Reznor T5BP Unit Installation Manual

T5BP SERIES 11.0 EER

USER’S MANUAL / INSTALLATION INSTRUCTIONS

R410A SPLIT SYSTEM HEAT PUMP - 3 PHASE

IMPORTANT

Please read this information thoroughly and become familiar with the capabilities and use of your appliance before attempting to operate or maintain this unit. Keep this literature where you have easy access to it in the future. If a problem occurs, check the instructions and follow recommendations given. If these suggestions don’t eliminate your problem, call your servicing contractor.

These instructions are primarily intended to assist qualiﬁ ed individuals experienced in the proper installation of this appliance. Some local codes require licensed installation/ service personnel for this type of equipment. Please read all instructions carefully before starting the installation.

DO NOT DESTROY. PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

USER INFORMATION

Important Safety Information ....................................4

About the Heat Pump .................................................4

Operating Instructions ...............................................4

Cooling Operation .....................................................4

Heating Operation .....................................................4

Emergency Heat........................................................4

Defrost Operation ......................................................4

INSTALLER INFORMATION

Operating the Heat Pump for Automatic

Cooling and Heating ..................................................5

Operating the Indoor Blower Continuously ................5

Shutting the Heat Pump Off ......................................5

System Maintenance ..................................................5

Regular Cleaning.......................................................5

Before You Call a Technician .....................................5

Troubleshooting ..........................................................5

Warranty Information .................................................5

Important Safety Information ....................................6

Heat Pump Installation ...............................................7

Before You Install the Heat Pump ..............................7

Locating the Heat Pump ............................................7

Packaging Removal ...................................................7

Rigging and Hoisting .................................................7

Rooftop ......................................................................7

Ground Level .............................................................8

Connecting Refrigerant Tubing Between the

Indoor & Outdoor Unit ...............................................8

Electrical Wiring ..........................................................9

Pre - Electrical Checklist ...........................................9

Line Voltage ...............................................................9

Grounding..................................................................9

Unbalanced 3-Phase Supply Voltage ......................10

Thermostat Connections .........................................10

Defrost Cycle Timer .................................................10

Defrost Control Board..............................................11

Operational Information........................................11

Normal Defrost Procedure ...................................11

Defrost Test Procedure ........................................11

Optional Electric Heater Kits ...................................11

Startup & Adjustments ............................................12

Pre - Start Checklist ................................................12

Start-up Procedure ..................................................12

Air Circulation - Indoor Blower .............................12

Short Cycle Protection .........................................12

System Cooling ....................................................12

System Heating ....................................................12

Refrigerant Charging ............................................... 12

Charging R410A Units in AC Mode with

Outdoor Temperatures Above 55° F ..................... 13

Heat Pump Maintenance .......................................... 13

Replacement Parts ................................................... 13

Component Functions .............................................14

Figures & Tables ....................................................... 14

Figure 5. T5BP Heat Pump Dimensions .............. 14

Table 3. Unit Dimensions & Shipping Weights ..... 14

Electrical Information ............................................... 15

Table 4. Electrical Specs & Physical Data ............15

Figure 6. T5BP Wiring Diagram ............................ 16

Figure 7. Heat Pump Thermostat Connections .... 17

Cooling Charging Charts ......................................... 18

Figure 8. Charging Chart for 7.5 Ton Units ........... 19

Figure 9. Charging Chart for 10 Ton Units ............ 19

Heat Mode Veriﬁ cation Charts ................................. 20

Figure 10. Veriﬁ cation Chart for 7.5 Ton Units ...... 21

Figure 11. Veriﬁ cation Chart for 10 Ton Units ....... 21

Installation Performance Checklist ......................... 20

USER INFORMATION

IMPORTANT SAFETY INFORMATION

Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored. WARNING indicates a potentially hazardous situation that if not avoided, could result in personal injury or death. CAUTION indicates a potentially hazardous situation that if not avoided, may result in minor or moderate injury or property damage.

ABOUT THE HEAT PUMP

Your heat pump is a unique, all weather comfort-control appliance that will heat and cool your home year round and provide energy saving comfort. It’s an unknown fact that heat is always in the air, even when the outside temperature is below freezing. The heat pump uses this basic law of physics to provide energy saving heat during the winter months. For example, If the outdoor temperature is 47° F (8° C), your heat pump can deliver approximately

3.5 units of heat energy per each unit of electrical energy used, as compared to a maximum of only 1 unit of heat energy produced with conventional heating systems.

In colder temperatures, the heat pump performs like an air conditioner run in reverse. Available heat energy outside the home is absorbed by the refrigerant and exhausted inside the home. This efﬁ cient process means you only pay for “moving” the heat from the outdoors to the indoor area. You do not pay to generate the heat, as is the case with more traditional furnace designs.

During summer, the heat pump reverses the ﬂ ow of the heat-absorbing refrigerant to become an energy-efﬁ cient, central air conditioner. Excess heat energy inside the home is absorbed by the refrigerant and exhausted outside the home.

OPERATING INSTRUCTIONS

Please refer to the thermostat manufacturer’s User manual for detailed programming instructions.

Cooling Operation

1. Set the thermostat’s system mode to COOL or AUTO

and change the fan mode to AUTO. See Figure 1

2. Set the temperature selector to the desired

temperature level. The outdoor fan, compressor, and blower motor will all cycle on and off to maintain the indoor temperature at the desired cooling level.

NOTE: If the temperature level is re-adjusted, or the system mode is reset, the fan and compressor in the outdoor unit may not start immediately. A protective timer circuit holds the compressor and the outdoor fan off for approximately 5 minutes following a previous operation or the interruption of the main electrical power.

Heating Operation

1. Set the thermostat’s system mode to HEAT or AUTO

and change the fan mode to AUTO. See Figure 1.

2. Set the temperature selector to the desired

temperature level. The compressor, outdoor fan, and blower motor will cycle on and off to maintain the indoor temperature at the desired heating level.

Emergency Heat

Some thermostats may include a system mode called EM HT or AUX HT, etc. This is a back-up heating mode that should only be used if a problem is suspected. With the mode set to EM HT, etc., the compressor and outdoor fan will be locked off and supplemental heat (electric resistance heating) will be used as a source of heat. Sustained use of electric resistance heat in place of the heat pump will result in an increase in electric utility costs.

Defrost Operation

During cold weather heating operation, the outdoor unit

Fan

Mode

Figure 1. Digital Thermostat

System

Mode

Temperature

Selector

will develop a coating of snow and ice on the heat transfer coil. This is normal and the unit will defrost itself. This unit monitors ambient and coil temperatures to regulate the defrost function accordingly.

USER INFORMATION

At the beginning of the defrost cycle, both the outdoor condenser fan and compressor will turn off. After approximately 30 seconds, the compressor will turn on and begin to heat the outdoor coil causing the ice and snow to melt.

NOTE: While the ice and snow is melting, some steam may rise from the outdoor unit as the warm coil causes the melting frost to evaporate. When defrost is completed, the outdoor fan motor will start, and the compressor will turn off again. In approximately 30 seconds the compressor will start up again and continue normal operation.

Operating the Heat Pump for Automatic Cooling and Heating

1. Set the thermostat system switch to AUTO and the thermostat fan switch to AUTO. See Figure 1.

NOTE: Thermostat styles vary. Some models will not include the AUTO mode and others will have the AUTO in place of the HEAT and COOL. Others may include all three. Refer to the instructions supplied with your thermostat for speciﬁ c instructions.

2. Set the thermostat temperature to the desired temperature level. The outdoor unit and the indoor blower will then cycle on and off in either the heating or cooling mode of operation as required to automatically maintain the indoor temperature within the desired limits.

Operating the Indoor Blower Continuously

The continuous indoor blower operation is typically used to circulate the indoor air to equalize a temperature unbalance due to a sun load, cooking, or ﬁ replace operation.

Set the thermostat fan mode to ON (Figure 1). The indoor blower starts immediately, and will run continually until the fan mode is reset to AUTO.

The continuous indoor blower operation can be obtained with the thermostat system mode set in any position, including OFF.

Shutting the Heat Pump Off

Change the thermostat’s system mode to OFF and the fan mode to AUTO. See Figure 1. NOTE: The system will not operate, regardless of the temperature selector setting.

HEAT PUMP MAINTENANCE

CAUTION:

Shut off all electrical power to the unit before performing any maintenance. Failure to comply may result in personal injury or death.

Proper maintenance is most important to achieve the best performance from the appliance and should be performed by a qualiﬁ ed service technician at least once a year. Read the maintenance items below and follow the instructions for years of safe, trouble free operation.

Regular Cleaning

WARNING:

Do not place combustible material on or against the unit cabinet. Do not place combustible materials, including gasoline and any other ﬂ ammable vapors and liquids, in the vicinity of the unit.

• Clean or replace the indoor air ﬁ lter at the start of each heating and cooling season, and when an accumulation of dust and dirt is visible on the air ﬁ lter.

• Remove any leaves and grass clippings from around the coil of the outdoor unit, being careful not to damage the aluminum ﬁ ns.

• Check and remove any obstructions, such as twigs, sticks, etc.

TROUBLESHOOTING

If the unit fails to operate, check the following:

• The thermostat is properly set. See Cooling Operation for air conditioning or Heating Operation for furnace.

• The unit disconnect fuses are in good condition and the electrical power to the unit is turned on.

WARRANTY INFORMATION

A warranty certiﬁ cate with full details is included with the heat pump. Carefully review these responsibilities with your dealer or service company. The manufacturer will not be responsible for any costs found necessary to correct problems due to improper setup, improper installation, adjustments, improper operating procedure on the part of the user, etc. Some speciﬁ c examples of service calls which are not included in the limited warranty are:

• Correcting wiring problems in the electrical circuit

supplying the heat pump.

• Resetting circuit breakers or other switches.

• Adjusting or calibrating of thermostat.

INSTALLER INFORMATION

IMPORTANT SAFETY INFORMATION

Please read all instructions before servicing this equipment. Pay attention to all safety warnings and any other special notes highlighted in the manual. Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored. WARNING indicates a potentially hazardous situation that if not avoided, could result in personal injury or death. CAUTION indicates a potentially hazardous situation that if not avoided, may result in minor or moderate injury or property damage.

WARNING:

Shut off all electrical power to the unit before performing any maintenance or service on the system. Failure to comply may result in personal injury or death.

WARNING:

Unless noted otherwise in these instructions, only factory authorized parts or accessory kits may be used with this product. Improper installation, service, adjustment, or maintenance may cause explosion, ﬁ re, electrical shock or other hazardous conditions which may result in personal injury or property damage

WARNING:

T5BP Split System Heat Pumps leave the factory with a 90 oz. (5.63 Lbs.) R410A refrigerant holding charge. Follow all charging instructions for maximum unit performance and efﬁ ciency. Some local codes require licensed installation/service personnel to service this type of equipment. Refrigerant charging must be done by qualiﬁ ed personnel familiar with safe and environmentally responsible refrigerant handling procedures. Under no circumstances should the owner attempt to install and/or service this equipment. Failure to comply with this warning could result in property damage, personal injury, or death.

CAUTION:

This unit uses refrigerant R-410A. DO NOT use any other refrigerant in this unit. Use of another refrigerant will damage the unit.

WARNING:

The information listed below must be followed during the installation, service, and operation of this unit. Unqualiﬁ ed individuals should not attempt to interpret these instructions or install this equipment. Failure to follow safety recommendations could result in possible damage to the equipment, serious per

injury or death

• The installer must comply with all local codes and regulations which govern the installation of this type of equipment. Local codes and regulations take precedence over any recommendations contained in these instructions. Consult local building codes and the National Electrical Code (ANSI CI) for special installation requirements.

• All electrical wiring must be completed in accordance with local, state and national codes and regulations and with the National Electric Code (ANSI/NFPA 70) or in Canada the Canadian Electric Code Part 1 CSA C.22.1.

• This equipment contains liquid and gaseous refrigerant under high pressure. DO NOT USE ANY PORTION OF

THE CHARGE FOR PURGING OR LEAK TESTING.

Installation or servicing should only be performed by qualiﬁ ed trained personnel thoroughly familiar with this type equipment.

• Fully annealed, refrigerant grade copper tubing should be used when installing the system. Refrigerant suction line tubing should be fully insulated.

• Installation of equipment may require brazing operations. Installer must comply with safety codes and wear appropriate safety equipment (safety glasses, work gloves, ﬁ re extinguisher, etc.) when performing brazing operations.

• This unit is designed for outdoor installations only and should be located as descibed on page 7.

• Follow all precautions in the literature, on tags, and on labels provided with the equipment. Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment.

sonal

HEAT PUMP INSTALLATION

General Information

The T5BP series heat pump is designed only for outdoor rooftop or ground level installations. This unit has been tested for capacity and efﬁ ciency in accordance with A.R.I. Standards and will provide many years of safe and dependable comfort, providing it is properly installed and maintained. Abuse, improper use, and/or improper maintenance can shorten the life of the appliance and create unsafe hazards.

To achieve optimum performance and minimize equipment failure, it is recommended that periodic maintenance be performed on this unit. The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools.

Before You Install the Heat Pump

 The cooling load of the area to be conditioned must be

calculated and a system of the proper capacity selected. It is recommended that the area to be conditioned be completely insulated and vapor sealed.

 Check the electrical supply and verify the power supply

is adequate for unit operation. The system must be wired and provided with circuit protection in accordance with local building codes. If there is any question concerning the power supply, contact the local power company.

 The indoor section (air handler, furnace, etc) should be

installed before routing the refrigerant tubing. Refer to the indoor unit's installation instructions for installation details.

 All units are securely packed at the time of shipment and

upon arrival should be carefully inspected for damage prior to installing the equipment at the job site. Verify coil ﬁ ns are straight. If necessary, comb ﬁ ns to remove ﬂ attened or bent ﬁ ns. Claims for damage (apparent or concealed) should be ﬁ led immediately with the carrier.

 Please consult your dealer for maintenance information

and availability of maintenance contracts. Please read all instructions before installing the unit.

Locating the Heat Pump

• Survey the job site to determine the best location for mounting the outdoor unit.

• Overhead obstructions, poorly ventilated areas, and areas subject to accumulation of debris should be avoided.

• Sufﬁ cient clearance for unobstructed airﬂ ow through the outdoor coil must be maintained in order to achieve rated performance. See Figure 2 for minimum clearances to obstructions.

• Consideration should be given to availability of electric power, service access, noise, and shade.

TOP OF UNIT

18"

TO BE

UNOBSTRUCTED

18"

Figure 2. Clearance Requirements

Packaging Removal

Locate and remove all screws securing the unit to the shipping skid. NOTE: To prevent damage to the tubing connections, carefully remove the carton and user’s manual from the equipment. Discard the shipping carton.

Rigging and Hoisting

WARNING:

To avoid the risk of property damage, personal injury, or death, it is the rigger’s responsibility to ensure that whatever means are used to hoist the unit are safe and adequate:

• The lifting equipment must be adequate for the

load. Refer to Table 3 (page 14) for unit weights.

• The unit must be lifted from the holes in the

base rails using cables or chains.

• Spreader bars are required to protect the unit

and ensure even loading.

• Keep the unit in an upright position at all times.

• All panels must be securely in place during

rigging and hoisting.

Rooftop

Rooftop installations must be located according to local building codes or ordinances and these requirements:

• Units may be installed on Class A, B, or C roof covering material. The roof must be capable of handling the weight of the unit. For unit weights, see Table 3. Reinforce the roof if necessary.

• Secure optional mounting pad or frame to roof using acceptable mechanical methods per local codes.

Ground Level

Ground level installations must be located according to local building codes or ordinances and these requirements:

• Clearances must be in accordance with those shown in Figure 2 (page 7).

• A suitable mounting pad (Figure 3) must be provided and be separate from the building foundation. The pad must be level and strong enough to support the unit’s weight. The slab height must be a minimum of 2” (5 cm) above grade and with adequate drainage.

Connecting Refrigerant Tubing Between the Indoor & Outdoor Unit

CAUTION:

This system uses R-410A refrigerant with POE oil. When servicing, cover or seal openings to minimize the exposure of the refrigerant system to air to prevent accumulation of moisture and other contaminants.

After outdoor and indoor unit placement has been determined, route refrigerant tubing between the equipment in accordance with sound installation practices.

• When connecting refrigerant linesets together, it is recommended that dry nitrogen be ﬂ owing through the joints during brazing. This will prevent internal oxidation and scaling from occurring.

• Refrigerant tubing should be routed in a manner that minimizes the length of tubing and the number of bends in the tubing.

• Refrigerant tubing should be supported in a manner that the tubing will not vibrate or abrade during system operation.

• Tubing should be kept clean of foreign debris during installation.

• Every effort should be made by the installer to ensure that the ﬁ eld installed refrigerant containing components of the system have been installed in accordance with these instructions and sound installation practices to insure reliable system operation and longevity.

• The maximum recommended interconnecting refrigerant line lengths are listed in Table 4 (page 15). The vertical elevation difference between the indoor and outdoor sections should not exceed 20 feet.

• If precise forming of refrigerant lines is required, a copper tubing bender is recommended. Avoid sharp bends and contact of the refrigerant lines with metal surfaces.

• A ﬁ lter dryer is provided with the unit and must be installed in the liquid line of the system. If the installation replaces a system with a ﬁ lter dryer already present in the liquid line, the ﬁ lter dryer must be replaced with the one supplied with the unit. The ﬁ lter dryer must be installed in strict accordance with the manufacturer’s installation instructions.

• Optional equipment such as liquid line solenoid valves, low ambient, etc., should be installed in strict accordance with the manufacturer’s installation instructions.

2”

Figure 3. Ground Level Installation

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Reznor T5BP Unit Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual