Rheem 24P20, 36P20, 48P20, 60P20 Installation Manual

WARNING:

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION

WARNING

THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT, AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE, OR MAINTENANCE POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

VARIABLE SPEED R-410A HEAT PUMP OUTDOOR UNITS

Enabled

INSTALLATION INSTRUCTIONS

(-)P20 (20 SEER) EQUIPPED WITH ECONET™ COMMUNICATIONS

Do not destroy this manual. Please read carefully and keep in a safe place for future reference by a serviceman.

[ ] indicates metric conversions.

92-105074-09-01 (5/16)

Printed in USA

CONTENTS

Important

Safety Information ............................................. 3

Efficiency Testing Notice ..............................................3

General Information ........................................4-7

Contents

Checking Product Received ........................................4

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

Electrical and Physical Data ..................................... 5-6

Specifications ........................................................... 6-7

Proper Installation ........................................................7

Installation .................................................... 8-22

Choosing a Location .....................................8-10

Operational Issues........................................................8

Corrosive Environment .................................................8

For Units With

Space Limitations .........................................................9

Customer Satisfaction Issues ......................................9

Unit Mounting ............................................................... 9

Factory-Preferred

Tie-Down Method.........................................................9

Snow Depth Table ......................................................10

Tools and Refrigerant .......................................11

Tools Required for Installing and

Servicing R-410A Models ..........................................11

Specifications of R-410A ...........................................11

Quick-Reference

Guide for R-410A .......................................................11

Replacement Units .......................................... 12

Indoor Coil ....................................................... 12

Location ...................................................................... 12

Interconnecting Tubing ............................... 12-26

Refrigerant Level Adjustment .....................................12

Maximum Length of Lines ..........................................12

Interconnecting Tubing and

Fitting Losses .............................................................13

Liquid Line Selection ..................................................13

Long Line Set Applications ........................................14

Oil Level Adjustments for Long Line ..........................14

Suction Line Selection ...............................................15

Refrigerant Migration During Off Cycle ......................15

Tubing Installation ......................................................20

Tubing Connections ...................................................21

Leak Testing ...............................................................22

Wiring .........................................................23-26

EcoNet™ Control Communications ...........................23

Control Wiring ............................................................23

EcoNet™ Control Board

Communication Wiring .............................................. 23

Conventional 24VAC Thermostat Control Wiring ...... 24

Conventional 24VAC Mode of Operation ...................24

Typical Noncommunicating Thermostat

Wiring Diagrams .........................................................25

Power Wiring .............................................................. 25

Grounding ...................................................................26

Start-Up ......................................................27-32

Start-Up ......................................................................27

Checking Airflow ........................................................27

Evacuation Procedure ............................................... 28

Final Leak Testing .......................................................28

Checking Refrigerant Charge .....................29-32

Charging Units

With R-410A Refrigerant ............................................29

Confirm ID Airflow and Coils Are Clean .....................29

Measurement Device Setup .......................................29

Charging by Weight ....................................................29

Setting Compressor Speed ........................................30

Gross Charging by Pressures ....................................30

Final Charge by Subcooling .......................................31

Finishing Up Installation ............................................. 31

Components and Controls ..........................33-54

Compressor Stator Heat (CSH) ........................ 33

Stator Heat Operation ................................................33

High- and Low-Pressure

Controls (HPC and SPT) ................................... 33

Accumulator .................................................... 34

Outdoor Fan Motors......................................... 34

Outdoor Fan Blades ......................................... 34

Electronic Expansion ....................................... 34

Alternate Suction Line Thermistor .................. 35

Coil Thermistor ................................................ 35

Compressor Sump Thermistor 35

Suction Pressure Transducer (SPT) ................. 36

Discharge Line Thermistor .............................. 36

Power Inverter Compressor Controls .............. 36

Choke/Inductor ................................................ 37

Filter & Ferrite Rings ....................................... 37

EcoNet™ Variable Speed

Unitary Control ................................................ 38

Test and SW2 Buttons .............................................. 38

Memory Card ............................................................ 39

Factory Programmed Superheat ............................... 39

Superheat Offset Dip Switch Settings ...................... 39

Compressor Operation .............................................. 41

Demand Defrost ........................................................ 42

Active Compressor Protection Mode ........................ 44

Default Operations Upon Component Failure ........... 51

Test and Fault Recall Modes ..................................... 51

Agency Test Mode Instructions ................................. 52

Accessories .....................................................55

Heat Pump Thermostat Warning Light Kit ................ 55

Diagnostics ................................................ 56-77

Replacement of EcoNet™ Variable Speed

Unitary Control Board ............................................... 56

ICC Diagnostic Codes .......................................... 57-60

Electrical, Mechanical Checks Flowcharts ..........61-64

General Troubleshooting Chart ................................. 65

Service Analyzer Charts .......................................66-71

Cooling and Heating Mode Troubleshooting Tips .... 72

Wiring Diagram .......................................................... 73

IMPORTANT SAFETY INFORMATION

WARNINGS:

• These instructions are intended as an aid to

qualified, licensed service personnel for proper installation, adjustment, and operation of this unit. Read these instructions thoroughly before attempting installation or operation. Failure to

follow these instructions may result in improper installation, adjustment, service, or maintenance possibly resulting in fire, electrical shock, property damage, personal injury, or death.

• The unit must be permanently grounded. Failure to do so can cause electrical shock resulting in severe personal injury or death.

• Turn off electric power at the fuse box or service panel before making any electrical connections.

• Complete the ground connection before making line voltage connections. Failure to do so can result in electrical shock, severe personal injury, or death.

• Disconnect all power to unit before starting maintenance. Failure to do so can cause electrical shock resulting in severe personal injury or death.

• Never assume the unit is properly wired and/or grounded. Always test the unit cabinet with a noncontact voltage detector available at most electrical supply houses or home centers before removing access panels or coming into contact with the unit cabinet.

• Do not use oxygen to purge lines or pressurize system for leak test. Oxygen reacts violently with oil, which can cause an explosion resulting in severe personal injury or death.

• The top of the scroll compressor shell is hot.

Touching the compressor top may result in serious personal injury.

• The manufacturer’s warranty does not cover any damage or defect to the unit caused by the attachment or use of any components, accessories, or devices (other than those authorized by the manufacturer) into, onto, or in conjunction with the heat pump. You should be aware that the

use of unauthorized components, accessories, or devices may adversely affect the operation of the heat pump and may also endanger life and property. The manufacturer disclaims any

responsibility for such loss or injury resulting from the use of such unauthorized components, accessories, or devices.

CAUTIONS:

• R-410A systems operate at approximately 60%

higher pressures (1.6 times) than R-22 systems. Do not use R-22 service equipment or components on R-410A equipment. Use appropriate care when using this refrigerant. Failure to exercise care may result in equipment damage or personal injury.

• Only match this outdoor unit with a matched indoor

coil or air handler approved for use with this outdoor unit per the unit manufacturer’s specification sheet. The use of unmatched coils or air handler will likely result in a charge imbalance between the cooling and heating modes which can cause unsatisfactory operation including a high-pressure switch lockout condition.

• Only use indoor coils approved for use on R-410A

systems. An R-22 coil will have a TXV or fixed restrictor device that is not designed to operate properly in an R-410A system and will result in serious operational issues. The R-22 coil could also contain mineral oil which is incompatible with the POE oil used in R-410A systems and could result in reliability issues with the compressor and TXVs.

• When coil is installed over a finished ceiling and/or

living area, it is required that a secondary sheet metal condensate pan be constructed and installed under the entire unit. Failure to do so can result in property damage.

• The compressor has an internal overload protector.

Under some conditions, it can take up to 2 hours for this overload to reset. Make sure overload has had time to reset before condemning the compressor.

• UNIT MAY START SUDDENLY AND WITHOUT

WARNING. A flashing red light on the heat pump/ defrost control indicates a call for unit operation is present at the heat pump/defrost control. The heat pump/defrost control will attempt to start unit after the anti-short cycle time expires, when a high or low pressure control automatically resets, or when the heat pump/defrost control exits the lockout mode as the temperature rises above 5°F.

Efficiency Testing Notice:

For purposes of verifying or testing efficiency ratings, the test procedure in Title 10 APPENDIX M to Subpart B of Part 430 (Uniform Test Method for Measuring the Energy Consumption of Central Air Conditioners and Heat Pumps) and the clarifying provisions provided in the AHRI Operations Manual 210/240 that were applicable at the date of manufacture should be used for test set up and performance.

Safety

GENERAL INFORMATION

WARNING:

Improper installation, or installation not made in accordance with these instructions, can result in unsatisfactory operation and/or dangerous conditions and can cause the related warranty not to apply.

The RP series of heat pumps are designed to operate with standard 24 VAC thermostats and air handlers or gas furnaces.

This installation instruction manual contains complete instructions for installation and setup using conventional 24 VAC controls. Please refer to the manufacturer’s specification sheets for complete performance data, thermostat, and accessory listings.

The information contained in this manual has been prepared to assist in the proper installation, operation, and maintenance of the air conditioning system.

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

To achieve optimum efficiency and capacity, the matching indoor cooling coils listed in the manufacturer’s specification sheet must be used

General Information

for this model heat pump.

Checking Product Received

Upon receiving unit, inspect it for any shipping damage. Claims for damage, either apparent or concealed, should be filed immediately with the shipping company. Check model number, electrical characteristics, and accessories to determine if they are correct. Check system components (indoor coil, outdoor unit, air handler/furnace, etc.) to make sure they are properly matched.

Application

Before specifying any heat pump equipment, a survey of the structure and a heat loss and heat gain calculation must be made. A heat loss calculation involves identifying all surfaces and openings that lose heat to the surrounding air and quantifying that heat loss. A cooling heat gain calculation makes similar measurements and determines the amount of heat needed to be removed. A heat gain calculation also calculates the extra heat load caused by sunlight and by humidity removal. These factors must be considered before selecting a heat pump system to provide year-round comfort. The Air Conditioning Contractors of America (ACCA) J Manual method of load calculation is one recognized procedure for determining the heating and cooling load.

After the proper equipment combination has been selected, satisfying both sensible and latent requirements, the system must be properly installed. Only then can the unit provide the comfort it was designed to provide.

There are several factors that installers must consider.

• Outdoor unit location

• Indoor unit blower speed and airflow

• Proper equipment evacuation

• Supply and return air duct design and sizing

• Refrigerant charge

• System air balancing

• Diffuser and return air grille location and sizing

Electrical and Physical Data

]

[2]

]

[

]

GENERAL INFORMATION

Fan Motor

Amperes (FLA)

PHYSICAL

Refrig. Pe

135.2[3832

215.2[6100

ELECTRICAL

Full Load

Minimum

Circuit Ampacity Amperes

223[101

293[133

Fuse or HACR Circuit Breaker

Minimum Amperes

231[104

301[137

Rev. 03/16

Compressor

Model

Number

(-)P20

24 1-60-208/230 20.7/20.7 35 1.4 28/28 35/35 45/45

36 1-60-208/230 21.9/21.9 35 5.3 33/33 40/40 50/50

48 1-60-208/230 21.6/21.6 50 5.3 46/46 60/60 70/70

60 1-60-208/230 31.7/31.7 50 5.3 45 60/60 70/70

Rev. 03/16

Model

Numbe

(-)P20

24 21.53

36 22.34 [2.1] 1 4094 [1932] 169 [4791] 273 [124] 280 [127]

48 28.24

60 61.43 [5.7] 2 2947 [1391] 321 [9100] 355 [161] 362 [164]

Phase Frequency (Hz) Voltage (Volts)

Face Are

. Ft. [m

2.6

Rated Load

Amperes

(RLA)

Outdoor Coil Weight

No. Rows CFM [L*s] Circuit Oz. [g] Net Lbs. [kg] Shipping Lbs. [kg]

1 2770 [1307

1 2618 [1236

Locked

Rotor

Amperes

(LRA)

4375 [2065],

2078 [981]

4251 [2006]

1919 [906]

4994 [2357],

2057 [971]

6242 [2946]

1775 [838]

Maximum

Amperes

General Information

“L”

“W”

“H”

ALLOW 60” [1524mm]

OF CLEARANCE

AIR INLET LOUVERS ALLOW

6” [152mm] Min. OF CLEARANCE ALL SIDES

12” [305mm] RECCOMMENDED

SERVICE PANELS/

INLET CONNECTIONS / HIGH & LOW

VOLTAGE ACCESS

ALLOW 24” [ 610 mm] OF CLEARANCE

ST-A1226-02-00

GENERAL INFORMATION

R P 20 36 A J V C A

CAPACITY 24 = 24000 BTU/HR [7.03 kW] 36 = 36000 BTU/HR [10.55 kW] 48 = 48000 BTU/HR [14.07 kW] 60 = 60000 BTU/HR [17.58 kW]

TYPE V - INVERTER

VOLTAGE J = 1 PH, 208-230/60

MAJOR SERIES

MINOR SERIES

CONTROLS C - COMMUNICATING

General Information

20 SEER

HEAT PUMP

BRAND

ALLOW 60" [1524mm] OF

CLEARANCE

AIR INLET LOUVERS ALLOW 6" [152 mm] OF CLEARANCE ALL SIDES 12" [305 mm] RECOMMENDED

SERVICE PANELS/ INLET CONNECTIONS / HIGH & LOW VOLTAGE ACCESS ALLOW 24" [610 mm] OF CLEARANCE

Speciﬁ cations

GENERAL INFORMATION

DIMENSIONAL DATA

Height “H” inches (mm)

Length “L” inches (mm)

Width “W” inches (mm)

(-)P20

35.75 (908) 35.75 (908) 35.75 (908)35.75 (908)

35.75 (908)

Proper Installation

Proper sizing and installation of this equipment is critical to achieve optimal performance. Use the information in this Installation Instruction Manual and reference the applicable manufacturer’s specification sheet when installing this product.

IMPORTANT: This product has been

designed and manufactured to meet ENERGY STAR criteria for energy efficiency when matched with appropriate indoor components. However, proper refrigerant charge and proper airflow are critical to achieve rated capacity and efficiency. Installation of this product should follow the manufacturer’s refrigerant charging and airflow instructions. Failure to confirm proper charge

and airflow may reduce energy efficiency and shorten equipment life.

35 (889) 45 (1143) 51 (1295)51 (1295)

36 6048

35.75 (908)

MATCH ALL COMPONENTS:

• OUTDOOR UNIT

• INDOOR COIL

• INDOOR AIR HANDLER/FURNACE

• REFRIGERANT LINES

• INDOOR THERMOSTAT

35.75 (908)35.75 (908)

General Information

INSTALLATION

Choosing a Location

Location

IMPORTANT:

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

Consult local and

NOTICE: These units must be installed

outdoors. No ductwork can be attached, or other modifications made, to the discharge grille. Modifications will affect performance or operation.

Operational Issues

IMPORTANT: Locate the unit

in a manner that will not prevent, impair, or compromise the performance of other equipment installed in proximity to the unit. Maintain all required minimum distances to gas and electric meters, dryer vents, and exhaust and inlet openings. In the absence of national codes or manufacturers’ recommendations, local code recommendations and requirements will take precedence.

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

• Locate the unit where water runoff will not create a problem with the equipment. Position the unit away from the drip edge of the roof whenever possible. Units are weatherized, but can be affected by the following:

• Water pouring into the unit from the junction of rooflines, without protective guttering. Large volumes of water entering the heat pump while in operation can impact fan blade or motor life, and coil damage may occur to a heat pump if moisture cannot drain from the unit under freezing conditions.

• Freezing moisture or sleeting conditions can cause the cabinet to ice-over prematurely and prevent heat pump operation, requiring backup heat, which generally results in less economical operation.

• Closely follow the clearance recommendations on page 8.

• 24" [61.0 cm] to the service panel access

• 60" [152.4 cm] above heat pump fan discharge (unit top) to prevent recirculation

• 6" [15.2 cm] to heat pump coil grille air inlets with 12" [30.5 cm] minimum recommended

Corrosive Environment

The metal parts of this unit may be subject to rust or deterioration if exposed to a corrosive environment. This oxidation could shorten the equipment’s useful life.

Corrosive elements include, but are not limited to, salt spray, fog or mist in seacoast areas, sulphur or chlorine from lawn watering systems, and various chemical contaminants from industries such as paper mills and petroleum refineries.

If the unit is to be installed in an area where contaminants are likely to be a problem, special attention should be given to the equipment location and exposure.

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

• In coastal areas, locate the unit on the side of the building away from the waterfront.

• Shielding provided by a fence or shrubs may give some protection, but cannot violate minimum airflow and service access clearances.

• Elevating the unit off its slab or base enough to allow air circulation will help avoid holding water against the base pan.

WARNING: Disconnect all power

to unit before starting maintenance. Failure to do so can cause electrical shock resulting in severe personal injury or death.

Regular maintenance will reduce the buildup of contaminants and help to protect the unit’s finish.

• Frequent washing of the cabinet, fan blade, and coil with fresh water will remove most of the salt or other contaminants that build up on the unit.

• Regular cleaning and waxing of the cabinet with a good automobile polish will provide some protection.

• A good liquid cleaner may be used several times a year to remove matter that will not wash off with water.

Choosing a Location (cont.)

SERVICE PANELS/

INLET CONNECTIONS

/ HIGH & LOW

VOLTAGE ACCESS

ALLOW 24” [610 mm] OF

CLEARANCE

ALLOW 60” [1524 mm]

OF CLEARANCE

AIR INLET LOUVERS ALLOW

6” [152 mm] Min. OF

CLEARANCE ALL SIDES

12” [305 mm] RECOMMENDED

ST-A1226-04-00

6" MIN. (152 mm) FOR 1.5 & 2 TON 9" MIN. (229 mm) FOR 2.5-5 TON 24" MIN. (610 mm)

ST-A1226-03-00

ELEVATE ABOVE

ANTICIPATE HIGH

SNOW FALL

DO NOT BLOCK

OPENINGS

IN BASE PAN

BASE PAD

(CONCRETE OR OTHER SUITABLE

MATERIAL)

INSTALLATION

For Units With Space Limitations

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

Single-Unit Applications: Clearances below 6" [15.2 cm] will reduce unit capacity and efficiency. Do not reduce the 60" [152.4 cm] discharge or the 24" [61.0 cm] service clearances.

Multiple-Unit Applications: When multiple condenser grille sides are aligned, a 6" [15.2 cm] clearance is recommended for 1.5 and 2 ton models and 9" [22.9 cm] for 2.5 ton to 5 ton models. Two combined clearances below the minimum will reduce capacity and efficiency. Do not reduce the 60" [152.4 cm] discharge or 24" [61.0 cm] service clearances.

• If elevating a unit on a flat roof, use 4" x 4" [10.2 cm x 10.2 cm] or equivalent stringers positioned to distribute unit weight evenly and prevent noise and vibration.

• Where snowfall is anticipated, raise the unit above the base pad to prevent ice buildup and coil damage. Mount the unit high enough to be above the average accumulated area snowfall. See “Ground Snow Depth” chart on page 10 for representative snow depths.

NOTICE: Do not block drain openings on

bottom of unit.

• If unit must be elevated because of anticipated snowfall, secure unit and elevating stand such that unit and/or stand will not tip over or fall off. Keep in mind that someone may try to climb on unit.

Customer Satisfaction Issues

• The heat pump should be located away from the living, sleeping, and recreational spaces of the owner and those spaces on adjoining property.

• To prevent noise transmission, the mounting pad for the outdoor unit should not be connected to the structure and should be located a sufficient distance above grade to prevent ground water from entering the unit.

Unit Mounting

WARNING: Secure an elevated unit

and its elevating stand in order to prevent tipping. Failure to do so may result in severe personal injury or death.

Elevation of Unit

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

Location

Factory-Preferred Tie-Down Method for High Wind or Seismic Loads

IMPORTANT: The manufacturer-

approved/recommended method is a guide to securing equipment for wind and seismic loads. Other methods might provide the same result, but the manufacturer method is the only one endorsed by the manufacturer for securing equipment where wind or earthquake damage can occur. Additional information is available in the PTS (Product Technical Support) section of the manufacturer’s Web sites MyRheem.com, or MyRuud.com and can be found as a listing under each outdoor model. If you do not have access to this site, your distributor can offer assistance.

INSTALLATION

Choosing a Location (cont.)

ALABAMA INDIANA MINNESOTA NEW MEXICO PENNSYLVANIA VIRGINIA

Huntsville 7 Evansville 12 Duluth 64 Albuquerque 4 Allentown 23 Dulles Airport 19

ARIZONA

Flagstaff 48 Indianapolis 21

Prescott 3 South Bend 44 Rochester 50

Winslow 7

ARKANSAS

Ft. Smith 5 Des Moines 22 Jackson 3 Buffalo 42 Williamsport 20

Little Rock 6 Dubuque 38 MISSOURI

CALIFORNIA

Blue Canyon 25 Waterloo 36 Kansas City 18 Rochester 38

Mt. Shasta 69

COLORADO

Alamosa 15 Dodge City 12

Colorado Springs 14 Goodland 14 Billings 17 Cape Hattaras 5 Aberdeen 42

Denver 15 Topeka 19 Glasgow 17 Charlotte 10 Huron 43 Beckley 51

Grand Junction 16 Wichita 11 Great Falls 16 Greensboro 11 Rapid City 14 Charleston 20

Pueblo 7

CONNECTICUT

Bridgeport 23 Lexington 12 Kalispell 53 Winston-Salem 17 Bristol 8

Hartford 29 Louisville 11 Missoula 23

New Haven 15

DELAWARE

Wilmington 13 Portland 62 Lincoln 20 Williston 25 Nashville 8 Milwaukee 32

GEORGIA MARYLAND

Location

Athens 5 Baltimore 17 North Platte 15 Akron-Canton 15 Abilene 6 Casper 10

Macon 8

IDAHO

Boise 6 Nantucket 18 Valentine 22 Dayton 11 El Paso 5 Sheridan 25

Lewiston 9 Worcester 35

0 Pocatello 7

ILLINOIS

Chicago O’Hare 18 Detroit City 9 Reno 11

Chicago 22 Detroit Airport 17 Winnemucca 6 Oklahoma City 5 Wichita Falls 5

Moline 17

Peoria 16 Flint 28 Concord 66

Rockford 25 Grand Rapids 37

Springﬁ eld 23 Houghton Lake 56 Atlantic City 11 Eugene 17 Wendover 3

NOTICE:

Local records and experience must be considered when establishing the unit installation height. There is a 2% probability that the ground snow depth shown in this table will be exceeded annually. Drifts have not been considered. This data represents 184 National Weather Service locations at which measurements are made and assumes a nationwide snow density of 12 lb./ft.

Fort Wayne 17 International Falls 43 Clayton 10 Erie 19 Lynchburg 16

IOWA

Burlington 17

Sioux City 33 Columbia 21

KANSAS

Concordia 23 Springﬁ eld 14

KENTUCKY

Covington 12 Helena 18 Wilmington 9

MAINE NEBRASKA

Caribou 100 Grand Island 30 Fargo 34 Memphis 5 Madison 32

MASSACHUSETTS

Boston 30 Scottsbluff 11 Columbus 10 Dallas 3 Lander 20

MICHIGAN

Alpena 53 Ely 9 Youngstown 12 Midland 2

Detroit – Willow Run

Lansing 42 Newark 15 Medford 8

Marquette 53 Pendleton 11 Burlington 37

Muskegon 43 Portland 10

Sault Ste. Marie 80 Salem 7

GROUND SNOW DEPTH – INCHES

Minneapolis/St. Paul

St. Cloud 53 Albany 25 Pittsburgh 22 Richmond 12

MISSISSIPPI

St. Louis 16 Syracuse 35 Columbia 12 Spokane 41

MONTANA

Havre 24 Raleigh-Durham 10 Sioux Falls 38 Elkins 21

Norfolk 29

Omaha 20 Cleveland 16 Amarillo 10 Cheyenne 15

NEVADA

Elko 20 Toledo Express 8 Lubbock 10

NEW HAMPSHIRE

NEW JERSEY

50 Roswell 8 Harrisburg 23 National Airport 18

NEW YORK

Binghamton 35 Scranton 16 Roanoke 17

NYC – Kennedy Airport 18

NYC – LaGuardia Airport 18

NORTH CAROLINA

Asheville 12

NORTH DAKOTA

Bismarck 25 Knoxville 8 La Crosse 32

OHIO TEXAS WYOMING

Mansﬁ eld 17 Fort Worth 6

OKLAHOMA

Tulsa 8

OREGON

Burns City 24 Salt Lake City 8

Philadelphia 16 Norfolk 9

WASHINGTON

RHODE ISLAND

Providence 21 Quillayute 24

SOUTH CAROLINA

Greenville 4 Stampede Pass 51

SOUTH DAKOTA

TENNESSEE

Chattanooga 6 Green Bay 36

San Antonio 3

UTAH

Milford 16

VERMONT

Olympia 24

Seattle-Tacoma 14

Yakima 25

WEST VIRGINIA

Huntington 15

WISCONSIN

Tools and Refrigerant

Ambient and Tube

Thermometers

Manifold

Gauge

Set

Brazing

Rods

Torch Nitrogen

Reclaimer

Recovery Cylinders

Allen Wrench

Crescent Wrench

INSTALLATION

Tools Required for Installing and Servicing R-410A Models

Manifold Sets: – Up to 800 PSIG High-Side – Up to 250 PSIG Low-Side – 550 PSIG Low-Side Retard Manifold Hoses: – Service Pressure Rating of 800 PSIG Recovery Cylinders: – 400 PSIG Pressure Rating – Dept. of Transportation 4BA400 or BW400

CAUTION: R-410A systems operate

at higher pressures than R-22 systems. Do not use R-22 service equipment or components on R-410A equipment.

Specifications of R-410A

Application: R-410A is not a drop-in replacement for R-22. Equipment designs must

accommodate its higher pressures. It cannot be retrofitted into R-22 heat pumps.

Physical Properties: R-410A has an atmospheric boiling point of -62.9°F [-52.7°C] and its saturation pressure at 77°F [25°C] is 224.5 psig.

Composition: R-410A is a near-azeotropic mixture of 50% by weight difluoromethane (HFC-

32) and 50% by weight pentafluoroethane (HFC-

125).

Pressure: The pressure of R-410A is approximately 60% (1.6 times) greater than R-22. Recovery and recycle equipment, pumps,

hoses, and the like must have design pressure ratings appropriate for R-410A. Manifold sets

need to range up to 800 psig high-side and 250 psig low-side with a 550 psig low-side retard. Hoses need to have a service pressure rating of 800 psig. Recovery cylinders need to have a 400 psig service pressure rating, DOT 4BA400 or DOT BW400.

Combustibility: At pressures above 1 atmosphere, a mixture of R-410A and air can become combustible. R-410A and air should

never be mixed in tanks or supply lines or be allowed to accumulate in storage tanks. Leak checking should never be done with a mixture of R-410A and air. Leak-checking can

be performed safely with nitrogen or a mixture of R-410A and nitrogen.

Quick-Reference Guide For R-410A

• R-410A refrigerant operates at approximately 60% higher pressure (1.6 times) than R-22. Ensure that servicing equipment is designed to operate with R-410A.

• R-410A refrigerant cylinders are light rose in color.

• R-410A, as with other HFCs, is only compatible with POE oils.

• Vacuum pumps will not remove moisture from POE oil used in R-410A systems.

• R-410A systems are to be charged with liquid refrigerants. Prior to March 1999, R-410A refrigerant cylinders had a dip tube. These cylinders should be kept upright for equipment charging. Post-March 1999 cylinders do not have a dip tube and should be inverted to ensure liquid charging of the equipment.

• Do not install a suction line filter drier in the liquid line.

• A factory-approved biflow liquid line filter drier is shipped with every unit and must be installed in the liquid line at the time of installation. Only manufacturer-approved liquid line filter driers can be used. These are Sporlan (CW083S) and Alco (80K083S) driers. These filter driers are rated for minimum working pressure of 600 psig. The filter drier will only have adequate moisture-holding capacity if the system is properly evacuated.

• Desiccant (drying agent) must be compatible for POE oils and R-410A refrigerant.

Tools

INSTALLATION

Replacement Units

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

Indoor Coil

CAUTION: Only use evaporators

approved for use on R-410A systems that are specifically matched with the outdoor unit per the manufacturer’s specification sheets. Use of existing R-22 evaporators can introduce mineral oil to the R-410A refrigerant, forming two different liquids and decreasing oil return to the compressor. This can result in compressor failure.

REFER TO INDOOR COIL MANUFACTURER’S INSTALLATION INSTRUCTIONS.

IMPORTANT: The manufacturer is not

responsible for the performance and operation of a mismatched system or for a match listed with another manufacturer’s coil.

NOTICE: All outdoor units must be

installed with a matched TXV indoor coil. Refer to manufacturer’s outdoor unit specification sheet for approved indoor coils.

IMPORTANT: When replacing an

R-22 unit with an R-410A unit, either replace the line set or ensure that residual mineral oil is drained from existing lines including oil trapped in low spots.

The thermostatic expansion valve in the matching coil is specifically designed to operate with R-410A. DO NOT use an R-22 TXV or

evaporator. The existing evaporator must be replaced with the factory-specified EXV evaporator specifically designed for R-410A.

Location

Do not install the indoor coil in the return duct system of a gas or oil furnace. Provide a service inlet to the coil for inspection and cleaning. Keep the coil pitched toward the drain connection.

CAUTION: When coil is installed

over a finished ceiling and/or living area, it is required that a secondary condensate pan be installed under entire unit. Failure to do so can result in property damage.

Tubing

Interconnecting Tubing

The purpose of this section is to specify the best construction/sizing practices for installing interconnection tubing between the indoor and outdoor unit.

Refrigerant Level Adjustment

All units are factory-charged with R-410A refrigerant to cover 15 feet of standard size interconnecting liquid and vapor lines, not including the required liquid line filter drier. Refrigerant must be added for the filter/drier. Adjustment of charge may be necessary even if the application has exactly 15 feet of line set due to other installation variables such as pressure drop, vertical lift, and indoor coil size. For different lengths, adjust the charge as indicated below.

• 1/4" ± .3 oz./foot [6.4 mm ± 8.5 g/.30 m]

• 5/16" ± .4 oz./foot [7.9 mm ± 11.3 g/.30 m]

• 3/8" ± .6 oz./foot [9.5 mm ± 17.0 g/.30 m]

• 1/2" ± 1.2 oz./foot [12.7 mm ± 34.0 g/.30 m]

• 6 oz. required factory supplied field-installed

• filter drier.

Charge Adjustment = (Line Set (oz./ft.) x Total Length) – Factory Charge for Line Set

Example: A three ton heat pump unit with factory

installed 3/8” liquid service valve requires 75 ft. of line set with a liquid line diameter of 1/2”.

Factory Charge for Line Set = 15 ft. x .6 oz. = 9 oz. Charge Adjustment = (1.2 oz. x 75 ft.) – 9 oz. =

+ 81 oz.

Interconnecting Tubing (cont.)

INSTALLATION

Interconnecting Tubing and Fitting Losses

Refrigerant tubing is measured in terms of actual length and equivalent length. Actual length is used for refrigerant charge applications. Equivalent length takes into account pressure losses from

Equivalent Length for Fings ()

90° Short

Line Size

(in)

3/8 1.3 0.8 0.3 6 4 0.4 6 1/2 1.4 0.9 0.4 9 5 0.6 6 5/8 1.5 1 0.5 12 6 0.8 6 3/4 1.9 1.3 0.6 14 7 0.9 6 7/8 2.3 1.5 0.7 15 8 1 6

1-1/8 2.7 1.8 0.9 22 12 1.5 6

Radius

Elbow

90° Long

Radius Elbow

45°

Elbow

Liquid Line Selection

The purpose of the liquid line is to transport warm sub-cooled liquid refrigerant from the outdoor unit to the indoor unit in cooling mode. In heating mode the liquid line returns sub-cooled liquid from the indoor unit to the outdoor unit. It is important not to allow the refrigerant to ﬂ ash any superheated vapor prior to the expansion device of the indoor coil. The ﬂ ashing of refrigerant can occur for the follow- ing reasons:

• Low refrigerant charge

• Improperly selected liquid line size

• Absorption of heat prior to expansion device

• Excessive vertical rise between the condenser and evaporator

Table 2 lists the equivalent length per 25’ of liquid

tubing length, ﬁ ttings, vertical separation, acces- sories, and ﬁ lter dryers. The table below references diﬀ erent commonly used equivalent lengths.

Table 1

Solenoid

Valve

line at various diameters up to 300’. The total pressure drop allowed for the liquid line is 50 PSI. The procedure for selecting the proper liquid line is as follows:

• Measure the total amount of vertical rise

• Measure the total amount of liquid line needed

• Add all of the equivalent lengths associated with any ﬁ ttings or accessories using the table above.

• Add the total length and ﬁ tting pressure drop. This will equal your total equivalent length.

• Round-down the total equivalent length to the closest value in Table 2.

• Reference Table 2 to verify the rounded-down value of the calculated equivalent length is compatible with the required vertical rise and diameter of liquid line.

Check

Valve

Site

Glass

Filter

Dryer

Note: Elevaon is deﬁned as the

highest point of the line set to the

lowest

Tubing

INSTALLATION

Interconnecting Tubing (cont.)

Example: A 3-Ton heat pump unit is installed 50’ below the ID unit, requires a 75’ of 1/2” diameter liquid line, and 4 90° LR elbows.

• Fitting Equivalent Length (ft.) = 4 x .9 = 3.6’

• Total Equivalent Length (ft.) = 75’ + 3.6’ = 78.6’

• Rounded-down value (ft.) = 75’

Liquid Line

R-410A System

Capacit y

Model

(Exerpt from Table 2, page 17)

Size

Connection

Size (Inch I.D.) [mm]

37 3/8" [9. 53]

Liquid Line

Size (Inch

O.D.) [mm]

1/4 [6.35] 25 [7.62]

5/16 [7.94] 25 [7.62] 50 [15.24] 60 [18.29] 45 [13.72] 35 [10.67] 20 [6. 1] 5 [1.52]

3/8 [9.53] 25 [7.62] 50 [15.24] 75 [22.86] 80 [24.38] 80 [24.38] 75 [22. 86] 70 [ 21.34] 65 [19.81] 60 [18.29] 55 [16.76] 50 [15.24] 45 [13.72]

7/16 [11.12] 25 [7. 62] 50 [15.24] 75 [22.86] 95 [28.96] 90 [27.43] 90 [27.43] 85 [25.91] 85 [25.91] 85 [25.91] 80 [24.38] 80 [24. 38] 80 [24.38]

1/2 [12.71] 25 [7.62] 50 [15.24] 75 [22.86] 95 [28.96] 95 [28.96] 95 [28.96] 95 [28.96] 95 [28.96] 95 [28.96] 90 [27.43] 90 [27.43] 90 [27.43]

25 [7.62] 50 [15.24] 75 [22.86] 100 [30.48] 125 [45. 72] 150 [ 45.72] 175 [53.34] 200 [60.96] 225 [68. 58] 250 [ 76.20] 275 [83.82] 300 [91.44]

N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R

Long Line Set Applications

Long line set applications are deﬁ ned as applica- tions that require accessories or alternate construction methods. The following are special considerations that need to be addressed when installing a long line set application:

• Additional refrigerant charge

• Fitting losses and maximum equivalent length considerations

• Refrigerant migration during the oﬀ cycle

• Oil return to the compressor

• Capacity losses

• System oil level adjustment

This application is acceptable because the 50’ vertical rise is less than the maximum rise of 75’ for this application. The application is also considered to have a long line set. Reference the long line set section of the I&O for detail.

Liquid Line S ize

Elevation (Above or Below) Indoor Coil

Tot al

Maximum

Length - Feet [ m]

Equi val ent

Vertic al Separation - Feet [m ]

OD Model

(-)P2024

(-)P2036

(-)P2048

(-)P2060

N/R N/R N/R N/R N/R

Compressor

Nameplate Oil

Charge (oz)

ZPV0212E-ZE9-130 40

ZPV0342E-ZE9-130 40

ZPV038CE-2E9-130 40

Table 2 is used to determine if the application is considered to have a long line set. The region of

the chart that is shaded grey is considered to be a long line set application.

Oil Level Adjustments for Long Line Set Applications

Additional oil will need to be added for long line set applications. (Ref. Table 2). Below is the equation for the oil level adjustment and the compressor name plate oil charge for the diﬀ erent od units.

Oil to be Added = [(Charge Adjustment + OD Unit Name Plate Charge (oz.)) x (0.022) – [(0.10) x (Compressor Name Plate Oil Charge (oz.))]

Example: An application requires 125ft of line set

with a liquid line diameter of 3/8”, Charge Adjustment = 52.4 oz., Name Plate Charge = 107 oz.,

Tubing

Name Plate Oil Charge = 25 oz., Oil to be Added = ((52.4 oz. +107 oz.) x .022) – (.10 x 25 oz.) = 1.0 oz.

Interconnecting Tubing (cont.)

INSTALLATION

Suction Line Selection

Purpose of the suction line is to return superheated vapor to the condensing unit from the evaporator in cooling mode. While in heating mode the suction line transports discharge vapor to the indoor unit from the outdoor unit. Proper suction line sizing is important because it plays an important role in returning oil to the compressor to prevent potential damage to the bearings, valves, and scroll sets. Also, an improperly sized suction line can dramatically reduce capacity and performance of the system. The procedure for selecting the proper suction line is as follows:

• The total amount of suction line needed

• Add all of the equivalent lengths associated with any ﬁ ttings or accessories using the table on previous page.

• Add the total length and ﬁ tting pressure drop. This will equal your total equivalent length.

• Reference Table 2 to verify that the calculated equivalent length falls within the compatibility region of the chart.

• Verify Table 3 to verify the capacity diﬀ erence is compatible with the application.

Outdoor Unit Level or Near Level to Indoor Section Line Set

Refrigerant Migration During Off Cycle

Long line set applications can require a considerable amount of additional refrigerant. This additional refrigerant needs to be managed throughout the entire ambient operating envelope that the system will go through during its life cycle. Oﬀ -Cycle mi- gration is where excess refrigerant condenses and migrates to the lowest part of the system. Excessive build-up of refrigerant at the compressor will result in poor reliability and noisy operation during startup. This section demonstrates the required accessories and unit conﬁ guration for diﬀ erent ap- plications.

REFERENCE TABLE 2 FOR

MAXIMUM LENGTH LIMITATIONS

IDEALLY, LINE SET SLOPES AWAY

SUB-COOLING PRIOR TO

THROTTLEING DEVICE, INSULATED

FROM OUTDOOR. VERIFY

LIQUID LINE.

ST-A1219-01-01

Tubing

INSTALLATION

Interconnecting Tubing (cont.)

For applications that are considered to have a long line set with the outdoor unit and indoor unit on the same level the following is required:

• EXV on the indoor unit (standard equipment)

• Insulated liquid and suction line in unconditioned space only.

Outdoor Unit Below Indoor Section Line Set

INSULATE LIQUID

AND SUCTION

LINE

• Vapor line should slope toward the indoor unit

• Follow the proper line sizing, equivalent length, charging requirements, and oil level adjustments spelled out in this document

• Verify at least 5°F sub-cooling at the ID unit prior to throttling device

INVERT TRAP

EVEN WITH TOP

OF THE COIL

REFERENCE TABLE 2 FOR

MAXIMUM LENGTH LIMITATIONS

Tubing

For applications that are considered to have a long line set with the outdoor unit below the indoor unit the following is required:

• EXV at the IDunit (standard equipment)

• Inverted vapor-line trap (Reference Figure 3)

• Insulated liquid and suction line in unconditioned space only.

ST-A1219-02-01

Figure 4

• Follow the proper line sizing, equivalent length, charging requirements, and oil level adjustments spelled out in this document

• Measure pressure at the liquid line service valve and prior to expansion device. Verify that it is not greater than 50 PSI

• For elevations greater that 25’ can expect a lower sub-cooling

Interconnecting Tubing (cont.)

Outdoor Unit Above Indoor Unit

INSTALLATION

Verify sub-cooling prior to throlin

device

Insulated liquid and sucon line

TXV or EEV at indoor eva

Figure 5

Reference Table 2

for elevaon

limitaons

orator

For applications that are considered to have a long line set with the outdoor unit above the indoor unit the following is required:

• EXV at the indoor unit (standard equipment)

• Insulated liquid and suction line in unconditioned space only.

• Follow the proper line sizing, equivalent length, charging requirements, and oil level adjustments spelled out in this document

• Verify at least 5°F sub-cooling at the ID unit prior to throttling device

Tubing

Grey = This application is acceptable, but the long line guidelines must be followed. Reference Long Line Set section in the I&O.

NOTES:

N/R = Application not recommended.

RP2060A 3/8" [9.53]

RP2048A 3/8" [9.53]

RP2036A 3/8" [9.53]

3/8" [9.53]RP2024A

Capacity

R-410A

System

Model

Size (Inch I.D.)

Connection

Liquid Line

[mm]

Interconnecting Tubing

INSTALLATION

1/2 [12.71] 25 [7.62] 50 [15.24] 75 [22.86] 80 [24.38] 75 [22.86] 75 [22.86] 75 [22.86] 70 [21.34] 70 [21.34] 65 [19.81] 65 [19.81] 65 [19.81]

7/16 [11.12] 25 [7.62] 50 [15.24] 75 [22.86] 70 [21.34] 65 [19.81] 65 [19.81] 60 [18.29] 55 [16.76] 50 [15.24] 50 [15.24] 45 [13.72] 40 [12.19]

3/8 [9.53] 25 [7.62] 50 [15.24] 60 [18.29] 50 [15.24] 40 [12.19] 30 [9.14] 25 [7.62] 15 [4.57] 5 [1.52] N/R N/R N/R

5/16 [7.94] 25 [7.62] 35 [10.67] 10 [3.05] N/R N/R N/R N/R N/R N/R N/R N/R N/R

5/16 [7.94] 25 [7.62] 50 [15.24] 50 [15.24] 40 [12.19] 30 [9.14] 15 [4.57] N/R N/R N/R N/R N/R N/R

1/2 [12.71] 25 [7.62] 50 [15.24] 75 [22.86] 100 [30.48] 100 [30.48] 100 [30.48] 100 [30.48] 100 [30.48] 100 [30.48] 100 [30.48] 100 [30.48] 100 [30.48]

1/4 [6.35] 25 [7.62] N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R

7/16 [11.12] 25 [7.62] 50 [15.24] 75 [22.86] 100 [30.48] 100 [30.48] 95 [28.96] 95 [28.96] 95 [28.96] 95 [28.96] 95 [28.96] 95 [28.96] 90 [27.43]

3/8 [9.53] 25 [7.62] 50 [15.24] 75 [22.86] 95 [28.96] 90 [27.43] 90 [27.43] 85 [25.91] 85 [25.91] 85 [25.91] 80 [24.38] 80 [24.38] 75 [22.86]

5/16 [7.94] 25 [7.62] 50 [15.24] 75 [22.86] 75 [22.86] 70 [21.34] 65 [19.81] 60 [18.29] 50 [15.24] 45 [13.72] 40 [12.19] 30 [9.14] 25 [7.62]

O.D.) [mm]

1/4 [6.35] 25 [7.62] 50 [15.24] 25 [7.62] N/R N/R N/R N/R N/R N/R N/R N/R N/R

Liquid Line

Size (Inch

25 [7.62] 50 [15.24] 75 [22.86] 100 [30.48] 125 [45.72] 150 [45.72] 175 [53.34] 200 [60.96] 225 [68.58] 250 [76.20] 275 [83.82] 300 [91.44]

Maximum Vertical Separation - Feet [m]

Elevation Above or Below Indoor Coil

Total Equivalent Length - Feet [m]

Liquid Line Size

7/16 [11.12] 25 [7.62] 50 [15.24] 75 [22.86] 80 [24.38] 75 [22.86] 75 [22.86] 70 [21.34] 65 [19.81] 65 [19.81] 60 [18.29] 60 [18.29] 55 [16.76]

1/2 [12.71] 25 [7.62] 50 [15.24] 75 [22.86] 85 [25.91] 85 [25.91] 80 [24.38] 80 [24.38] 80 [24.38] 80 [24.38] 75 [22.86] 75 [22.86] 75 [22.86]

3/8 [9.53] 25 [7.62] 50 [15.24] 70 [21.34] 65 [19.81] 55 [16.76] 50 [15.24] 45 [13.72] 35 [10.67] 30 [9.14] 25 [7.62] 15 [4.57] 10 [3.05]

1/4 [6.35] N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R

7/16 [11.12] 25 [7.62] 50 [15.24] 75 [22.86] 80 [24.38] 80 [24.38] 80 [24.38] 75 [22.86] 75 [22.86] 70 [21.34] 70 [21.34] 70 [21.34] 65 [19.81]

5/16 [7.94] 25 [7.62] 50 [15.24] 30 [9.14] 10 [3.05] N/R N/R N/R N/R N/R N/R N/R N/R

1/2 [12.71] 25 [7.62] 50 [15.24] 75 [22.86] 85 [25.91] 85 [25.91] 85 [25.91] 80 [24.38] 80 [24.38] 80 [24.38] 80 [24.38] 80 [24.38] 80 [24.38]

3/8 [9.53] 25 [7.62] 50 [15.24] 75 [22.86] 70 [21.34] 65 [19.81] 65 [19.81] 60 [18.29] 55 [16.76] 50 [15.24] 45 [13.72] 45 [13.72] 40 [12.19]

1/4 [6.35] 10 [3.05] N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R

Tubing

RN/R

All calculations accume a 3/8" liquid line

NOTES:

N/R = Application not recommended.

RP2060A 3/4" [19.06]

RP2048A 3/4" [19.06]

RP2036A 3/4" [19.06]

RP2024A

3/4" [19.06]

Capacity

R-410A

System

Model

Connection Size

(Inch I.D.) [mm]

Vapor Line

Interconnecting Tubing (cont.)

INSTALLATION

7/8 [22.23] 1.00 0.99 0.99 0.98 0.97 0.97 0.96 0.95 0.95 N/R N/R N/R

3/4 [19.05] 0.97 0.93 0.9 0.86 0.84 0.82 0.81 0.8 0.8 N/R N/R N/R

5/8 [15.88] 0.99 0.98 0.96 0.95 0.94 0.92 0.91 0.9 0.89 N/R N/R N/R

1-1/8 [28.58] N/

1 [25.4] N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R

1-1/8 [28.58] N/

1 [25.4] N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R

7/8 [22.23] 1.00 0.99 0.98 0.97 0.97 0.97 0.96 0.96 0.95 0.95 0.95 0.94

3/4 [19.05] 0.96 0.94 0.91 0.89 0.86 0.84 0.82 0.82 0.81 0.81 0.8 0.81

5/8 [15.88] 0.99 0.97 0.97 0.96 0.95 0.93 0.93 0.92 0.91 0.9 0.89 0.88

1-1/8 [28.58] N/

1 [25.4] N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R

7/8 [22.23] 1.00 1.01 1.01 0.99 0.99 0.99 0.98 0.98 0.98 0.98 0.97 0.97

3/4 [19.05] 1.00 0.99 0.98 0.98 0.97 0.97 0.96 0.95 0.95 0.94 0.93 0.93

5/8 [15.88] 0.98 0.97 0.95 0.93 0.92 0.9 0.89 0.87 0.86 0.85 0.84 0.84

1-1/8 [28.58] N/

5/8 [15.88] 0.99 0.99 0.97 0.96 0.95 0.94 0.93 0.92 0.91 0.91 0.89 0.89

3/4 [19.05] 1.00 1.00 0.99 0.99 0.99 0.98 0.97 0.97 0.96 0.96 0.96 0.95

7/8 [22.23] N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R

1 [25.4] N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R

O.D.) [mm]

Vapor Line

Size (Inch

25 [7.62] 50 [15.24] 75 [22.86] 100 [30.48] 125 [45.72] 150 [45.72] 175 [53.34] 200 [60.96] 225 [68.58] 250 [76.20] 275 [83.82] 300 [91.44]

Total Equivalent Length - Feet [m]

Vapor Line Selection Chart

Capacity Multiplier Table

Tubing

INSTALLATION

Interconnecting Tubing (cont.)

Tubing Installation

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

• Check the tables on pages 18 and 19 for the correct suction line size and liquid line size.

• If a portion of the liquid line passes through a

very hot area where liquid refrigerant can be heated to form vapor, insulating the liquid line is required.

• Use clean, dehydrated, sealed refrigerationgrade tubing.

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

• A high-quality biflow filter drier is included with all R-410A heat pump units and must be installed in the liquid line upon unit installation.

• When replacing an R-22 system with an R-410A system and the line set is not replaced, use a flush kit available through aftermarket stores such as Prostock.

• If tubing has been cut, make sure ends are

• For best operation, keep tubing run as short as

• Locations where the tubing will be exposed to

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

possible with a minimum number of elbows or bends.

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

Tubing

INSTALLATION

TEMPORARY

HANGER

PERMANENT

HANGER

ST-A1226-05-00

Interconnecting Tubing

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

• Use care in routing tubing and do not kink or twist. Use a good tubing bender on the vapor line to prevent kinking.

• Route the tubing using temporary hangers; then straighten the tubing and install permanent hangers. Line must be adequately supported.

• If the vapor line comes in contact with inside walls, ceiling, or flooring, the vibration of the vapor line in the heating mode will result in noise inside the structure.

(cont.)

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

Remove the caps and Schrader cores from the

• pressure ports to protect seals from heat damage. Both the Schrader valves and the service valves have seals that may be damaged by excessive heat.

• Blow out the liquid and vapor lines with dry nitrogen before connecting to the outdoor unit and indoor coil. Any debris in the line set will end up plugging the expansion device.

Tubing Connections

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

• Use type “L” copper refrigeration tubing. Braze the connections with the following alloys:

– copper to copper, 5% silver minimum – copper to steel or brass, 15% silver minimum

•

Clean the inside of the fittings and outside of the tubing with a clean, dry cloth before soldering. Clean out debris, chips, dirt, etc., that enters tubing or service valve connections.

•

Wrap valves with a wet rag or thermal barrier compound before applying heat.

Tubing

INSTALLATION

ST-A1226-07-00

ST-A1226-06-00

Interconnecting Tubing

•

Braze the tubing between the outdoor unit and

indoor coil. Flow dry nitrogen into a pressure port and through the tubing while brazing, but do not allow pressure inside tubing which can result in leaks. Once the system is full of nitrogen, the nitrogen regulator should be turned off to avoid pressuring the system.

(cont.)

The variable speed inverter driven heat pumps are equipped with OD EXVs and matched to ID units that are also equipped with EXVs. During shipment, vibration has been found to move the EXV stem valve to a near closed position despite being set to a fully open position in the factory. Prior to leak testing it is recommended to apply 24VAC low voltage power to the ID and outdoor units making sure there is no call for operation by disconnecting the EcoNet™ control center or two stage legacy thermostat. By doing this, each control will immediately close their respective EXVs followed immediately by opening them to the wide open position, therefore, permitting free flow of nitrogen through the system.

Tubing

• A

fter brazing, use an appropriate heatsink material

to cool the joint.

• Reinstall the Schrader cores into both pressure ports.

• Do not allow the vapor line and liquid line to be in contact with each other. This causes an undesirable heat transfer resulting in capacity loss and increased power consumption.

Leak Testing

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

WARNING: Do not use oxygen

to purge lines or pressurize system for leak test. Oxygen reacts violently with oil, which can cause an explosion resulting in severe personal injury or death.

Pressurize line set and coil through service fittings

• with dry nitrogen to 150 PSIG maximum. Close nitrogen tank valve, let system sit for at least 15 minutes, and check to see if the pressure has dropped. If the pressure has dropped, check for leaks at the line set braze joints with soap bubbles and repair leak as necessary. Repeat pressure test. If line set and coil hold pressure, proceed with line set and coil evacuation (see page 21).

• The vapor line must be insulated for its entire length to prevent dripping (sweating) and prevent performance losses. Closed-cell foam insulation such as Armaflex and Rubatex® are satisfactory insulations for this purpose. Use 1/2" [12.7 mm] minimum insulation thickness. Additional insulation may be required for long runs.

Control Wiring

WARNING: Tu rn oﬀ electric power

at the fuse box or service panel before making any electrical connections. Also, the ground connection must be completed before making line voltage connections. Failure to do so can result in electrical shock, severe personal injury, or death.

EcoNet™ Control Communications

The EcoNet™ enabled (-)P20 series of heat pumps are designed to operate with conventional 24VAC Thermostat or an EcoNet™ communicating control center. If the (-)P20 outdoor unit is installed with a conventional 24VAC Thermostat some features and comfort settings will not be available.

Control Wiring

Running low-voltage wires in conduit with line voltage power wires is not recommended. Lowvoltage wiring may be run through the insulated bushing provided in the 7/8" [19 mm] hole in the base panel, up to and attached to the pigtails from the bottom of the control box. Conduit can be run to the base panel if desired by removing the insulated bushing.

A thermostat and a 24-volt, 40 VA minimum transformer are required for the control circuit of the system. The furnace or the air handler transformer may be used if sufficient. See the wiring diagram for reference. Use “Wire Size” table on page 23 to size the 24-volt control wiring.

FIELD WIRE SIZE FOR 24-VOLT THERMOSTAT CIRCUITS

Thermostat Load (amps)

3.0

2.5

2.0

(1) Wire length equals twice the run distance. NOTICE: Do not use control wiring smaller than No. 18

AWG between thermostat and outdoor unit.

EcoNet™ Control Board Communication Wiring

The four 18 AWG low-voltage control wires must be installed from the control center to the indoor unit and from the indoor unit to the outdoor unit. The wire length between the control center and indoor unit should not be greater than 100 feet [30.5 m].

SOLID COPPER WIRE – AWG

16 14 12 10 10 10 16 14 12 10 10 10 16 14 12 10 10 10

50 100 150 200 250 300 [15] [30] [46] [61] [76] [91] Length of Run – Feet [m] (1)

WIRING

Wiring

The wire length between the indoor unit and outdoor unit should not be greater than 125 feet [38.1 m].

An EcoNet™ communicating HVAC system consists of these matched components:

• EcoNet™ communicating heat pump or

EcoNet™ communicating condensing unit.

• EcoNet™ communicating air handler or

EcoNet™ communicating furnace.

• EcoNet™ control center.

IMPORTANT: If the installed system

does not meet these requirements, the system must be wired using traditional control wiring. See “Conventional 24 VAC Thermostat Control Wiring” on page 24.

Do not use phone cord to connect indoor and outdoor units. This will damage the controls.

IMPORTANT: EcoNet™ require

systems continuous 18 AWG thermostat wire. The EcoNet™ Control requires four (4) control

wires for unit operation:

• R 24 VAC

• C 24 VAC common

• Data wire E1 Communications

• Data wire E2 Communications

Air Handler Air Conditioner or Furnace or Heat Pump Control Center Indoor Outdoor

E1 – – – – – – – – – – – E1– – – – – – – – – E1 E2 – – – – – – – – – – – E2 – – – – – – – – E2 R – – – – – – – – – – – – R – – – – – – – – – R C – – – – – – – – – – – – C – – – – – – – – – C

These wires need to be connected to each device control center, indoor air handler or furnace, and outdoor unit (heat pump or AC).

Once all devices are connected, apply the line and low voltage to the system.

When all devices are powered, the control center should detect the indoor and outdoor units within 45 seconds.

Once the system is powered, the airflow settings will be configured for all devices.

+ 53 hidden pages