
MPF-1-**-**-144-11⁄2 liquid11⁄8 suction
MPF-2-**-**-144-11⁄2 liquid11⁄8 suction
MPF-2-**-**-192-15⁄8 liquid13⁄8 suction
MPF-2-**-**-240-15⁄8 liquid13⁄8”suction
1
Field supplied 11⁄8” - 7⁄8” OD coupling may be needed at DOAS for
installation.
2
Field supplied 13⁄8” - 11⁄8” OD coupling will be needed at DOAS for
installation.
At the time of shipping, the outdoor air unit is charged with refrigerant. As this charge does not include the amount
needed for extended piping, additional charging for the refrigerant lines will be required on site. In order that future
servicing may be properly provided, always keep a record of the size and length of the refrigerant lines and the
amount of additional charge by writing it in the space provided on the condensing unit.
Calculation of the Additional Refrigerant Charge
• Calcuate the amount of additional charge based on the length of the piping and the size of the refrigerant line.
• Use the table below as a guide to calculate the amount of additional charge and add this amount to the system.
• If the calculation results in a fraction of less than 0.1kg [4 oz], round up to the next 0.1kg [4 oz]. For example, if the
result of the calculation was 12.38 kg [436.4 oz], round the result to up to 12.4 kg [437 oz].
<Additional Charge>
TOTAL
additional
refrigerant
charge
(kg)
(oz)
Total length of liquid
pipe sized 15.88
[5⁄8 in.]
=
(m) x 0.20 (kg/m)
(ft.) x 2.16 [oz/ft.]
Total length of liquid
pipe sized 12.70
[1⁄2 in.]
+
(m) x 0.12 (kg/m)
(ft.) x 1.3 [oz/ft.]
Total length of liquid
pipe sized 9.52
[3⁄8 in.]
+
(m) x 0.06 (kg/m)
(ft.) x 0.65 [oz/ft.]
+
Additional Charge for OD Unit
Outdoor UnitAmount
PUHY-P962 kg [71 oz]
PUHY-P1448 kg [283 oz]
PUHY-P1928 kg [283 oz]
PUHY-P24016 kg [566 oz]
+
DOAS
Charge
DOAS Charge Amount
Amount of Factory Charged Refrigerant
Model NumberCharge Amount
MPF-1-**-**-96-15.5 kg194 oz
MPF-1-**-**-144-15.5 kg194 oz
MPF-2-**-**-144-15.6 kg198 oz
MPF-2-**-**-192-118.8 kg663 oz
MPF-2-**-**-240-118.8 kg663 oz
Outdoor Unit
Model
PUHY-P96
PUHY-P144
PUHY-P192
PUHY-P240
Example: MPF-1-**-**-96 DOAS with PUHY-P96 Outdoor Unit
Image represents a typical installation for MP-1-1 or MPE-2-1. Components and locations will vary on
MPE-4-0, MP and MPF models.
High Voltage Side
1. Power distribution block; high voltage
supply is terminated here
2. Fuse holders
3. Phase monitor
4. VFDs
5. Compressor motor contactors
6. Condensing fan motor contactors
7. Wheel motor contactor
8. Transformer
9. Unit Disconnect
Low Voltage Side
10. Microprocessor controller
11. Monitoring points
12. Low voltage terminal strip
13. Relays
14. Dirty lter switch
15. Wheel pressure switch
16. Outdoor airow monitor
17. Exhaust airow monitor
18. Digital scroll controller
4
4
4
10
11
12
13
LOW VOLTAGE SIDE
Accessible via compressor door
16
17
14
18
15
HIGH VOLTAGE SIDE
Accessible via control center door
8
3
2
2
2
5
67
9
1
5 6
Optional Indirect Gas-Fired Furnace
Note: In some models, two furnaces are installed to provide greater output. When two furnaces are installed, they are
in parallel and both will operate at the same time and the same output. Both furnaces will have identical controls.
7
1. Single-stage valve
2. Modulating valve
3. PCOE expansion board
4
3
5
4
3
4. Ignition controller
5. Transformer
6. Combustion blower
7. Burner manifold
1
2
1
2
8. Collector box
6
8
6
For further information on the optional furnace and its control center, see the Indirect Gas-Fired Heat lOM shipped
with the unit.
The unit control circuitry includes
a phase monitor that constantly
checks for phase reversal, phase
imbalance, loss of phase or
a power brownout. It requires
24 VAC to operate and when it
detects a fault, it cuts off the 24
VAC that goes to the low voltage
terminal strip, thereby shutting off
all motors.
Variable Frequency Drive (VFD)
If a VFD was provided and installed at the factory, it has
been pre-set to control the speed of the blower motor
for optimum performance. The motor speed needs to
be veried during test and
balance of the unit.
If the system was congured
for Constant Air Volume
(CAV), the VFD will operate
in an ON / OFF fashion and
the speed of the motor will
not change. If the system
was congured for Variable
Air Volume (VAV), the
microprocessor controller will
constantly monitor operating
conditions and provide a signal to the VFD, changing the
VFD output as needed.
The VFD may alternatively be connected to an external
signal such as provided by a BMS and be operated by a
2 - 10 VDC or a 4-20 mA input.
Supply Fan VFD Sequence
Optional Room CO2 Sensor: The microprocessor
controller will modulate the supply fan based on a
comparison of the CO2 setpoint to the actual CO2
levels reported from the sensor. Mechanical high static
protection cutoffs must be installed by others to protect
the system and equipment from over-pressurization.
Typical Phase Monitor
Typical Variable
Frequency Drive (VFD)
Optional Exhaust Fan Only Power
The exhaust fan will have a dedicated power circuit
where in the case of a power outage, the exhaust fan will
still run. A phase monitor will detect an outage or power
loss and open the contact, disconnecting all power to the
unit and controller. An external signal will need to be sent
to a relay to power the exhaust fan, enabling the fan to
run at a maximum speed. This sequence is NOT to be
used for high temperature exhaust applications.
Airow Monitor
A factory-wired, mounted, and powered airow
monitoring system is provided in the outdoor and/or
exhaust air streams. The airow control system offers
the following functionality:
• Display of outdoor and/or exhaust airow rate in actual
cubic feet per minute (CFM) or actual liters per second
(LPS) on a 16 character LCD display.
• Two congurable analog outputs for transmitting
outdoor and/or exhaust airow rate, outdoor air
temperature, or a proportional-integral-derivative (PID)
control signal based on an outdoor airow set point.
• A congurable digital output that operates based on an
airow set point or range.
Operation
Outdoor and/or exhaust airow monitoring is
accomplished using two thermal dispersion sensors
that accurately measure airow velocity down to zero
feet per minute (fpm). The airow controller takes the
average measurement for two sensor congurations,
and determines the outdoor airow rate based on the
effective intake area. Field calibration of the outdoor
airow monitoring device determines the effective intake
area of the unit.
Refer to GreenTrol® Automation Inc. GF-2200A and
GF-N2211technical data sheet for further detail.
Important
For the airflow monitoring device to perform as
intended, field calibration is required. Calibration of
the airflow monitoring device requires an independent
measurement of airflow and should be performed
when the system undergoes test and balance.
Packaged DX Cooling with Three Way Hot Gas Reheat and Hot Gas Bypass
MP, MPE
LLF
REC
8
SCC
7
Condensing Coil
1091211
SG
6
6
Supply Airflow
FCS
SV
15
5
HCV
1. Compressor
2. High Limit Pressure Switch
The switch opens when refrigerant pressure
increases above the set point in the discharge line.
A manual reset is then required.
3. Hot Gas Reheat Valve (optional)
Units equipped with a reheat coil use a threeway valve with actuator to control the supply
air discharge temperature of the unit during
dehumidication mode. The unit controller provides
a 0-10 VDC signal to control the amount of reheat
to meet the supply temperature set point
4. Hot Gas Reheat Coil (Optional)
5. Hot Gas Reheat Check Valve (Optional)
6. Condenser Fans
7. Condensing Coil
8. Liquid Receiver (Optional)
9. Liquid Line Filter Drier
10. Sight Glass
11. Fan Cycle Switch(es)
The switch(es) open or close based on liquid
refrigerant pressure to control the condensing fans
to maintain liquid pressure.
12. Thermostatic Expansion Valve (TXV)
Each unit is equipped with a TXV on each
refrigerant circuit. The valve controls the ow of
liquid refrigerant entering the evaporator coil by
maintaining a constant, factory-set superheat of
10°F. The valve is adjustable and is located on the
Condenser Airflow
413
TXV
3
HRV
S
15
SV
HPS
2
MV
16
Evaporator Coil
14
LPS
SV
Compressor
1
15
HGB
17
side of the evaporator coil and can be accessed
through the coil access panel.
13. Evaporative Coil
14. Low Limit Pressure Switch
The switch is installed on the suction line and
disables the DX system when the suction pressure
drops below the set point. The switch will auto reset
when the pressure rises above the auto-reset set
point.
15. Service Access Ports
16. Hot Gas Bypass Manual Shut Off Valve (Optional)
Used to disable hot gas bypass for service and
troubleshooting procedures.
17. Hot Gas Bypass Valve (Optional)
On units equipped with hot gas bypass, hot gas
from the compressor is injected into the liquid line of
the evaporator coil after the TXV.
Valve Adjustment - To adjust the valve, connect
a pressure gauge to the suction line and block the
entering air to the evaporator coil. The valve should
begin to open when the suction pressure drops to
approximately 115 PSIG for R-410A (the valve will
feel warm to the touch). Adjustments are made by
rst removing the cap on the bottom of the valve
and then turning the adjusting stem clockwise to
increase the setting pressure (counterclockwise
to decrease). Allow several minutes between
adjustments for the system to stabilize. When
adjustment is complete, replace the cap on the
valve.
Electric shock hazard. Can cause injury or death.
Before attempting to perform any service or
maintenance, turn the electrical power to unit to OFF
at disconnect switch(es). Unit may have multiple power
supplies.
CAUTION
Use caution when removing access panels or other
unit components, especially while standing on a ladder
or other potentially unsteady base. Access panels and
unit components can be heavy and serious injury may
occur.
CAUTION
Do not operate without the filters and birdscreens
installed. They prevent the entry of foreign objects
such as leaves, birds, etc.
CAUTION
Do not run unit during construction phase. Damage to
internal components may result and void warranty.
WARNING
WARNING
Prior to starting up the unit, power must be energized
for 24 hours without a call for cool to allow the
compressor crankcase heaters time to boil off any
liquid refrigerant present in the compressor.
Every installation requires a comprehensive start-up
to ensure proper operation of the unit. As part of that
process, the following checklist must be completed and
information recorded. Starting up the unit in accordance
with this checklist will not only ensure proper operation,
but will also provide valuable information to personnel
performing future maintenance. Should an issue arise
which requires factory assistance, this completed
document will allow unit experts to provide quicker
resolve. Qualied personnel should perform start-up to
ensure safe and proper practices are followed.
Unit Model No. ________________________________
Unit Serial No. ________________________________
Energy Wheel Date Code ________________________
Compressor 1 Model No. ________________________
• Unit was factory tested. All blowers, fans, and
compressors are set-up to run correctly when
supplied power. If any one fan is running backwards
or the compressor is making loud noises,
immediately turn off the power. Switch two leads
on the incoming power to the disconnect. This
will ensure proper operation of the unit. Failure to
comply may damage the compressors and void the
warranty.
• Do not jumper any safety devices when operating
the unit. This may damage components within or
cause serious injury or death.
• Do not operate compressor when the outdoor
temperature is below 40ºF.
• Do not short-cycle the compressor. Allow 5 minutes
between “on” cycles to prevent compressor
damage.
oDisconnect and lock-out all power switches.
o Remove any foreign objects that are located in the
unit.
o Check all fasteners, set-screws, and locking collars
on the fans, bearings, drives, motor bases and
accessories for tightness.
o Rotate the fan wheels and energy recovery wheels
by hand and ensure no parts are rubbing.
o Filters can load up with dirt during building
construction. Replace any dirty pleated filters and
clean the aluminum mesh filters in the intake hood.
o Verify that non-motorized dampers open and close
properly.
o Check the tightness of all factory wiring connections.
o Verify control wire gauge.
o Verify diameter seal settings on the energy recovery
wheel.
o Verify proper drain trap installation.
o Check condensing fans for any damage or
misalignment. Spin the blades and make sure they
don’t contact any parts and are free turning without
any resistance.
o Look over the piping system.
o Inspect all coils within the unit. Fins may get
damaged in transit or during construction. Carefully
straighten fins with a fin comb.
o If there is an indirect gas-fired furnace in this unit,
refer to the manual provided with this unit for PreStart-Up information.
o This unit contains a crankcase heater for each
compressor which needs power supplied to it 24
hours prior to start-up. If start-up is scheduled in 24
hours, unlock the disconnect power and energize
unit.
SPECIAL TOOLS REQUIRED
• Voltage Meter (with wire probes)
• Amperage Meter
• Pressure Gauges – (refrigerant)
• Tachometer
• Thermometer
• Incline manometer or equivalent
Start- Up Procedure
The unit will be in operational mode during start-up. Use
necessary precautions to avoid injury. All data must be
collected while the unit is running.
o Make sure Pre-Start-Up checklist is complete.
o Jumper R to G, R to Y1, and R to Y2 (if applicable) on
the control board.
o Turn the disconnect on. After 3 minutes compressors
will come on. Make sure all fans and compressors
are rotating the correct direction.
o Allow the unit to run until the refrigerant system
stabilizes. Approximately 1-2 minutes.
Voltage Imbalance
In a 3-phase system, excessive voltage imbalance
between phases will cause motors to overheat and
eventually fail. Maximum allowable imbalance is 2%.
To determine voltage imbalance, use recorded voltage
measurements in this formula.
Key: V1, V2, V3 = line voltages as measured
VA (average) = (V1 + V2 + V3) / 3
VD = Line voltage (V1, V2 or V3) that
deviates farthest from average (VA)
Formula: % Voltage Imbalance = [100 x (VA-VD)] /VA
The fan should be checked for free rotation. If any
binding occurs, check for concealed damage and foreign
objects in the fan housing.
CAUTION
When operating conditions of the fan are to be
changed (speed, pressure, temperature, etc.), consult
manufacturer to determine if the unit can operate
safely at the new conditions.
Supply Fan (Plenum Type)
The unit contains one plenum supply fan located on
the end of the unit opposite the outdoor air intake and
may optionally have a relief air blower which is referred
to as an exhaust blower in this document. Efcient fan
performance can be maintained by having the correct
offset.
Offset: Proper offset, or overlap, is
adjusted by loosening the wheel hub
from the shaft and moving the wheel
to the desired position along the shaft.
The transition between the inlet cone
and the wheel should
Wheel
Offset
Inlet
Cone
be as shown; there is
a smooth feel to the
prole when moving
one component to the
other.
Supply/Exhaust Fan
The optional exhaust fan is a direct-drive plenum type.
Fan speed is controlled by a VFD which, in turn, is
controlled by the microprocessor controller or by an
external signal. Motor speed will be set on the VFD
during the unit Test and Balance, but after that, the
VFD will not normally be changed. Always check the
motor amperage rating shown on the motor nameplate
when changing the fan RPM. All access doors must be
installed except the control center door.
Vibration
Excessive vibration may be experienced during initial
start-up. Left unchecked, excessive vibration can
cause a multitude of problems, including structural and/
or component failure. The most common sources of
vibration are listed.
Many of these conditions can be discovered by careful
observation. Refer to the Troubleshooting section of
this manual for corrective actions. If observation cannot
locate the source of vibration, a qualied technician
using vibration analysis
Vibration Causes
Off axis or loose components
Drive component unbalance
Poor inlet / outlet conditions
Foundation stiffness
building by the ductwork. To eliminate this undesirable
effect, the use of exible connectors is recommended.
equipment should be
consulted.
Generally, fan vibration
and noise is transmitted
to other parts of the
Fan Size
Offset
(inches)
Tolerance
(inches)
ER35C5/32± 1/32
ER45C3/16± 1/32
ER50C13/64± 1/32
ER56C1/4± 1/32
Refer to the respective Installation, Operation and
Maintenance Manual shipped with this unit for additional
start-up and maintenance information regarding the
plenum fan.
Fan Wheel Rotation Direction
Check for proper wheel rotation by momentarily
energizing the fan. Rotation is determined by viewing the
wheel from the drive side and should match the rotation
decal afxed to the fan housing.
If the wheel is rotating the wrong way, direction can be
reversed by interchanging any two of the three electrical
leads. Check for unusual noise, vibration or overheating
of the bearings. Refer to the Troubleshooting portion of
this manual if a problem develops.
Discharge Air Temperature Sensor
Units are supplied with a Discharge Air Temperature
Sensor that is to be eld-installed prior to unit start-
up. The sensor is to be installed at least three duct
diameters downstream of the heat exchanger. The
sensor must be connected
directly to the microprocessor
controller.
All other sensors and low
voltage devices are to be
connected to the low voltage
terminal strip in the control
center. The discharge air sensor is shipped loose and
can be found in the unit’s control center. See the unit-
For additional information on how to navigate through
the airflow controller menus, refer to technical manuals
GF-2200A from GreenTrol® Automation Inc. at www.
greentrol.com.
Field calibration procedure:
1. Turn off power to the unit using the power
disconnect(s).
2. Remove the cover from the GreenTrol airow
monitoring controller.
3. Install a jumper wire between terminals R and G on
the unit’s terminal board if one isn’t present.
4. When safe, turn the power back on to the unit using
the power disconnect(s).
If no microprocessor controller, skip to step 8.
Steps 5 thru 7 are for microprocessor only.
5. Look at the unit’s microprocessor controller screen
and view the status of the unit. If the displayed
status is “System Off” continue with step 6,
otherwise go to step 7.
6. Adjust the unit on/off priorities on the unit’s
microprocessor controller so that the unit will run for
calibration.
a. Push the “Prg” button on the microprocessor
controller.
b. Use the up and down arrows to get to the “On/
Off Unit” menu.
c. Push the enter button to view the current unit
on/off priorities.
d. Push the down arrow to display the Unit ON/
OFF Control screen.
e. Record the settings below so they can be
changed back when calibration is complete.
By digit input: __________
By BMS: __________
By Scheduler: __________
f. Use the enter button to navigate between the
different settings on the page, use the up and
down arrows to change the values so that “By
digit input” is the only setting with “Yes”.
7. Enter the service override menu to control the
damper position.
a. At the Home Screen push the “Prg” button. (If
you’re not at the home screen push the escape
button until you get there).
b. Use the up and down arrows to get to the
“Service” menu, then push the enter button.
c. If you’re asked for a password, enter “1000” for
the password and push enter.
d. Use the up and down arrows to get to the
“Overrides” screen, then push enter.
e. Use the arrow buttons to get the supply
override.
8. Measure the supply airow rate of the unit using an
approved test and balance method.
9. Without making any changes to the system,
calibrate the airow monitoring controller so it reads
the airow measured in step 8 by using the Field
Calibration Wizard.
a. The eld calibration lasts for two minutes. Any
signicant changes in airow will affect the
accuracy of the reading.
b. To enter the Field Calibration Wizard, hold the
Down and Enter buttons simultaneously on the
airow controller, then release the buttons.
c. Push the enter to enter to go Wizard 1
d. Push the enter button twice and change Wiz1
Enable to YES.
e. When asked for the number of calibration
points (Cal Points), set the value to 1.
f. Push the enter button when the display says
“Set Flow 1”.
g. After completing the steps above, set the
FLOW1 value to the airow measured in step 8,
then push the enter button to begin calibration.
10. After the calibration is completed, measure the
supply airow rate again and compare with the
value on the airow controller’s display
a. If the values are within 5% of each other the
device has been successfully calibrated.
b. If the values are not within 5% of each other
repeat the eld calibration process.
11. If you had to change the On/Off priorities on the
microprocessor unit controller, change them back to
the values that were written down in part 6.
12. Turn off power to the unit using the power
disconnect(s) and wait one minute for the variable
frequency drive(s) to lose backup power.
13. Replace the cover to the GreenTrol airow
monitoring station.
14. If you added a jumper between terminals R and
G in step 3 remove it at this time. If a jumper was
already in place, leave it in place.
15. When safe, turn the power back on to the unit using
the power disconnect(s).
a. Recycling of the power resets the manual
override values that were set during the
calibration.
If selected, the energy wheel is installed in the unit’s
airstream with one half of the wheel in the intake
airstream and one half in the exhaust airstream. Air
leakage between the two airstreams has to be kept to
a minimum and the wheel has air seals that must be
adjusted for that purpose. The seals must be adjusted at
time of start-up.
Retaining
Adjustable
Air Seals
Drive Belt
Screws
Bearing
Support
Label
showing
cassette
serial # and
date code
Drive Pulley
Drive Belt
Inspect the drive belt. Make sure the belt rides smoothly
in the pulley and around the outside of the wheel. Note
the directional arrow and data information shown in the
image.
Adjust the Air Seals
Make sure the unit power supply is locked out.
Disconnect the wiring to the wheel module and pull the
wheel cassette out of the cabinet on its tracks. Large
cassettes are not removable. Then slowly rotate the
wheel by hand to make sure there is no binding or
misalignment.
There is a perimeter seal located around the outside of
the wheel and a diameter seal across the face of the
wheel on both sides. Check to make sure that all air
seals are secure and in good condition.
Adjust the air seals by loosening all the air seal retaining
screws on the bearing support. Using a piece of paper
as a feeler gauge, adjust the seals so they almost touch
the face of the wheel while tugging slightly on the paper.
When the wheel is rotated, there should be a slight tug
on the paper. Tighten the screws, repeat the steps on
the other set of seals.
Push the wheel cassette back into the unit and plug
in the power connector. Turn the main power supply
back on and then observe the operation of the wheel by
opening the wheel access door slightly. Remove lters if
necessary to observe the wheel.
Sequence of Operation
Optional Economizer - The economizer will be locked
out when: the outside air is <40° F (- 2° F hysteresis,
adjustable); the unit is operating in dehumidication
mode; or there is a call for heating.
• Stop Wheel: When economizer mode is enabled
and there is a signal for cooling, the wheel will stop
rotating to allow free cooling.
• Modulate Wheel: When economizer mode
is enabled and there is a signal for cooling, the
wheel VFD modulates wheel speed to maintain the
discharge temperature set point.
Optional Frost Control - The microprocessor controller
will output a signal when wheel frosting is occurring
which is determined by a temperature set point (OA <5°
F – 2° F hysterisis, adjustable) and wheel pressure drop
increase.
• Preheat: When frosting is occurring, the preheater
is energized to defrost the wheel. Once the pressure
drop decreases below the set point, the preheater is
de-energized.
• Timed Exhaust: When frosting is occurring, the
supply blower is cycled off. The exhaust blower
shall continue to run, allowing the warm exhaust
air to defrost the wheel. After the 10 minute cycle,
the supply fan is re-energized to continue normal
operation.
• Modulating Wheel: Includes a VFD in addition
to the thermostat and pressure sensor. When
modulating wheel frost control is initiated, the VFD
will reduce the speed of the wheel, which keeps the
exhaust air condition from reaching saturation, thus,
eliminating condensation and frosting. If the outdoor
air temperature is greater than the frost threshold
temperature OR the pressure differential is less
than the set point, the wheel will run at full speed.
If the outdoor air temperature is less than the frost
threshold temperature AND the pressure differential
is greater than the set point, the wheel will run at
reduced speed until the pressure differential falls
below the set point. The temperature and pressure
differential set points are set at the factory, but are
eld-adjustable. The VFD will be fully programmed at
the factory.
Alarms Indication - Microprocessor shall have one
digital output for remote indication of an alarm
condition.
Possible alarms include:
• Wheel Rotation Alarm: Monitors wheel
rotation, and sends a signal to controller (after a 15
second time delay with no rotation) that signals the
microprocessor controller to activate an alarm.
Whenever performing maintenance or inspections,
always disconnect the power source.
Inspection
The wheel should be inspected semiannually in
accordance with the maintenance
schedule. Maintenance of the
wheel consists mainly of
inspecting the wheel for
cleanliness and then checking
the drive motor, belt, and pulley
for wear. If the wheel layers
appear dirty, the wheel should
be disassembled and cleaned.
The wheel rotates through the
two airstreams which are moving
in opposite directions, the wheel is
self-cleaning, up to a point. If the
Energy Wheel
Cassette
wheel media becomes blocked by
dirt or dust, or if the media collects a layer of smoke
residue or an oily lm, the energy transfer efciency
drops.
The main factor in the frequency of cleaning is the
cleanliness of the air. If air lters are not changed
frequently, the wheel will collect contaminants and will
then have to be cleaned.
Wheel Disassembly
Wheels are part of a cassette that may be pulled from
the unit for easy access. There may be a small damper
assembly or other component that blocks removal of the
cassette. Before sliding out the cassette or any other
component, disconnect any power supply cord and
secure it so it cannot jam or otherwise get damaged.
Each wheel has removable segments that hold the
coated layers of media and each segment is held in
place with two retaining clips located on the outer rim of
the wheel. When removing
more than one segment,
remove them in sequence
from opposite sides of the
wheel (180 degrees apart)
to reduce the imbalance.
Secure the wheel against rotation. Carefully release
the two retaining clips and swing them fully open. The
segment can now be removed by pushing the face
of the segment close to the outer rim of the wheel.
Wheel segments are built to close tolerances and the
segment may have to be jiggled to remove it. Do not
use a hammer or otherwise force the segment because
these are high value items and are not built to withstand
abuse.
Whenever retaining clips are opened, they should be
closed as soon as possible. If the wheel should rotate
when a clip is open, the clip will jam against the bearing
support bar and could cause damage.
Segment Retaining Clip
Cleaning
Maintenance or cleaning of the wheel segments
should be done with the segments removed from
the wheel cassette to avoid splashing liquids or
cleaning agents inside the cabinet. If the energy wheel
appears excessively dirty, it should be cleaned to
ensure maximum operating efciency. Only excessive
buildup of foreign materials needs to be removed.
DISCOLORATION AND STAINING OF ENERGY
RECOVERY WHEEL DOES NOT AFFECT ITS
PERFORMANCE.
Thoroughly spray the wheel matrix with a household
cleaner such as Fantastik™ or the equivalent. Gently
rinse with warm water and use a soft brush to remove
any heavy accumulations. A detergent/water solution
can also be used. Avoid aggressive organic solvents,
such as acetone. Wheel segments can be soaked in the
above solution overnight for removal of stubborn dirt or
accumulations.
After cleaning is complete, shake excess water from the
wheel or segments. Dry the wheel or segments before
putting them back into the cassette.
Reassembly
When reinstalling the segments, be sure to install
them with the correct face toward the motor side of the
cassette. Note that one face of each segment is smooth
and the other face has a reinforcing channel or support
cut into the surface.
Wheel Segment
(Pulley Side)
Wheel Segment
(Motor Side)
Energy Recovery Wheel Belt
Inspect belts each time lters are replaced. Belts that
look chewed up or are leaving belt dust near the motor
pulley may indicate a problem with the wheel. Be sure to
inspect wheel for smooth and unrestricted rotation. If a
belt requires replacement, contact the local manufacturer
representative. Instructions for replacement will ship with
the new belt.
Energy Recovery Wheel Bearing
In the unlikely event that a wheel bearing fails, the
bearing is behind a removable plate on the wheel
support beam (slide cassette halfway out of cabinet to
access). Contact the local manufacturer representative
for detailed instructions on how to replace the bearing.
Refer to Adjust the Air Seals in the Optional Energy Wheel
Start-Up section.
No power to wheel motor.Make sure wheel drive is plugged in. Verify power is available.
Energy
wheel runs
intermittently
Wheel motor overloads are
tripping due to rubbing between
wheel and air seals.
Recheck air seals, make sure they are not too tight. See Adjust
the Air Seals in the Optional Energy Wheel Start-Up section.
Troubleshooting – Alarms
Several of the electronic controls in the unit monitor the
system for faults and will go into alarm, shutting down
the unit or a single function within the unit.
Microprocessor Controller
Check the screen on the microprocessor controller for an
alarm condition. If it is in an alarm condition, a message
will show on the screen.
The microprocessor controller is located in the main
control center. If it is in alarm condition, the Alarm button
will blink red. Press the Alarm button to see the specic
condition or to reset the microprocessor controller.
Refer to the microprocessor controller IOM for detailed
information on fault codes and see the unit-specic
wiring diagram.
Phase Monitor
The phase monitor has two LED indicator lights, one
red and one green. Green indicates proper operational
status, red indicates the unit has detected a fault and is
in alarm condition. The alarm LED will blink to show the
specic fault and there is a chart printed on the monitor
that shows the code for the blinking light. The phase
monitor is self-resetting once the alarm condition is
corrected. It is located in the main control center.
Variable Frequency Drive (VFD)
Variable frequency drives have a display screen that
will show an alarm condition. If a fault such as a voltage
spike occurs, the VFD will go into alarm and will not
reset until a hard restart is performed. See the unit-
specic manufacturer’s manual supplied with the unit.
VFDs are located in the main control center.
Optional Digital Scroll Compressor
Controller
Present only if packaged DX with digital scroll option is
selected. The controller has
three LED indicator lights.
One is green, indicating that
it has power, one is an alarm
indicator that will ash a code
for various alarm conditions
and the third indicates
whether the compressor
is operating in a loaded or unloaded condition. See
the manufacturer’s unit-specic manual for further
information.
See the Fault Code chart below. The Fault Code chart
is also printed on the back of the controller. Note that
if the controller generates either a Code 2 or a Code 4
Lockout, a manual reset must be performed. Manual
Reset is accomplished by shutting off main power to the
unit and then turning it back on.
Blown fuse or open circuit breaker.Replace fuse or reset circuit breaker and check amps.
Blower fails
to operate
Motor
starters
“chatter” or
do not pull in
Motor over
amps
Low airow
(cfm)
High airow
(cfm)
Excessive
noise or
vibration
Defective motor or capacitor.Replace.
Motor overloaded.Reset VFD and check amps.
Electrical.
Control power (24 VAC) wiring run is too
long. (Resistance should not
exceed 0.75 ohms).
Check for On/Off switches. Check for correct supply
voltage. Check Control wiring.
Shorten wiring run to mechanical room or install a relay
to turn unit on/off. Consult factory for relay information.
Increase wire gauge size so that resistance is 0.75 ohms
or less.
Incoming supply power is less than
anticipated. Voltage supplied to starter
coil must be within +10% / -15% of
Need to increase supply power or use a special control
transformer which is sized for the actual supply power.
nominal voltage stated on the coil.
Static pressures are higher than design.Check for dirty lters. Improve ductwork.
Motor voltage incorrect.
Motor horsepower too low.
Check motor wiring. Check motor nameplate versus
supplied voltage.
See specications and catalog for fan curves to determine
if horsepower is sufcient.
Shorted windings in motor.Replace motor.
Unit damper not fully open.Adjust damper linkage or replace damper motor.
System static pressure too high.
Improve ductwork to eliminate losses using good duct
practices.
Check maximum motor RPM and compare with catalog
Blower speed too low.
data. Verify that external control wiring is in place if
required.
Fan wheels are operating backwards.
Dirty lter.
For 3-phase, see Direction of Fan Wheel Rotation
Direction in Start-Up, Components section.
Replace lters or follow cleaning procedures in Routine
Maintenance section of this manual.
Leaks in ductwork.Repair.
Elbows or other obstructions may be
obstructing fan outlet.
Blower fan speed too high.
Correct or improve ductwork.
Check for correct maximum fan RPM. Decrease maximum
fan speed if necessary in the VFD.
Do not release refrigerant to the atmosphere! If
Before any components are changed on the
refrigeration system, the cause of the failure must be
identified. Further problems will exist unless the true
cause or problem is identified and corrected.
required service procedures include the adding or
removing of refrigerant, the service technician must
comply with all federal, state and local laws. The
procedures discussed in this manual should only be
performed by a qualified EPA Certified Technician.
NOTE: Unit is equipped with a phase loss/phase reversal control. If system does not start, check phase of electrical
supply. The rst step in troubleshooting a refrigeration circuit is to examine the microprocessor controller and digital
scroll compressor controller
(if present) and see if there is a fault code. The next step is to check airow conditions (e.g. improper ductwork,
atypical wet bulb / dry bulb, etc.). After these steps have been eliminated, proceed with troubleshooting by following
this guide.
SymptomPossible CauseCorrective Action
Open disconnect switch or circuit
breaker.
Compressor contactor not closing.
Blown fuse or tripped breaker.
Close switch and/or breaker.
Check voltage to contactor coil, transformer, slave relay,
system. Replace parts as necessary.
Check for reason and repair. Replace fuse after correcting
problem.
Compressor
will not run
or does not
start
Compressor
starts but
cuts out on
low pressure
Low pressure
switch
activates at
50 PSIG
Low line voltage.
Check line voltage. If more than 10% from compressor
marking, correcting is necessary.
Motor thermal protector automatically resets.
Compressor motor protector open.
Allow time (2 hours) for compressor to cool down so
protector will reset. Restart and check for reason overheat
occurred.
Check motor for open circuit, short circuit, grounded
Compressor defective.
windings, or burn out. Compressor may be seized; check
refrigerant. If necessary, replace compressor.
High pressure switch open
or defective.
Low pressure switch open
or defective.
Open room thermostat or control.
(No cooling required).
If manual reset (high pressure), reset switch.
(Switch opens at 600 psi and will not reset above 420 psi
for R-410A). Replace if defective.
Switch will open at 50 psi and auto-close at 90 psi.
Replace if defective.
Check room temperature. If temperature is proper, wait for
thermostat to close.
Loose wiring.Check all wire terminals and tighten as necessary.
Low or loss of refrigerant charge.
Check refrigerant pressures and temperatures
(subcooling.)
Check for dirty evaporator coil, dirty lters, dampers
* When the power is turned on, the valve closing signal
of 2200 pulses will be output from the inboard to LEV to
x the valve position. It must be xed at Point A.
When the valve operates smoothly, no sound from LEV
or no vibration occurs, however, when the pulses change
from E to A in the chart of the valve is locked, a big
sound occurs.
* Whether a sound is generated or not can be
determined by holding a screwdriver against it, then
placing your ear against the handle.
Judgment Methods and Possible Failure Mode
PremiSys
Malfunction ModeJudgment MethodRemedy
Microcomputer driver
circuit failure
Disconnect the control board connector and connect the check
LED as shown in the gure below.
6
5
4
3
2
1 k
LED
1
When the drive circuit
has a problem, replace
the control board.
resistance: 0.25W 1kΩ
LED: DC15V 20mA or more
When the main power is turned on, the control board pulse
signals to the LEV’s for 10 seconds
LEV mechanism is
locked
If the LEV is locked, the drive motor runs idle, and makes a small
clicking sound.
Replace the LEV.
When the valve makes a closing and opening sound, the valve
has a problem.
Disconnected or
short-circuited LEV
motor coil.
Faulty wire
connections in the
connector or faulty
contact.
Measure resistance between the coils (red-white, red-orange,
brown-yellow, brown-blue)using a tester. They are normal if
resistance is 200 ohm ± 10%.
1. Check for loose pins on the connector and check the colors
of the lead wires visually.
2. Disconnect the control board’s connector and conduct a
continuity check using a tester.
Replace the LEV coils.
Check the continuity
at the points where an
errors occurs.
Solenoid Valve
Judgement methods and possible failure mode
Solenoid valves are normally closed when de-energized and open when energized. Solenoid valves should make a
clicking noise when coil is energized. If no noise is heard, follow coil test procedure below.
Measure the temperature at the upstream and dwonstream pipes of the solenoid valve. When the solenoid valve in
ON: There is no temperature difference. When the solenoid valve is OFF: there is a temperature difference.
Solenoid valve coil
SV10, SV11
Measure the resistance between the terminals with a tester.
Electric shock hazard. Can cause injury or death.
Before attempting to perform any service or
maintenance, turn the electrical power to the unit to
OFF at disconnect switch(es). Unit may have multiple
power supplies.
CAUTION
Use caution when removing access panels or other
unit components, especially while standing on a ladder
or other potentially unsteady base. Access panels and
unit components can be heavy and serious injury may
occur.
This unit requires minimal maintenance to operate
properly. Maintenance requirements for this model
vary for each installation and depend greatly on how
much the system is used and the cleanliness of the air.
Proper maintenance will both increase the life of the
system and maintain its efciency. Maintenance must be
performed by experienced technicians and in the case of
refrigeration systems, must be done by an EPA certied
technician.
Maintenance frequency is based on a presumed nominal
use of the system. If the system is being run constantly,
the frequency should be adjusted accordingly. If there
is seasonal debris in the air which can be drawn into
the lters and the coils, they should be checked more
frequently. If the system is being used for only a few
hours per day, the frequency may be reduced. Use the
maintenance log at the end of this manual to record
each maintenance session and observations and then
establish a maintenance schedule that is appropriate for
the installation. The following is provided as a guideline:
1. Check motor and motor bearings
Check for excessive heat, vibration or noise.
Lubricate bearings in accordance with the motor
manufacturer’s recommendations.
2. Condensate Drain (if applicable)
Inspect and clean – rell with water
3. Condenser Coils
Inspect for cleanliness – clean as required
Annually
It is recommended that the annual inspection and
maintenance occur at the start of the cooling season.
After completing the checklist, follow the unit startup checklist provided in the manual to ensure the
refrigeration system operates in the intended matter.
1. Lubrication
Apply lubricant where required
2. Dampers
Check for unobstructed operation
3. Blower Wheel and Fasteners
Check for cleanliness
Check all fasteners for tightness
Check for fatigue, corrosion, wear
4. Door Seal
Check if intact and pliable
5. Wiring Connections
Check all connections for tightness
6. Cabinet
Check entire cabinet, inside and out, for dirt
buildup or corrosion. Remove accumulated dirt,
remove any surface corrosion and coat the area
1. Evaporator Coil Maintenance
Check for cleanliness - clean if required
2. Condenser Coil Maintenance
Check for cleanliness - clean if required
3. Condensate Drain
Inspect and clean - rell with water
4. Condensing Fan Blades and Motors
Check for cleanliness
Check all fasteners for tightness
Check for fatigue, corrosion and wear
Maintenance Procedures
Filter
PremiSys
Lubrication - Check all moving components for
proper lubrication. Apply lubricant where required.
Any components showing excessive wear should be
replaced to maintain the integrity of the unit and ensure
proper operation.
Dampers - Check all dampers to ensure they open and
close properly and without binding. Backdraft dampers
can be checked by hand to determine if blades open
and close freely. Apply power to motorized dampers to
ensure the actuator opens and closes the damper as
designed.
Gas Furnace - Maintain furnace in accordance with
instructions in the Indirect Gas-Fired Heat IOM shipped
with this unit.
Fan Motors - Motor maintenance is generally limited
to cleaning and lubrication. Cleaning should be limited
to exterior surfaces only. Removing dust and grease
buildup on the motor housing assists proper cooling.
Never wash-down the motor with high pressure spray.
Greasing of motors is only intended when ttings are
provided. Fan motors typically have two grease ttings.
Each motor manufacturer has different lubrication
schedules for different models. Go to the motor
manufacturer’s website and download their maintenance
requirements. Do not over-lubricate motors or use an incompatible grease. Many fractional motors are
permanently lubricated for life and require no further
lubrication.
Fan Wheel and Fasteners - Wheels require very little
attention when moving clean air. Occasionally oil and
dust may accumulate on the wheel causing imbalance.
When this occurs, the wheel and housing should be
cleaned to assure smooth and safe operation. Inspect
fan impeller and housing for fatigue, corrosion, or wear.
Routinely check all fasteners, set screws and locking
collars on the fan, bearings, drive, motor base and
accessories for tightness. A proper maintenance
program will help preserve the performance and
reliability designed into the fan.
Internal Filter Maintenance - The unit will typically be
provided with 2-inch thick pleated paper lters in the
airstream. These lters should be checked according
to a routine maintenance schedule and replaced as
necessary to ensure proper airow through the unit.
Replacement lters shall be of same performance and
quality as factory installed lters. Filter must be pleated
design with integral metal grid. Two acceptable lter
replacements are Aerostat Series 400 or Farr 30/30®.
Filters upstream of the coil should be checked regularly.
If the lters are dirty, they should be cleaned or replaced.
It is important the lters stay clean to maintain desired
airow.
WARNING
REFER TO GENERAL SAFETY INFORMATION
Do not operate this unit without the lters and
birdscreen installed. They prevent the entry of foreign
objects such as leaves, birds, etc.
Do not remove access panels or other unit
components while standing on a ladder or other
unsteady base. Access panels and unit components
are heavy and serious injury may occur.
External Filter Maintenance- Aluminum mesh, 2-inch
thick lters are located in the supply weatherhood
(if the weatherhood
option was purchased).
These lters should be
checked and cleaned
on a regular basis for
best efciency. The
frequency of cleaning
depends upon the
cleanliness of the
Outdoor Air Intake Hood
Mesh Filter Access
incoming air. These lters should be cleaned by rinsing
with a mild detergent in warm water prior to start-up.
Coil Maintenance- Coils must be cleaned to maintain
maximum performance. Check coils once per year
under normal operating conditions and if dirty, brush or
vacuum clean. Soiled ns reduce the capacity of the
coil, demand more energy from the fan and create an
environment for odor and bacteria to grow and spread
through the conditioned zone. High pressure water
(700 psi or less) may be used to clean coils with a n
thickness over 0.0095 inches thick. TEST THE SPRAY
PRESSURE over a small corner of the coil to determine
if the ns will withstand the spray pressure.
For coils with fragile ns or high n density, foaming
chemical sprays and washes are available. Many coil
cleaners use harsh chemicals, so they must be used
with caution by qualied personnel only. Care must be
taken not to damage the coils, including the ns, while
cleaning. Caution: Fin edges are sharp!
WARNING
Biological hazard. May cause disease. Cleaning
should be performed by qualied personnel.
Drain pans in any air conditioning unit will have some
moisture in them, therefore, algae and other organisms
will grow due to airborne spores and bacteria. Periodic
cleaning is necessary to prevent this buildup from
plugging the drain and causing the drain pan to overow.
Inspect twice a year to avoid the possibility of overow.
Also, drain pans should be kept clean to prevent the
spread of disease. Cleaning should be performed by