Rheem PNL-*AZ Series, PPL-JAZ Series Installation Instructions Manual

INSTALLATION INSTRUCTIONS

RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORT TION!

!

DO NOT DESTROY THIS MANUAL

PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICEMAN

WARNING

!

ANT SAFETY INFORMA

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

HEAT PUMP OUTDOOR UNITS FEATURING
EARTH-FRIENDLY R-410A REFRIGERANT

(-)PNL-*AZ MODEL SERIES - 13 SEER
(-)PPL-JAZ MODEL SERIES - 14 SEER

[ ] INDICATES METRIC CONVERSIONS

(14 SEER MODELS &
13 SEER MODELS IN

CERTAIN MATCHED

SYSTEMS)

SUPERSEDES 92-20522-43-06

92-20522-43-07

TABLE OF CONTENTS

1.0 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.0 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

2

2.2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.4 Electrical and Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.5 Proper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3.0 LOCATING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.1 Corrosive Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.2 Heat Pump Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.3 Operational Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

.4 For Units With Space Limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3

3.5 Customer Satisfaction Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.6 Unit Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.7 Factory-Prepferred Tie-Down Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.0 REFRIGERANT CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5.0 REPLACEMENT UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.0 INDOOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7.0 INTERCONNECTING TUBING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7.1 Vapor & Liquid Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7.2 Maximum Length of Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7.3 Vertical Separation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7.4 Tubing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7.5 Tubing Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7.6 Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

8.0 DEMAND DEFROST CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8.1 Defrost Initiation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8.2 Defrost Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8.3 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8.4 Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8.5 Demand Defrost Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8.6 High/Low Pressure Control Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

8.7 Enhanced Feature Defrost Control Diagnostic Codes . . . . . . . . . . . . . . . . . 15

9.0 EVACUATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

10.0 START UP & PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

11.0 CHECKING AIRFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

12.0 CHECKING REFRIGERANT CHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

12.1 Charging By Liquid Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

12.2 Charging By Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

12.3 Final Leak Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

13.0 ELECTRICAL WIRING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

13.1 Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

13.2 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

13.3 Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

14.0 FIELD INSTALLED ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

14.1 Compressor Crankcase Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

14.2 Time Delay Control (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

14.3 Low Ambient Control (LAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

15.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

15.1 Electrical Checks Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

15.2 Cooling Mechanical Checks Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

15.3 Heating Mechanical Checks Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

15.4 Defrost Mechanical Checks Flow Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

15.5 Subcooling Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

15.6 General Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

15.7 Service Analyzer Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

16.0 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2

1.0 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.

WARNING

!

The manufacturer’s warranty does not cover any damage or defect to the air
conditioner caused by the attachment or use of any components, accessories

r devices (other than those authorized by the manufacturer) into, onto or in

o
conjunction with the air conditioner. You should be aware that the use of
unauthorized components, accessories or devices may adversely affect the
operation of the air conditioner and may also endanger life and property. The
manufacturer disclaims any responsibility for such loss or injury resulting
from the use of such unauthorized components, accessories or devices.

WARNING

!

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

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.

WARNING

!

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

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

WARNING

!

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

WARNING

!

Secure elevated unit and elevating stand in order to prevent tipping. Failure to
do this may result in severe personal injury or death.

CAUTION

Wh e n coil is insta l led over a fini s hed ceili n g and/or livi n g area, it is
recommended th a t a se c o n d a r y sh e et meta l co n d e n s a te pan be
constructed and installed under entire unit. Failure to do so may result
in property damage.

CAUTION

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

CAUTION

Dual fuel (fossil fuel) applications require the use of a high pressure control in
the heat pump section. If a high pressure control was not originally provided
with the heat pump section from the factory, a factory approved high pressure
control kit must be purchased from the manufacturer and installed in the heat
pump. Dual fuel (fossil fuel) applications in which a high pressure control is
not installed in the outdoor heat pump section will void the safety approval of
the product.

3

MATCH ALL COMPONENTS:

• OUTDOOR UNIT

• INDOOR COIL/METERING DEVICE

• INDOOR AIR HANDLER/FURNACE

• REFRIGERANT LINES

2.0 GENERAL

WARNING

!

The manufacturer’s warranty does not cover any damage or defect to the
air conditioner caused by the attachment or use of any components.
Accessories or devices (other than those authorized by the manufactur­er) into, onto or in conjunction with the air conditioner. You should be
aware that the use of unauthorized components, accessories or devices
may adversely affect the operation of the air conditioner and may also
endanger life and property. The manufacturer disclaims any responsibility
for such loss or injury resulting from the use of such unauthorized compo-

ents, accessories or devices.

n

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

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

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

2.1 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 heat pump model number, electrical characteristics and accessories to
determine if they are correct. Check system components to make sure they are
properly matched.

2.2 APPLICATION

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

There are several factors that installers must consider.

• Outdoor unit location • Indoor unit blower speed

• Proper equipment evacuation • Supply and return air duct design and sizing

• Refrigerant charge • System air balancing

• Indoor unit air flow • Diffuser and return air grille location and sizing

4

AIR INLETS
(LOUVERS)
ALLOW 120 [305 mm]
M

IN. CLEARANCE

3 SIDES

AIR DISCHARGE

A

LLOW 600 [1524 mm] CLEARANCE

ALLOW 240 [610 mm]
ACCESS CLEARANCE

ACCESS
PANEL

L

W

H

ALTERNATE HIGH VOLTAGE
CONNECTION (KNOCKOUT)
1

1

1

/320[34 mm]

SERVICE
FITTINGS

LOW VOLTAGE
CONNECTION

7

/8" [22 mm]

HIGH VOLTAGE
CONNECTION
1

11

/32" [34 mm]

LIQUID LINE
CONNECTION

SERVICE ACCESS
TO ELECTRICAL &
VALVES ALLOW
24" [610 mm]
CLEARANCE
ONE SIDE

2

7

/8" [73 mm] DIA.
ACCESSORY
KNOCKOUTS

VAPOR LINE
CONNECTION

HIGH PRESSURE
CONTROL
MANUAL RESET
(FIELD INSTALLED
ACCESSORY)

A

-000

03

A-00002

BOTTOM VIEW SHOWING DEFROST CONDENSATE
DRAIN OPENINGS (\\\\\\

SHADED AREAS).

2.3 DIMENSIONS (SEE FIGURE 1)

IGURE 1

F

DIMENSIONS AND INSTALLATION CLEARANCES

IR DISCHARGE

A

LLOW 60” [1524 mm] CLEARANCE

A

ACCESS
PANEL

W

ALTERNATE HIGH VOLTAGE

CONNECTION (KNOCKOUT)

111⁄32" [34 mm]

UNIT MODEL NUMBER EXPLANATION

(-)PNL – 036*AZ

COOLING CONNECTION FITTING
Z-SWEAT WITH SCROLL

- COMPRESSOR

Z

ARIATIONS

V
A - SERIES = FULL-FEATURED

ELECTRICAL DESIGNATION

= 208/230V-1-60

J

= 208/230V-3-60 (Available only on (-)PNL

C

= Models)

H

AIR INLETS
(LOUVERS)
ALLOW 6" [153 mm]
MIN. CLEARANCE
3 SIDES

C

= 460V-3-60 (Available only on (-)PNL

D

= Models)

D

OOLING CAPACITY

C

18 = 18,000 BTU/HR

0
024 = 24,000 BTU/HR

30/031 = 30,000 BTU/HR

0
036 = 36,000 BTU/HR

42/043 = 42,000 BTU/HR

0
048/049 = 48,000 BTU/HR

60 = 60,000 BTU/HR

0

ESIGN SERIES (R-410A)

D

N = STANDARD EFFICIENCY (13 SEER)

= HIGH EFFICIENCY (14 SEER)

P

ALLOW 24" [610 mm]
ACCESS CLEARANCE

P = REMOTE HEAT PUMP

TRADENAME

BASE PAN

REQUIRED PUMP-UP
INSTALLATION
LOCATIONS

NOTE: SERVICE ACCESS
TO ELECTRICAL & VALVES
ALLOW 24” [610 mm]
CLEARANCE ON SIDE

DIMENSIONAL DATA

(-)PNL

(-)PPL

HEIGHT “H” (INCHES) [mm]
LENGTH “L” (INCHES) [mm]

WIDTH“W” (INCHES) [mm]

018, 024, 031

018, 024

19” [482]

40-1/2” [1028]

27-5/8” [701]

030

19” [482]

44-3/8” [1127]

31-1/2” [800]

030, 043, 049

036, 042, 048, 060

036, 042, 048, 060

29” [736]

44-3/8” [1127]

33” [838]

44-3/8” [1127]

31-1/2” [800] 31-1/2” [800]

5

2.4 ELECTRICAL & PHYSICAL DATA (SEE TABLES 1 & 2)

TABLE 1

-)PNL ELECTRICAL AND PHYSICAL DATA

(

ELECTRICAL

Model

Number

(-)PNL-

v. 12/16/2008

018JAZ 1-60-208/230 9/9 48 0.6 12/12 15/15 20/20 8.18 (0.76) 1 1925 [908] 83 [2353] 155 [70.3] 165 [74.8]
024JAZ 1-60-208/230 12.8/12.8 58.3 0.6 17/17 20/20 25/25 8.18 [0.76] 1 1925 [908] 86 [2438] 155 [70.3] 165 [74.8]

30JAZ 1-60-208/230 14.1/14.1 73 0.8 19/19 25/25 30/30 20.13 [1.87] 1 2650 [1251] 133 [3771] 200 [90.7] 210 [95.3]

0

31JAZ 1-60-208/230 14.1/14.1 73 0.6 20/20 25/25 30/30 13 [1.21] 1 1925 [908] 101 [2863] 164.5 [74.6] 174.5 [79.2]

0

36CAZ 3-60-208/230 13.2/13.2 88 1.2 18/18 25/25 30/30 23.01 [2.14] 1 3575 [1687] 145 [4111] 246.5 [111.8] 256.5 [116.3]

0

36DAZ 3-60-460 6 44 0.6 9 15 15 23.01 [2.14] 1 3575 [1687] 145 [4111] 246.5 [111.8] 256.5 [116.3]

0

36JAZ 1-60-208/230 17.9/17.9 112 1.2 24/24 30/30 40/40 23.01 [2.14] 1 3575 [1687] 145 [4111] 246.5 [111.8] 256.5 [116.3]

0
042CAZ 3-60-208/230 13.6/13.6 83.1 1.2 19/19 25/25 30/30 23.01 [2.14] 1 3575 [1687] 160 [4536] 257 [116.6] 267 [121.1]
042DAZ 3-60-460 6.1 41 0.6 9 15 15 23.01 [2.14] 1 3575 [1687] 160 [4536] 257 [116.6] 267 [121.1]

042JAZ 1-60-208/230 20.5/20.5 109 1.2 27/27 35/35 45/45 23.01 [2.14] 1 3575 [1687] 160 [4536] 257 [116.6] 267 [121.1]
043CAZ 3-60-208/230 13.6/13.6 83.1 1 18/18 25/25 35/35 20.1 [1.87] 1 2650 [1251] 168 [4763] 227 [103] 237 [107.5]

43DAZ 3-60-460 6.1 41 0.6 10 15 15 20.1 [1.87] 1 2650 [1251] 168 [4763] 227 [103] 237 [107.5]

0

43JAZ 1-60-208/230 20.5/20.5 109 1 27/27 35/35 45/45 20.1 [1.87] 1 2650 [1251] 168 [4763] 227 [103] 237 [107.5]

0

48CAZ 3-60-208/230 13.7/13.7 83.1 1.2 19/19 25/25 30/30 23.01 [2.14] 1 3575 [1687] 160 [4536] 246 [111.6] 256 [116.1]

0
048DAZ 3-60-460 6.2 41 0.6 9 15 15 23.01 [2.14] 1 3575 [1687] 160 [4536] 246 [111.6] 256 [116.1]

48JAZ 1-60-208/230 21.8/21.8 117 1.2 29/29 35/35 50/50 23.01 [2.14] 1 3575 [1687] 160 [4536] 246 [111.6] 256 [116.1]

0

49CAZ 3-60-208/230 13.7/13.7 83.1 1 19/19 25/25 30/30 20.1 [1.87] 1 2650 [1251] 157 [4451] 229 [103.9] 239 [108.4]

0
049DAZ 3-60-460 6.2 41 0.6 9 15 15 20.1 [1.87] 1 2650 [1251] 157 [4451] 229 [103.9] 239 [108.4]

049JAZ 1-60-208/230 21.8/21.8 117 1 29/29 35/35 50/50 20.1 [1.87] 1 3575 [1687] 157 [4451] 229 [103.9] 239 [108.4]
060CAZ 3-60-208/230 15.6/15.6 110 1.2 21/21 25/25 35/35 23.01 [2.14] 1 3350 [1581] 242 [6861] 260 [117.9] 270 [122.5]
060DAZ 3-60-460 7.8 52 0.6 11 15 15 23.01 [2.14] 1 3350 [1581] 242 [6861] 260 [117.9] 270 [122.5]

60JAZ 1-60-208/230 26.3/26.3 134 1.2 35/35 45/45 60/60 23.01 [2.14] 1 3350 [1581] 242 [6861] 260 [117.9] 270 [122.5]

0

Phase
Frequency (Hz)
Voltage (Volts)

Compressor

Rated Load

Amperes

(RLA)

Locked Rotor

Amperes

(LRA)

Fan Motor

Full Load
Amperes

(FLA)

Minimum

Circuit

Ampacity

Amperes

Fuse or HACR

Circuit Breaker

Minimum

Amperes

Maximum

Amperes

Face Area

Sq. Ft. (m

Outdoor Coil

No.

2

)

Rows

CFM
[L/s]

PHYSICAL

Refrig.

Circuit
Oz. [g]

Per

Net

Lbs. [kg]

Weight

Shipping
Lbs. [kg]

TABLE 2

(-)PPL ELECTRICAL AND PHYSICAL DATA

Model

Number

(-)PPL-

Phase
Frequency (Hz)

Voltage (Volts)

Compressor

Rated Load

Amperes

(RLA)

ELECTRICAL

Locked Rotor

Amperes

(LRA)

Fan Motor

Full Load

Amperes

(FLA)

Minimum

Circuit

Ampacity

Amperes

Fuse or HACR

Circuit Breaker

Minimum

Amperes

Maximum

Amperes

Face Area

Sq. Ft. (m

Outdoor Coil

No.

2

)

Rows

CFM
[L/s]

PHYSICAL

Refrig.

Per
Circuit
Oz. [g]

Net

Lbs. [kg]

Weight

Shipping
Lbs. [kg]

018JAZ 1-60-208/230 9/9 48 0.6 12/12 15/15 20/20 8.18 [0.76] 1 1925 [908] 83 [2353] 156 [70.8] 166 [75.3]
024JAZ 1-60-208/230 12.8/12.8 58.3 0.6 17/17 20/20 25/25 8.18 [0.76] 1 1925 [908] 86 [2438] 156 [70.8] 167 [75.8]
030JAZ 1-60-208/230 14.1/14.1 73 0.8 19/19 25/25 30/30 12.87 [1.2] 1 1925 [908] 101 [2863] 175 [79.4] 186 [84.4]
036JAZ 1-60-208/230 17.9/17.9 112 1.2 24/24 30/30 40/40 23.01 [2.14] 1 3575 [1687] 145 [4111] 246 [111.6] 256 [116.1]
042JAZ 1-60-208/230 20.5/20.5 109 1.2 27/27 35/35 45/45 23.01 [2.14] 1 3575 [1687] 160 [4536] 256 [116.1] 266 [120.7]
048JAZ 1-60-208/230 21.8/21.8 117 1.2 29/29 35/35 50/50 23.01 [2.14] 1 3575 [1687] 160 [4536] 258 [117] 268 [121.6]
060JAZ 1-60-208/230 26.3/26.3 134 1.2 35/35 45/45 60/60 44 [4.09] 1 3100 [1463] 277 [7853] 308 [139.7] 318 [144.2]

2.5 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 Engineering Specification Sheet when installing this product.

IMPORTANT: This product has been designed and manufactured to meet ENER­GY STAR
nents. 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.

®

criteria for energy efficiency when matched with appropriate coil compo-

6

3.0 LOCATING UNIT

3.1 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 basepan.

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

WARNING

!

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

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

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

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

Several different types of protective coil coatings are offered in some areas. These
coatings may provide some benefit, but the effectiveness of such coating materials
cannot be verified by the equipment manufacturer.

3.2 HEAT PUMP LOCATION

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

NOTE: These units must be installed outdoors. No ductwork can be attached, or
other modifications made, to the discharge grille. Modifications will affect perfor­mance or operation.

3.3 OPERATIONAL ISSUES

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

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

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

o Water from the junction of rooflines, without protective guttering, entering the

heat pump while in operation, can impact fan blade or motor life. Coil dam­age may occur to a heat pump if moisture cannot drain from the unit under
freezing conditions.

o 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 clearance recommendations (see Figure 1).
o 24” to the service panel access
o 60” above heat pump fan discharge (unit top) to prevent recirculation

o 6” to heat pump coil grille air inlets (per heat pump).

7

FIGURE 2

ECOMMENDED ELEVATED INSTALLATION

R

ELEVATION ABOVE
ANTICIPATED SNOW­’FALL IS NECESSARY.

O NOT BLOCK

D

PENINGS IN BASE

O

AN. REFER TO

P

IGURE 1.

F

3.4 FOR UNITS WITH SPACE LIMITATIONS

In the event that a space limitation exists, we will permit the following clearances:
Single Unit Applications: Heat pump grille side clearances below 6 inches will

reduce unit capacity and efficiency. Do not reduce the 60-inch discharge, or the 24­inch service clearances.

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

• Do not obstruct the bottom drain opening in the heat pump base pan. It is
essential to provide defrost condensate drainage to prevent possible refreezing
of the condensation. Provide a base pad for mounting the unit, which is slightly
pitched away from the structure. Route condensate off the base pad to an area
which will not become slippery and result in personal injury.

• Where snowfall is anticipated, the heat pump must be elevated above the base
pad to prevent ice buildup that may crush the tubing of the heat pump coil or
cause fin damage. Heat pump units should be mounted above the average
expected accumulated snowfall for the area.

8

3.5 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 sufficient distance above
grade to prevent ground water from entering the unit.

3.6 UNIT MOUNTING

If eleva ting th e heat pump, either on a flat roof or on a slab, observe the
following guidelines. (See Figure 2.)

• The base pan provided elevates the heat pump 3/4” above the base pad.

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

NOTE: Do not block drain openings shown in Figure 1.

• If unit must be elevated because of anticipated snow fall, secure unit and ele­vating stand such that unit and/or stand will not tip over or fall off.

CAUTION

!

Secure elevated unit and elevating stand in order to prevent tipping.
Failure to do this may result in minor or moderate injury.

3.7 FACTORY-PREFERRED TIE-DOWN METHOD
INSTRUCTIONS

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

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

STEP 2: Center base pan on pad, ensuring it is level.
STEP 3: Using basepad as a guide, mark spots on concrete where 4 holes will be

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

STEP 5: Center basepan over pre-drilled holes and insert concrete screws.
STEP 6: Tighten concrete screws.

STEP 7: Finish unit assembly per unit’s installation instructions.

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

drilled (see Figure 3).

than the concrete screw being used.

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

FIGURE 3

SCREW LOCATIONS ON BASEPAN

TABLE 3

BASEPAN DIMENSIONS

MODEL NUMBER LWAB CD

PNL-018/024, PPL-018/024 37.625” 25.938” 15” 34” 3.5” 22.5”

PNL-030/031/036/042/043/048/049/060,
PPL-030/036/042/048/060

41.5” 29.813” 15” 38” 3.5” 26.5”

9

4.0 REFRIGERANT CONNECTIONS

All units are factory charged with Refrigerant 410A. All models are supplied with
service valves. Keep tube ends sealed until connection is to be made to prevent
system contamination.

5.0 REPLACEMENT UNITS

To prevent failure of a new heat pump unit, the existing tubing system 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 should
be installed and refrigerant tubing should be properly sized. Test the oil for acid. If
positive, a liquid line filter drier is mandatory.

6.0 INDOOR COIL

REFER TO INDOOR COIL MANUFACTURER’S INSTALLATION INSTRUC­TIONS.

IMPORTANT: The manufacturer is not responsible for the performance and opera-

tion of a mismatched system, or for a match listed with another manufacturer’s coil.

6.1 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
recomm e n d e d that a se c onda r y she e t met a l con d e n s ate pan be
constructed and installed under entire unit. Failure to do so may result
in property damage.

7.0 INTERCONNECTING TUBING

7.1 VAPOR AND LIQUID LINES

Keep all lines sealed until connection is made.

Make connections at the indoor coil first.

Refer to Line Size Information in Tables 4 and 5 for correct size and multipliers to be
used to determine capacity for various vapor line diameters and lengths of run. The
losses due to the lines being exposed to outdoor conditions are not included.

The factory refrigeration charge in the outdoor unit is sufficient for 15 feet of inter­connecting lines. The factory refrigeration charge in the outdoor unit is sufficient for
the unit and 15 feet of standard size interconnecting liquid and vapor lines. For dif­ferent lengths, adjust the charge as indicated below.

1/4” ± .3 oz. per foot

5/16” ± .4 oz. per foot

3/8” ± .6 oz. per foot

1/2” ± 1.2 oz. per foot

10

7.2 MAXIMUM LENGTH OF LINES

The maximum length of interconnecting line is 150 feet. Always use the shortest
length possible with a minimum number of bends. Additional compressor oil is not
required for any length up to 150 feet.

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

7.3 VERTICAL SEPARATION

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

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

2. It is recommended to use the smallest liquid line size permitted to minimize sys-

tem charge which will maximize compressor reliability.

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

7.4 TUBING INSTALLATION

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

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

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

• Use clean, dehydrated, sealed refrigeration grade tubing.

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

made.

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

outdoor unit and indoor coil. Any debris in the line set will end up plugging the
expansion device.

• As an added precaution, a high quality, bi-directional filter drier is recommend-

ed to be installed in the liquid line, if not factory installed.

• 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. The vapor line must be insulated.

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

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

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

ber of elbows or bends.

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

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

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

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

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

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

• Check Table 4 for the correct vapor line size. Check Table 5 for the correct liq-

uid line size.

11

TABLE 4

SUCTION LINE LENGTH/SIZE VS. CAPACITY MULTIPLIER (R-410A)

1

1

Unit Size

Suction Line

Connection Size

Suction Line Run -

Feet [m]

ptional

O

tandard

S

5’

2

ptional

O

Optional

0’

5

Standard

Optional

Optional

100’

150’

OTES:

N

Standard

*

ote: Using suction line larger than shown in chart will result in poor oil return and is not recommended

N

Standard

Optional

Optional

Standard

Optional

⁄2 Ton

/4

.D.

3

I

"

5/8

3/4*

—

.00 1.00 1.00 1.00 1.00 1.00 1.00

1

.00 1.00 1.00 1.00 1.00 1.00 1.00

1

—

.98 0.98 0.96 0.98 0.99 0.99 0.99

0

.99 0.99 0.98 0.99 0.99 0.99 0.99

0

——0.99 ————

.95 0.95 0.94 0.96 0.96 0.96 0.97

0

.96 0.96 0.96 0.97 0.98 0.98 0.98

0

——0.97 ————

.92 0.92 0.91 0.94 0.94 0.95 0.94

0

.93 0.94 0.93 0.95 0.96 0.96 0.97

0

—

2 Ton

/4

.D.

3

I

"

/8 5/8

5

3/4* 3/4*

— 7/8*

— 1.00 ————

— 0.95 ————

2

3

1

⁄2 Ton

/4

"

3 Ton

/8

.D.

I

.D.

7

I

"

/4

3

7/8*

—

7.5 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 accepted
industry practices.

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

• Clean the inside of the fittings before brazing.

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

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

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

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

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

• Replace the valve cap finger tight then tighten an additional 1/2 hex flat for a
metal-to-metal seal.

3

7

1

⁄2 Ton

/8

"

/4

3

7/8*

—

4 Ton

.D.

I

7/8"I.D.

/8

7

1 1/8*

—

5 Ton

/8

7

1 1/8*

.D.

I

"

/8

7

—

12

7.6 LEAK TESTING

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

WARNING

!

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

TABLE 5

LIQUID LINE SIZE — OUTDOOR UNIT ABOVE OR BELOW INDOOR COIL

Outdoor unit above or below indoor coil

(Heat Pumps Only)

Total Equivalent Length - Feet

aximum Vertical Separation - Feet

M

System

apacity

C

Line Size

Connection

ize

S

(Inch I.D.)

Line Size

Inch OD)

(

25 50 75 100 125 150

1/4 25 40 25 9 N/A N/A

Liquid Line Size

1

1

⁄2 Ton 3/8” 5/16 25 50 62 58 53 49

3/8* 25 50 75 72 70 68

1/4 23 N/A N/A N/A N/A N/A

2 Ton 3/8” 5/16 25 36 29 23 16 9

3/8* 25 50 72 70 68 65

1/4 25 N/A N/A N/A N/A N/A

1

2

⁄2 Ton 3/8” 5/16 25 49 38 27 17 6

3/8* 25 50 68 65 62 58

3 Ton 3/8”

1

⁄2 Ton 3/8”

3

4 Ton 3/8”

5 Ton 3/8”

NOTES:

*Standard
N/A = Application not recommended

5/16 25 50 37 22 7 N/A

3/8* 25 50 68 63 58 53

5/16 25 23 4 N/A N/A N/A

3/8* 25 50 43 36 30 24
3/8* 25 46 38 30 22 15

1/2 25 50 56 55 53 52

3/8* 25 50 56 44 32 20

1/2 25 50 75 81 79 76

13

8.0 DEMAND DEFROST CONTROL AND HIGH/LOW

PRESSURE CONTROLS

The demand defrost control is a printed circuit board assembly consisting of solid
state control devices with electro-mechanical outputs. The demand defrost control
monitors the outdoor ambient temperature, outdoor coil temperature, and the com­pressor run-time to determine when a defrost cycle is required.

Enhanced Feature Demand Defrost Control (part number 47-2157-22): Found
in units with models numbers ending in “AZ” and units equipped with the field
installed Enhanced Compressor Protection Kit (RXPG-A02). Has high and low pres­sure control inputs with unique pressure switch logic built into the microprocessor to

rovide compressor and system protection without nuisance lock-outs. Cycles the

p
compressor off for 5 seconds at the beginning and end of the defrost cycle to elimi­nate the increased compressor noise caused by rapidly changing system pressures
when the reversing valve switches. See section 8.7 for diagnostic flash codes for
the two diagnostic LED’s provided on the control.

8.1 DEFROST INITIATION

A defrost will be initiated when the three conditions below are satisfied:

1) The outdoor coil temperature is below 35°F.

2) The compressor has operated for at least 34 minutes with the outdoor coil tem-

perature below 35°F.

3) The measured difference between the ambient temperature and the outdoor

coil temperature is greater than the calculated delta T.

Additionally, a defrost will be initiated if six hours of accumulated compressor run­time has elapsed without a defrost with the outdoor coil temperature below 35°F.

8.2 DEFROST TERMINATION

Once a defrost is initiated, the defrost will continue until fourteen minutes has
elapsed or the coil temperature has reached the terminate temperature. The termi­nate temperature is factory set at 70°F, although the temperature can be changed
to 50°F, 60°F, 70°F or 80°F by relocating a jumper on the board.

8.3 TEMPERATURE SENSORS

The coil sensor is clipped to the top tube on the outdoor coil at the point feed by the
distribution tubes from the expansion device (short 3/8” dia. tube). The air sensor is
located on the defrost control board.

If the ambient sensor fails the defrost control will initiate a defrost every 34 minutes
with the coil temperature below 35°F.

If the coil sensor fails the defrost control will not initiate a defrost.

8.4 TEST MODE

The test mode is initiated by shorting the TEST pins. In this mode of operation, the
enable temperature is ignored and all timers are sped up by a factor of 240. To initi­ate a manual defrost, short the TEST pins. Remove the short when the system
switches to defrost mode. The defrost will terminate on time (14 minutes) or when
the termination temperature has been achieved. Short TEST pins again to termi­nate the defrost immediately.

8.5 TROUBLE SHOOTING DEMAND DEFROST

Set the indoor thermostat select switch to heat and thermostat lever to a call for
heat.

Jumper the “test pins” to put the unit into defrost. If the unit goes into defrost and
comes back out of defrost, the indication is that the control is working properly.

If the unit did not go into defrost using the test pins, check to ensure that 24V is
being supplied to the control board. If 24V is present then replace the control.

14

8.6 HIGH/LOW PRESSURE CONTROL MONITORING - ENHANCED
DEFROST CONTROL ONLY (Units with Model Numbers Ending
with “AZ”).

Status of high and low pressure controls is monitored by the enhanced feature
demand defrost control and the following actions are taken.

igh Pressure Control – Provides active protection in both cooling and heating

H

modes at all outdoor ambient temperatures. The high pressure control is an auto­matic reset type and opens at approximately 610 psig and closes at approximately
420 psig. The compressor and fan motor will stop when the high pressure control
opens and will start again if the high side pressure drops to approximately 420 psig
when the automatic reset high pressure control resets. If the high pressure control
opens 3 times within a particular call for heating or cooling operation, the defrost
control will lock out compressor and outdoor fan operation.

Low Pressure Control – Provides active protection in both heating and cooling
modes at all outdoor ambient temperatures. The low pressure control is an auto­matic reset type and opens at approximately 25 psig and closes at approximately
40 psig. Operation is slightly different between cooling and heating modes.

Cooling Mode: The compressor and fan motor will stop when the low pressure
control opens and will start again when the low side pressure rises to approxi­mately 40 psig when the low pressure control automatically resets. If the low
pressure switch opens 3 times within a particular call for cooling operation, the
defrost control will lock out compressor and outdoor fan operation.

Heating Mode: The compressor and fan motor will stop when the low pressure
control opens and will start again when the low side pressure rises to approxi­mately 40 psig when the low pressure control automatically resets. If the low
pressure switch trips 3 times within 120 minutes of operation during a particular
call for heating operation, the defrost control will lock out compressor and out­door fan operation. If the lock-out due to low pressure occurs at an outdoor
ambient temperature below 5°F, the defrost control will automatically exit the
lock-out mode when the outdoor ambient temperature rises to 5°F. This feature
is necessary since the low pressure control could possibly have opened due to
the outdoor ambient being very low rather than an actual system fault.

Exiting Lock-Out Mode: To exit the lock-out mode, remove 24 volts to the defrost

control by removing power to indoor air-handler/furnace or by shorting the two
defrost control test pins together.

8.7 ENHANCED FEATURE DEFROST CONTROL DIAGNOSTIC CODES

LED 1 LED 2 Control Board Status

OFF OFF No Power
ON ON Coil Sensor Failure
OFF ON Ambient Sensor Failure
FLASH FLASH Normal
OFF FLASH Low Pressure Lockout (short test pins to reset)
FLASH OFF High Pressure Lockout (short test pins to reset)
ON FLASH Low Pressure Control Open
FLASH ON High Pressure Control Open

Alternate Flashing 5 Minute Time Delay

9.0 EVACUATION PROCEDURE

The life and efficiency of the equipment is dependent upon the thoroughness exer­cised by the technician when evacuating air and moisture from the system.

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

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

After the system has been leak checked and proven sealed, connect the vacuum
pump and evacuate system to 500 microns. The vacuum pump must be connected

15

to both the high and low sides of the system through adequate connections. Use
the largest size connections available since restrictive service connections may lead
to false readings because of pressure drop through the fittings.

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

10.0 START UP AND PERFORMANCE

Even though the unit is factory-charged with Refrigerant R-410A, the charge must
be checked to the charge table on the service panel and adjusted, if required. (See
Tables 1 and 2.) Allow the unit to run for a minimum of five minutes. Before analyz­ing charge, see the instructions on the unit service panel rating plate for marking
the total charge.

11.0 CHECKING AIRFLOW

The air distribution system has the greatest effect on airflow. The duct system is
totally controlled by the contractor. For this reason, the contractor should use only
industry-recognized procedures.

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

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

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

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

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

12.0 CHECKING REFRIGERANT CHARGE

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

IMPORTANT: Do not operate the compressor without charge in system.
Addition of R-410A will raise pressures (vapor, liquid and discharge).
If adding R-410A raises both vapor pressure and temperature, the unit is over-

charged.
IMPORTANT: Use industry-approved charging methods to ensure proper system

charge.

12.1 CHARGING BY LIQUID PRESSURE

Liquid pressure method is used for charging systems in the cooling and heating
mode. The service port on the liquid service valve (small valve) and suction (large
valve) is used for this purpose.

Verify that the outdoor unit is running and the indoor air mover is delivering the
maximum airflow for this system size. Read and record the outdoor ambient tem­perature. Read and record the liquid and suction pressures at the ports on the liquid
and suction valves. If refrigerant lines are sized using the nameplate charge, the
correct liquid pressure is found at the intersection of the suction pressure and the
outdoor ambient.

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

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

12.2 CHARGING BY WEIGHT

For a new installation, evacuation of interconnecting tubing and indoor coil is ade­quate; otherwise, evacuate the entire system. Use the factory charge shown in
Tables 1 through 6 of these instructions or unit data plate. Note that charge value
includes charge required for 15 ft. of standard size interconnecting liquid line.

16

Calculate actual charge required with installed liquid line size and length using:
1/4” O.D. = .3 oz./ft.

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

With an accurate scale (+/– 1 oz.) or volumetric charging device, adjust charge dif­ference between that shown on the unit data plate and that calculated for the new
system installation. If the entire system has been evacuated, add the total calculat­ed charge.

12.3 FINAL LEAK TESTING

After the unit has been properly evacuated and charged, a halogen leak detector
should be used to detect leaks in the system. All piping within the condensing unit,
evaporator, and interconnecting tubing should be checked for leaks. If a leak is
detected, the refrigerant should be recovered before repairing the leak. The Clean
Air Act prohibits releasing refrigerant into the atmosphere.

13.0 ELECTRICAL WIRING

WARNING

!

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

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

!

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

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

13.1 POWER WIRING

It is important that proper electrical power from a commercial utility is available at
the condensing unit contactor. Voltage ranges for operation are shown in Table 6.

Install a branch circuit disconnect within sight of the unit and of adequate size to
handle the starting current (see Tables 1 and 2).

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

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

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

DO NOT connect aluminum field wire to the contactor terminals.

TABLE 6

VOLTAGE RANGES (60 HZ)

Nameplate Voltage Maximum Load Design Conditions for

208/230 (1 Phase) 187 - 253

208/230 (3 Phase) 187 - 253

CAUTION

Operating Voltage Range at Copeland

Compressors

460 414 - 506

575 517 633

17

13.2 GROUNDING

FIGURE 4

CONTROL WIRING FOR AIR HANDLER

B

W2

G

Y

W1

B

ODD

C

R

Air Handler

Y

G

W2

E

Heat Pump Thermostat

Heat Pump
Outdoor Unit

C

R

Y

B

R

D

C

Y

F

ield Installed

L

ine Voltage

-

W

IRING INFORMATION

Factory Standard

-

W

H/BL

GR/BK

YL

WH/BK

GR/YL

BR

BL

RD

YL/BL

Optional Field Installed Jumper (see note 1)

1

*

*

*

2

*Not present on all
air-handler models.

OPTIONAL

- 1 STAGE HEAT

YL

BR

B

L

RD

P

R

NOTES:

1. Jumper “E” to “W2” on
thermostat to transfer
control of supplemental
heat to 1st stage when
the emergency heat
switch is on.

2. This wire turns on elec­tric heat strip during
defrost, omit for most
economical operation.

WIRE COLOR CODE

BK = BLACK
BL = BLUE
BR = BROWN
GR = GREEN
PR = PURPLE
RD = RED
WH = WHITE
YL = YELLOW

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

WARNING

!

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

13.3 CONTROL WIRING

(See Figure 4)

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

A thermostat and a 24 volt, 40 VA minimum transformer are required for the control
circuit of the condensing unit. The furnace or the air handler transformer may be
used if sufficient. See the wiring diagram for reference. Use Table 7 to size the 24
volt control wiring.

18

TABLE 7

FIELD WIRE SIZE FOR 24 VOLT THERMOSTAT CIRCUITS

SOLID COPPER WIRE - AWG.

3.0 16 14 12 10 10 10

2.5 16 14 12 12 10 10

2.0 18 16 14 12 12 10

50 100 150 200 250 300

Thermostat Load - Amps

(1) Wire length equals twice the run distance.

NOTE: Do not use control wiring smaller than No. 18 AWG between thermostat and outdoor unit.

14.0 FIELD INSTALLED ACCESSORIES

14.1 COMPRESSOR CRANKCASE HEATER (CCH)

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

Length of Run - Feet (1)

NOTE: The installation of a crankcase heater is recommended if the system charge

exceeds the values in Table 8. All 3-phase models come with a crankcase heater facto­ry installed.

ABLE 8

T

AXIMUM SYSTEM CHARGE VALUES: (-)PNL/(-)PPL

M

Model Compressor Without

Size* Model Number Crankcase Heater*

-018 ZP16K5E 8.0 lbs.

-024 ZP21K5E 8.0 lbs.

-030/-031 ZP25K5E 8.0 lbs.

-036 ZP34K5E 10.0 lbs.

-042/-043 ZP38K5E 10.0 lbs.

-048/-049 ZP42K5E 10.0 lbs.

*-060 comes with the crankcase heater factory-installed.

Charge Limit

All heaters are located on the lower half of the compressor shell. Its purpose is to drive
refrigerant from the compressor shell during long off cycles, thus preventing damage to
the compressor during start-up.

At initial start-up or after extended shutdown periods, make sure the heater is energized
for at least 12 hours before the compressor is started. (Disconnect switch on and wall
thermostat off.)

14.2 TIME DELAY CONTROL (TDC)

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

14.3 LOW AMBIENT CONTROL (LAC) – RXAD-A08

This component senses compressor head pressure and shuts the heat pump fan off
when the head pressure drops to approximately 220 PSIG. This allows the unit to build a
sufficient head pressure at lower outdoor ambient (down to 0°F) in order to maintain sys­tem balance and obtain improved capacity. Low ambient control should be used on all
equipment operated below 70°F ambient.

19

15.0 TROUBLE SHOOTING

In diagnosing common faults in the heat pump system, develop a logical thought
pattern as used by experienced technicians. The charts which follow are not intend­ed to be an answer to all problems but only to guide the technician’s thinking.
Through a series of yes and no answers, follow the logical path to a likely conclu­sion.

A novice technician should use these charts like a road map. Remember that the

hart should clarify a logical path to the problem’s solution.

c

15.1 ELECTRICAL CHECKS FLOW CHART

Unit Running?

NO YES

Thermostat Problem? Go to

YES NO for Cooling or Heating

Repair and Recheck

Transformer Problem?

YES NO

Repair and Recheck

Voltage on Compressor

Side of Contactor?

YES NO

Run Capacitor Voltage on Line

Start Capacitor

NO YES

Potential Relay

Circuit Breakers Compressor Contactor Failure

Compressor Internal or Fuses Open

Overload Open Hi Pressure Cut-Out/Lock-Out

YES

Mechanical Checks

Side of Contactor?

(see section 8.6 & 8.7)

Compressor Winding Open Low Pressure Cut-Out/Lock-Out

Unit Wiring and Grounded Compressor Time-Delay

Connections

20

Compressor Winding

(see section 8.6 & 8.7)

Outdoor Fan Motor Unit Wiring and

Grounded Connections

Grounded Capacitor

Replace Fuses

or Reset Breakers

and Recheck System

15.2 COOLING MECHANICAL CHECKS FLOW CHART

Unit Running?

Y

ES NO

Pressure problems? Checks Flow Chart

High Head Pressure Low Head Pressure Low Suction Pressure

Dirty Outdoor Coil Low on Charge Dirty Filters

Inoperative Outdoor Fan Open IPR Valve Dirty Indoor Coil

Overcharge Low Ambient Temperature Inadequate Indoor Air Flow

Recirculation of Inoperative Compressor Broken Indoor

Outdoor Air Valves Blower Belt

Non-condensibles Outdoor Check Valve Inoperative Indoor Blower

Closed

Higher than Ambient Low on Charge

Air Entering Outdoor Coil

Restricted Indoor Restricted Indoor

Wrong Outdoor Fan Rotation Metering Device Metering Device

Go to Electrical

Restricted Restriction in System
Filter Drier

Reversing Valve Indoor Air

Failure

Recirculation of

Wrong Indoor

Blower Rotation

Inadequate Ducts

Outdoor Check Valve Closed

Restricted Filter Drier

21

15.3 HEATING MECHANICAL CHECKS FLOW CHART

Unit Running?

YES NO

Pressure problems? Checks Flow Chart

High Head Pressure Low Head Pressure Low Suction Pressure

Dirty Filters Low on Charge Dirty Outdoor Coil

Dirty Indoor Coil Low Indoor Temperature Inadequate Air Flow

Inoperative Indoor Blower Open IPR Valve

Closed Indoor Inoperative OD Fan

Overcharge Check Valve (Check Defrost Control)

Inadequate Indoor Inoperative Compressor Low On Charge

Air Flow Valves

Non-condensibles Restricted Outdoor Restricted Outdoor

Metering Device Metering Device

Broken Indoor

Blower Belt Restricted Restriction in System

Filter Drier

Go to Electrical

Over Outdoor Coil

Wrong Indoor Blower Rotation Closed Indoor Check Valve

Inadequate Ducts Recirculation of Outdoor Air

Reversing Valve

Failure

Restricted
Filter Drier

22

15.4 DEFROST MECHANICAL CHECKS FLOW CHART

DEFROST SYSTEM

No Defrost Incomplete Defrost Excessive Defrost

Reversing Valve Stuck Poor Sensor Location Wrong Defrost Control

No Defrost Timer Wrong Defrost Control

Control Power Timer Setting Poor Sensor Location

Failed Defrost Control Failed Defrost Relay Low System Charge

(doesn’t stop O.D. Fan)

Failed Defrost Relay Thermostat Satisfies Wind Affecting

During Defrost in Defrost

Loose Defrost

Sensor

Timer Setting

23

TABLE 10

TEMPERATURE PRESSURE CHART

TEMP R-410A

(Deg. F) PSIG

-150 —

-140 —

-130 —

-120 —

-110 —

-100 —

-90 —
80 —

-

-70 —

-60 0.4

-50 5.1

-40 10.9

-35 14.2

-30 17.9

-25 22.0

-20 26.4

-15 31.3

-10 36.5

-5 42.2
0 48.4
5 55.1

10 62.4
15 70.2
20 78.5
25 87.5
30 97.2
35 107.5
40 118.5
45 130.2
50 142.7
55 156.0
60 170.1
65 185.1
70 201.0
75 217.8
80 235.6
85 254.5
90 274.3

95 295.3
100 317.4
105 340.6
110 365.1
115 390.9
120 418.0
125 446.5
130 476.5
135 508.0
140 541.2
145 576.0
150 612.8

15.5 SUBCOOLING CALCULATION

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

2. Convert the liquid line pressure to saturated temperature. See Table 10.

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

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

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

NOTE: The subcooling charging method should only be used in the cooling mode
as the heating subcooling design level varies widely from one unit to the next while

he cooling subcooling design level is fairly consistent at 8-12 degrees.

t

TABLE 11

EAT PUMP SYSTEM TROUBLESHOOTING TIPS

H

HEAT PUMP SYSTEM

ROUBLESHOOTING TIPS

T

SYSTEM PROBLEM

Overcharge High High Low High High

Undercharge Low Low High Low Low

Liquid Restriction (Drier) Low Low High High Low

Low Evaporator Airflow Low Low Low Low Low

Dirty Heat Pump High High Low Low High

Low Outside Ambient Temperature Low Low High High Low

Inefficient Compressor Low High High High Low

TEV Feeler Bulb Charge Lost Low Low High High Low

Poorly Insulated Sensing Bulb High High Low Low High

DISCHARGE SUCTION

PRESSURE PRESSURE AMPS

INDICATORS

SUPERHEAT SUBCOOLING

COMPRESSOR

24

15.6 GENERAL TROUBLE SHOOTING CHART

!

WARNING

Disconnect all power to unit before servicing. Contactor may break only one side. Failure to shut off power can

ause electrical shock resulting in personal injury or death.

c

SYMPTOM POSSIBLE CAUSE REMEDY

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

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

doesn’t • Start relay defective • Replace

Insufficient cooling • Improperly sized unit • Recalculate load

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

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

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

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

pressure - Cooling mode • Refrigerant overcharge • Correct system charge

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

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

compressor - iced indoor coil filter

High vapor pressure • Excessive load • Recheck load calculation

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

pressures TEV

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

expansion device or liquid line

• Thermostat out of calibration-set too high • Reset

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

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

• Transformer defective • Check wiring-replace transformer

• High pressure control open (if provided) or defrost • The high pressure control opens at 610 PSIG. Check for blocked

control lockout due to 3 high pressure control trips. coils, failed fan or blower motor, wiring issues, or defective high

• Low pressure control open (if provided) or defrost pressure control. See section 8.6 to reset defrost control.

control lockout due to 3 low pressure control trips. • The low pressure control opens at 25 PSIG. Check for low

charge, blocked coils, wiring issues, or defective low pressure
control. See section 8.6 to reset defrost control.

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

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

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

• Low voltage condition • Add start kit components

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

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

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

nameplate marking when unit is operating.

• Defective overload protector • Replace - check for correct voltage

• Refrigerant undercharge • Add refrigerant

filter

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

• Incorrect capillary tubes • Change coil assembly

• Outdoor fan not running • Repair or replace

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

• Defective Compressor valves • Replace compressor

• Incorrect capillary tubes • Replace coil assembly

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

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

• Low refrigerant charge • Repair leak, evacuate, & recharge.

• Defective compressor • Replace

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

25

15.7 SERVICE ANALYZER CHARTS

COMPRESSOR OVERHEATING

SYMPTOMS POSSIBLE CAUSE CHECK/REMEDIES

High superheat Low charge Check system charge

Faulty metering device Restricted cap tube, TEV (TXV)

Power element superheat
adjustment

Foreign matter stopping flow

High internal load Hot air (attic) entering return

eat source on; mis-wired or

H
faulty control

Restriction in liquid line Drier plugged

Line kinked

Low head pressure Low charge

Operating in low ambient
temperatures

Suction or liquid line subjected Hot attic
to high heat source

Low voltage Loose wire connections Check wiring

Dirty or pitted compressor Replace contactor
contactor contacts

Power company problem, Have problem corrected before
transformer diagnosis continues

Undersized wire feeding unit Correct and complete diagnosis

High voltage Power company problem Have problem corrected

High head pressure Overcharge Check system charge

Dirty heat pump coil Clean coil

Faulty or wrong size Replace fan motor
heat pump fan motor

Faulty fan blade Replace fan blade
or wrong rotation

Recirculation of air Correct installation

Additional Heat Source Check for dryer vent near unit

Non-condensibles Recover refrigerant, Evacuate and

Equipment not matched Correct mis-match

Short cycling of compressor Faulty pressure control Replace pressure control

Loose wiring Check unit wiring

Thermostat Located in supply air stream

TEV Internal foreign matter

Capillary tube Restricted with foreign matter

Hot water line

Replace with correct rotation motor

Check for recirculation from
other equipment

recharge system

Differential setting too close

Customer misuse

Power element failure

Valve too small

Distributor tube/tubes restricted

Kinked
I.D. reduced from previous

compressor failure

26

SYMPTOMS POSSIBLE CAUSE CHECK OR REMEDIES

Short cycling of compressor (cont.) Low charge Check system charge

ow evaporator air flow Dirty coil

L

Dirty filter

Duct too small or restricted

Faulty run capacitor Replace

Faulty internal overload Replace compressor

Faulty Compressor Valves Fast equalization/ Replace compressor and examine

Low pressure difference system to locate reason

ELECTRICAL

SYMPTOMS POSSIBLE CAUSE CHECK OR REMEDIES

Voltage present on load side Compressor start components Check start capacitor
of compressor contactor and
compressor won’t run Check potential relay

Run capacitor Check with ohmmeter

Internal overload Allow time to reset

Compressor windings Check for correct ohms

Voltage present on line side of Thermostat Check for control voltage to com­pressor contactor only contactor coil

Compressor control circuit High pressure switch open

Low pressure switch open

Ambient thermostat
Solid state protection control or

internal thermal sensors

Compressor timed off/on
control or interlock

Defrost control locked out due to 3
high or low pressure control trips.
See sections 8.6 & 8.7

No voltage on line side Blown fuses or tripped circuit breaker Check for short in wiring or unit
of compressor contactor

Improper wiring Re-check wiring diagram

Improper voltage High voltage Wrong unit

Power supply problem

Low voltage Wrong unit

Power supply problem

Wiring undersized

Loose connections

Single Phasing (3 phase) Check incoming power and fusing

CONTAMINATION

SYMPTOMS POSSIBLE CAUSE CHECK OR REMEDIES

Moisture Poor evacuation on installation In each case, the cure is the same.

High head pressure Non-condensibles air

Unusual head and suction readings Wrong refrigerant

Foreign Matter­copper filings Copper tubing cuttings

Copper oxide Dirty copper piping

Welding scale Nitrogen not used

Soldering flux Adding flux before seating

Excess soft solder Wrong solder material

or during service Recover refrigerant. Add filter drier,

evacuate and re-charge

copper part way

27

LOSS OF LUBRICATION

SYMPTOMS POSSIBLE CAUSE CHECK OR REMEDIES

Compressor failures Line tubing too long Add oil to the recommended level

ine tubing too large Reduce pipe size to improve

L

Low suction pressure Low charge Check system charge

Refrigerant leaks Repair and recharge

Cold, Noisy compressor - Slugging Dilution of Oil with Refrigerant Observe piping guidelines

Noisy compressor Migration Check crankcase heater

Cold, sweating compressor Flooding Check system charge

Low Load Reduced air flow Dirty filter

Thermostat setting Advise customer

Short cycling of compressor Faulty pressure control Replace control

Loose wiring Check all control wires

Thermostat In supply air stream,

oil return

irty coil

D

Wrong duct size

Restricted duct

out of calibration,

Customer misuse

FLOODED STARTS

SYMPTOMS POSSIBLE CAUSES CHECK OR REMEDIES

Liquid in the compressor shell Faulty or missing crankcase heater Replace crankcase heater

Too much liquid in system Incorrect piping Check Piping guidelines

Overcharge Check and adjust charge

SLUGGING

SYMPTOMS POSSIBLE CAUSES CHECK OR REMEDIES

On start up Incorrect piping Review pipe size guidelines

TEV hunting when running Oversized TEV Check TEV application

FLOODING

SYMPTOMS POSSIBLE CAUSES CHECK OR REMEDIES

Poor system control Loose sensing bulb Secure the bulb and insulate
using a TEV

Bulb in wrong location Relocate bulb

Wrong size TEV Use correct replacement

Improper superheat setting Adjust, if possible;

Replace, if not

Poor system control Overcharge Check system charge
using capillary tubes

High head pressures Dirty heat pump

Restricted air flow

Recirculation of air

Evaporator air flow too low Adjust air flow to 350-400 CFM/Ton

28

THERMOSTATIC EXPANSION VALVES

SYMPTOMS POSSIBLE CAUSE CHECK OR REMEDIES

High Superheat, Low Suction Pressure Moisture freezing and blocking valve Recover charge, install filter-drier,

Dirt or foreign material blocking valve Recover charge, install filter-drier,

Low refrigerant charge Correct the charge

Vapor bubbles in liquid line Remove restriction in liquid line

Misapplication of internally equalized Use correct TEV
valve

Plugged external equalizer line Remove external equalizer line

Undersized TEV Replace with correct valve

Loss of charge from power Replace power head or complete
head sensing bulb TEV

Charge migration from sensing bulb Ensure TEV is warmer than
to power head (Warm power head sensing bulb
with warm, wet cloth. Does valve
operate correctly now?)

Improper superheat adjustment Adjust superheat setting counter­(Only applicable to TEV with adjustable clockwise
superheat settings)

Valve feeds too much refrigerant, Moisture causing valve to stick open. Recover refrigerant, replace filter­with low superheat and higher than drier, evacuate system and then nor­mal suction pressure recharge

Dirt or foreign material causing Recover refrigerant, replace filter­valve to stick open drier, evacuate system and

TEV seat leak (A gurgling or hissing Replace the TEV
sound is heard AT THE TEV during
the off cycle, if this is the cause.)
NOT APPLICABLE TO BLEED
PORT VALVES.

Oversized TEV Install correct TEV

Incorrect sensing bulb location Install bulb with two mounting

Low superheat adjustment Turn superheat adjustment
(only applicable to TEV with clockwise
adjustable superheat setting)

Incorrectly installed, or restricted Remove restriction, or relocate
external equalizer line external equalizer

Compressor flood back upon start up Refrigerant drainage from flooded Install trap riser to the top of the

evaporator evaporator coil

Compressor in cold location Install crankcase heater on

Any of the causes listed under Any of the solutions listed under
Symptoms of Problem #2 Solutions of Problem #2

evacuate system, recharge

evacuate system, recharge

Correct the refrigerant charge

emove non-condensible gases

R

Size liquid line correctly

restriction

recharge

straps, in 2:00 or 4:00 position on
suction line, with insulation

compressor

29

THERMOSTATIC EXPANSION VALVES

SYMPTOMS POSSIBLE CAUSE CHECK OR REMEDIES

Superheat is low to normal Unequal evaporator circuit loading Ensure air flow is equally distributed
with low suction pressure through evaporator

Check for blocked distributor
tubes

Low load or airflow entering Ensure blower is moving proper air
evaporator coil CFM

Remove/Correct any air flow
restriction

Superheat and suction Expansion valve is oversized Install correct TEV
pressure fluctuate (valve is hunting)

Sensing bulb is affected by liquid Relocate sensing bulb in another
refrigerant or refrigerant oil flowing position around the circumference of
through suction line the suction line

Unequal refrigerant flow through Ensure sensing bulb is located
evaporator circuits properly

Check for blocked distributor
tubes

Improper superheat adjustment Replace TEV or adjust superheat
(only possible with TEV having
superheat adjustment)

Moisture freezing and partially Recover refrigerant, change filter­blocking TEV drier, evacuate system and

Valve does not regulate at all External equalizer line not connected Connect equalizer line in proper

or line plugged location, or remove any blockage

Sensing bulb lost its operating charge Replace TEV

Valve body damaged during soldering Replace TEV
or by improper installation

recharge

30

16.0 WIRING DIAGRAMS

FIGURE 5

SINGLE-PHASE WIRING DIAGRAM (-)PNL/(-)PPL-***JAZ (208/230V SINGLE PHASE)

31

FIGURE 6

HREE-PHASE WIRING DIAGRAM (-)PNL-***CAZ (208/230V THREE-PHASE)

T

32

FIGURE 7

HREE-PHASE — 480V WIRING DIAGRAM (-)PNL-***DAZ (460V THREE-PHASE)

T

33

34

35

36

CM 1208