Rheem RA1460AJ1NA, RA1448AJ1NA, RA1442AJ1NA, RA1436AJ1NA, RA1430AJ1NA Installation Instructions Manual

WARNING:

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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 OPERA TION OF THIS UNIT . READ THESE INSTRUCTIONS THOROUGHLY BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOLLO W THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, ADJUSTMENT, SERVICE, OR MAINTENANCE POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.

AIR COOLED CONDENSING UNITS

INSTALLATION INSTRUCTIONS

RA14 MODEL SERIES – 14 SEER

FEATURING INDUSTRY STANDARD R-410A REFRIGERANT

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

[ ] indicates metric conversions.

92-104921-01-01 (11/14) Printed in USA

CONTENTS

Important Safety Information �� 3

General Information ��4-6

Checking Product Received ��4

Contents

Application ��4 Electrical and Physical Data ��5 Specifications ��6 Proper Installation ��6

Installation �� 7-17

Choosing a Location ��7-8

Operational Issues��7

Corrosive Environment ��7 For Units With Space Limitations ��8 Customer Satisfaction Issues ��8 Unit Mounting ��8 Factory-Preferred Tie-Down Method��8

Tools and Refrigerant

Tools Required for Installing and Servicing R-410A Models ��9 Specifications of R-410A ��9 Quick-Reference Guide for R-410A ��9

Replacement Units ��10 Indoor Coil ��10

Location ��10

Interconnecting Tubing �� 10-20

Vapor and Liquid Lines ��10 Maximum Length of Lines ��10 Outdoor Unit Installed Above or Below Indoor Coil �� 13-15 Tubing Installation �� 18-19 Tubing Connections �� 19-20 Leak Testing ��20

Wiring ��21-22

Control Wiring ��21 Conventional 24 VAC Thermostat Control Wiring ��21 Thermostat Wiring Diagrams �� 21-22 Power Wiring �� 22 Grounding �� 22

�� 9

Start-Up

Start-Up ��23 Checking Airflow ��23 Evacuation Procedure �� 24 Final Leak Testing ��24

Checking

Refrigerant Charge �� 25-27

Charging Units With R-410A Refrigerant ��25 Confirm ID Airflow and Coils Are Clean ��25 Measurement Device Setup �� 25 Charging by Weight �� 25 Gross Charging by Pressures �� 26 Final Charge by Subcooling �� 26 Finishing Up Installation �� 27

Components and Controls �� 28-29

Compressor

Crankcase Heat (CCH) ��28

High- and Low-Pressure

Controls (HPC and LPC) ��28 Hard-Start Components ��29

Accessories �� 29

Time-Delay Control ��29 Hard Start Components ��29 Low Ambient Control (LAC) ��29

Diagnostics �� 30-38

Cooling Mechanical Checks Flowchart ��30 General Troubleshooting Chart ��32 Service Analyzer Charts �� 33-37 Cooling/Heating Tips ��38

Wiring Diagrams ��39-40

��23–27

2

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�

Safety

3

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 condensing unit is 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

General Information

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 should be used�

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 air conditioning equipment, a survey of the structure and a heat gain calculation must be made� A cooling heat gain calculation 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 an air conditioning 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

4

GENERAL INFORMATION

Electrical and Physical Data

PHYSICALELECTRICAL

Circuit

Fuse or HACR Circuit

Breaker

Minimum

Maximum

Amperes

20/20

25/25

30/30

40/40

45/45

40/40 21.54 [2.00] 1 4139 [1953] 168 [4762] 202 [91.6] 209 [94.8]

50/50

Face

Area Sq.

Ft [m]

No.

Rows

CFM [L/s]

Refrig.

Per

Circuit

(oz.) [g]

Compressor

Model Number

RA1418AJ1NA 208-230 160 9.7/9.7 46.00.60 13 20/209.06 [0.84] 1 2225 [1050] 74 [2097] 122 [55.3] 129 [58.5]

RA1424AJ1NA 208-230 16011.2/11.2 60.80.70 15 20/20 11.14 [1.03] 1 2505 [1182] 78.4 [2222] 125 [56.7] 132 [59.9]

RA1430AJ1NA 208-230 16012.8/12.8 64.00.70 17 20/20 12.15 [1.13] 1 2605 [1229] 93.0 [2636] 141 [64.0] 148 [67.1]

RA1436AJ1NA 208-230 16014.1/14.1 77.00.60 19 25/25 14.82 [1.38] 1 3104 [1464] 112 [3175] 150 [68.0] 157 [71.2]

RA1442AJ1NA 208-230 16017.9/17.9 112.01.00 24 30/30 16.15 [1.5]13954 [1866] 125 [3543] 189 [58.7] 196 [88.9]

RA1448AJ1NA 208-230 16019.9/19.9 109.01.00 26 35/35 18.84 [1.75] 1 4264 [2012] 135 [3827] 192 [87.1] 199 [90.3]

RA1460AJ1NA 208-230 16023.7/23.7 152.51.00 31

Voltage Phase Freq

Rated

Load

Amperes

(RLA)

Locked

Rotor

Amperes

(LRA)

Fan Motor

Full Load

Amperes

(FLA)

Minimum

Ampacity

Amperes

Net Lbs.

[kg]

WeightOutdoor Coil

Shipping Lbs. [kg]

General Information

UNIT MODEL NUMBER EXPLANATION

R

24

A

14

AJ1NA

MINOR SERIES

TYPE C - COMMUNICATING

N - NON-COMM

TYPE 1 - SINGLE STAGE

VOLTAGE J= 1 PH, 208-230/60 C= 3 PH, 208-230/60 D= 3 PH, 460/60

MAJOR SERIES

CAPACITY

18 = 18,000 BTU/HR [5.28 kW] 24 = 24,000 BTU/HR [7.03 kW] 30 = 30,000 BTU/HR [8.79 kW] 36 = 36,000 BTU/HR [10.55 kW] 42 = 42,000 BTU/HR [12.31 kW] 48 = 48,000 BTU/HR [14.07 kW] 60 = 60,000 BTU/HR [17.58 kW]

SEER HEAT PUMP BRAND

5

GENERAL INFORMATION

“ L”

“W”

“H”

A

I

R

D

I

S

C

H

A

R

G

E

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

DIMENSIONAL DATA

Speciﬁcations

General Information

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

ALLOW 60" [1524mm] OF

CLEARANCE

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

CONDENSING UNIT MODEL

LENGTH “H” (INCHES)

LENGTH “L” (INCHES)

WIDTH “W” (INCHES)

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�

RA14

0

18, 24

25

19" 19" 29"23" 33"

29.75

351⁄2" 401⁄2" 443⁄8"443⁄8" 443⁄8"

29.75

243⁄4"

18

0

30 27

29.75

275⁄8"

36, 42

27

33.75

49043/037 060

48 31

33.75

311⁄2"311⁄2" 311⁄2"

35.75

MATCH ALL COMPONENTS:

• OUTDOOR UNIT

• INDOOR COIL

• INDOOR AIR HANDLER/FURNACE

• REFRIGERANT LINES

• INDOOR THERMOSTAT

60 35

6

Choosing a Location

INSTALLATION

IMPORTANT:

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

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 unit while in operation can impact fan blade or motor life, and coil damage may occur if moisture cannot drain from the unit under freezing conditions�

• Closely follow the clearance recommendations

on page 8�

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

• 60" [152.4 cm] above fan discharge (unit top)

to prevent recirculation

• 6" [15.2 cm] to 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�

Location

7

INSTALLATION

6” MIN. [152mm] FOR 1.5 & 2 TON

9”MIN [229mm] FOR 2.5 – 5 TON

24” [610mm]

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

Choosing a Location (cont�)

Location

For Units With Space Limitations

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

Single-Unit Applications: Side 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 installing 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�

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�

Customer Satisfaction Issues

• The unit 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�

8

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

9

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�

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 TXV 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

10

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 with a

required eld installed lter 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 dierent

lengths, adjust the charge as indicated below� 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 eld installed

• lter dry

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

Example: A three ton condensing 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 = 15ft 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� It is important not to allow the

refrigerant to ash any superheated vapor prior

to the expansion device of the indoor coil� The

ashing of refrigerant can occur for the following

reasons:

• Low refrigerant charge

• Improperly selected liquid line size

• Absorption of heat prior to expansion device

• Excessive vertical rise between the condenser

and evaporator

tubing length, ttings, vertical separation, accessories, and lter dryers. The table below references dierent commonly used equivalent lengths.

Table 1

Solenoid

Valve

Table 2 lists the equivalent length per 25’ of liquid 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 ttings or accessories using the table above.

• Add the total length and tting pressure drop.

This will equal your total equivalent length�

• Reference Table 2 to verify the calculated

equivalent length is compatible with the required vertical rise and diameter of liquid line�

Check

Valve

Site

Glass

Filter

Dryer

Tubing

Note: Elevaon is deﬁned as the

highest point of the line set to the

lowest

11

INSTALLATION

Interconnecting Tubing (cont�)

Example: A 3-Ton condensing 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’

Tubing

Liquid Line

R-410A

System

Capacity

Model

(excerpt fromTable 2, page 16)

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

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�

Long Line Set Applications

Long line set applications are dened as applications 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 o cycle

• Oil return to the compressor

• Capacity losses

• System oil level adjustment

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.

Liquid Line Size

Elevation (Above or Below) Indoor Coil

Total

Maximum

Length - Feet [m]

Equivalent

Vertical Separation - Feet [m]

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

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 dierent od units.

OD Model

RP1518

RP1524

RP1530

RP1536

RP1542

RP1548

RP1560

Compressor

ZP16K5E-PFV-13R 21 ZP21K5E-PFV-13R 21 ZP25K5E-PFV-13R 25 ZP31K6E-PFV-130 21 ZP36K5E-PFV-13R 42 ZP40K6E-PFV-130 42 ZP49K6E-PFV-130 42

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�, Name Plate Oil Charge = 25 oz�, Oil to be Added = ((52�4 oz� +107 oz�) x �022) – (�10 x 25 oz�) = 1�0 oz�

Name Plate Oil

Charge (oz)

12

Interconnecting Tubing (cont�)

Outdoor and Indoor Same Level

INSTALLATION

Suction Line Selection

Purpose of the suction line is to return superheated vapor to the condensing unit from the evaporator� 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 ttings or accessories using the table on

previous page�

• Add the total length and 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 dierence is

compatible with the application�

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. O-Cycle migration 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 conguration for dierent applications�

Ideally, line set slopes

away from outdoor.

Verify sub-cooling prior

to throling device,

Insulated liquid line

Tubing

Reference Table 2 for

maximum length

limitaons

Figure 3

13

INSTALLATION

Indoor Unit Above Outdoor Coil

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:

• TXV or EEV on the indoor unit

• Start components may be required depending

upon quality of voltage

• Crankcase heater

• Insulated liquid and suction line

Inverted trap even with

top of the coil

• 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 and the outdoor units I&O

• Verify adequate sub-cooling at the ID unit prior

to throttling device

Insulated liquid and

sucon line

Reference Table 2

for elevaon

limitaons

Tubing

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

• TXV or EEV at the IDunit

• Crankcase heater

• Start components may be required depending

upon quality of voltage

• Inverted vapor-line trap (Reference Figure 3)

• Insulated liquid and suction line

Figure 4

• Follow the proper line sizing, equivalent length,

charging requirements, and oil level adjustments spelled out in this document and the outdoor units I&O

• 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

14

p

g

Outdoor Unit Above Indoor Unit

Interconnecting Tubing (cont�)

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

Tubing

orator

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

• TXV at the indoor unit

• Crankcase heater

• Start components maybe required depending

upon quality of voltage

• Insulated liquid and suction line

• Follow the proper line sizing, equivalent length,

charging requirements, and oil level adjustments spelled out in this document and the outdoor units I&O

• Verify adequate sub-cooling at the ID unit prior

to throttling device

15

Grey = Considered a Long Line Se t Application.

NOTES:

N

Tubing

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

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

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

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

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

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

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

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

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

Maximum

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

Elevation Above or Below Indoor Coil

Equivalent

Liquid Line Size

16

N/R N/R

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

N/R N/R

NOTES:

N/R = Application not recommended.

60 3/8" [9.53]

48 3/8" [9.53]

42 3/8" [9.53]

36 3/8" [9.53]

30 3/8" [9.53]

24 3/8" [9.53]

18 3/8" [9.53]

1-1/8 [28.58] 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] 1.00 1.00 1.00 1.00 0.99 N/R N/R N/R N/R N/R N/R N/R

7/8 [22.23] 1.00 0.99 0.99 0.98 0.98 N/R N/R N/R N/R N/R N/R N/R

3/4 [19.05] 0.99 0.98 0.96 0.95 0.94 N/R N/R N/R N/R N/R N/R N/R

5/8 [15.88] 0.97 0.94 0.91 0.89 0.87 N/R N/R N/R N/R N/R N/R N/R

1-1/8 [28.58]

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] 1.00 1.00 0.99 0.99 0.99 0.98 0

.98 0.98 0.98 0.98 N/R N/R

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

3/4 [19.05] 0.99 0.98 0.97 0.96 0.96 0.95 0.94 0.93 0.92 0.92 N/R N/R

5/8 [15.88] 0.98 0.95 0.93 0.92 0.9 0.88 0.86 0.85 0.84 0.82 N/R N/R

1-1/8 [28.58] 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

1-1/8 [28.58] N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R

5/8 [15.88] 1.00 0.97 0.95 0.93 0.92 0.91 0.9 0.89 0.87 0.85 0.85 0.84

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

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

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

5/8 [15.88] 0.99 0.98 0.97 0.96 0.95 0.93 0.93 0.91 0.9 0.9 0.89 0.88

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

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

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] 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]

5/8 [15.88] 1.00 0.98 0.97 0.97 0.95 0.95 0.94 0.93 0.93 0.92 0.92 0.91

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

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

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] N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R N/R

3/4 [19.05] 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]

5/8 [15.88] 0.99 1.00 0.99 0.98 0.97 0.97 0.96 0.95 0.94 0.94 0.93 0.94

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

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

5/8 [15.88] 1.00 0.99 0.99 0.98 0.98 0.98 0.97 0.97 0.96 0.96 0.96 0.95

3/4 [19.05] 1.00 1.00 1.00 1.00 1.00 0.99 0.99 0.99 0.99 0.99 0.99 0.99

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]

Outdoor unit Above or Below Indoor Coil

Total Equivalent Length - Feet [m]

Suction Line Size

Tubing

17

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 page 10 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 refrigeration-

grade tubing�

• Always keep tubing sealed until tubing is in

place and connections are to be made�

• A high-quality filter drier is included with all

R-410A 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, drain any oil that has pooled in low spots in the

lineset� Commercially available flush kits are not recommended due to the risk of residual flushing agent being incompatible with POE oils or internal components� Up to 5% mineral oil is considered acceptable in R-410A systems�

• 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 number 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�

Tubing

18

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

19

INSTALLATION

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�)

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�

ST-A1226-07-00

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�

•

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�

20

Control Wiring

WIRING

WARNING: Turn o 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�

Control Wiring

Running low-voltage wires in conduit with line voltage power wires is not recommended� Lowvoltage wiring may be run through the plastic

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

to size the 24-volt control wiring� Do not use phone cord to connect indoor and

outdoor units and thermostat� This could damage the controls and may not be adequately sized for the controls electrical load�

FIELD WIRE SIZE FOR 24-VOLT THERMOSTAT CIRCUITS

Thermostat

Load (amps)

3.0 18 16 14 12 10 10 10

2.5 18 16 14 12 10 10 10

2.0 18 16 14 12 10 10 10 20 50 100 150 200 250 300

[6] [15] [30] [46] [51] [76] [91]

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

AWG between thermostat and outdoor unit�

SOLID COPPER WIRE –AWG.

Length of Run – Feet [m] (1)

CONTROL WIRING FOR GAS OR OIL FURNACE

TYPICAL THERMOSTAT

FOR TYPICAL GAS OR OIL HEAT

BR –BROWN WIRE

YL –YELLOW WIRE

X–WIRE CONNECTION

TYPICAL CONDENSING

UNIT

YL

X

BR

X

IF MAXIMUM OUTLET TEMPERAT URE RISE IS DESIRED, IT IS RECOMMENDED THAT

*

W1 (W/BK) AND W2 (W/BL) BE JUMPERED TOGETHER.

FOR TYPICAL ELECTRIC HEAT

BR –BROWN WIRE

R–RED WIRE

YL –YELLOW WIRE

W/BK –WHITE WIRE WITH BLACK STRIPE

G/BK–GREEN WIRE WITH BLACK STRIPE

PU –PURPLE WIRE (NOT USED)

X–WIRE CONNECTION

•

TYPICAL CONDENSING

UNIT

YL

BR

*

X X

SUBBASE

YGWR

TYPICAL GAS OR

OIL FURNACE

R

W

G

Y

C

TYPICAL THERMOSTAT

SUBBASE

YGWR

TYPICAL ELECTRIC HEAT

LOW VOLTAGE JUNCTION BOX

W/BL

X X

W/BK

X

G/BK

X X

X

YL

BR PU

R

Wiring

Typical Noncommunicating Thermostat Wiring Diagrams

The following figures show the typical wiring diagrams� Cooling airflows may need to be adjusted for homeowner comfort once the system is operational�

WIRE COLOR CODE

BK – BLACK GY – GRAY W – WHITE BR – BROWN O – ORANGE Y – YELLOW BL – BLUE PR – PURPLE G – GREEN R – RED

21

WIRING

ST-A1226-09

Control Wiring (cont�)

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

Power Wiring

It is important that proper electrical power from a commercial utility is available at the compressor contactor� Voltage ranges for operation are shown below�

VOLTAGE RANGES (60 HZ)

Nameplate

Voltage

208/230 187 - 253 (1 Phase)

208/230 187 - 253 (3 Phase)

460 414 - 506 575 517 - 633

Install a branch circuit disconnect within sight of the unit and of adequate size to handle the starting

current (see “Electrical Data” on page 5�)

Operating Voltage Range at

Copeland Maximum Load Design

Conditions for Compressors

Connect power wiring to line-voltage lugs located in the outdoor 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�

Grounding

WARNING: The unit must be

permanently grounded� Failure to do so can cause electrical shock resulting in severe personal injury or death�

Wiring

22

Power wiring must be run in a rain-tight conduit� Conduit must be run through the connector panel below the access cover (see page 6) and attached

to the bottom of the control box�

A grounding lug is provided near the line-voltage power entrance for a ground wire�

Start-Up

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

Checking Airﬂow

START-UP

Even though the unit is factory-charged with Refrigerant-410A, the charge must be checked to the charge table attached to the service panel and adjusted, if required� Allow a minimum of 15 minutes of run time before analyzing charge�

CAUTION: Single-pole contactors

are used on all standard single-phase units through 5 tons� Caution must be exercised when servicing as only one leg of the power supply is broken by the contactor�

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�

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

Air conditioning systems require a specified airflow� Each ton of cooling requires between 320 and 450 cubic feet of air per minute (CFM)� See the manufacturer’s spec sheet for rated airflow for the system being installed�

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

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

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

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

Electric resistance heaters can use: CFM = volts x amps x 3�413 SHC x temp rise Gas furnaces can use: CFM = Output Capacity in BTUH* SHC x temp rise

*Refer to furnace data plate for furnace output capacity� SHC = Sensible Heat Constant (see table below)

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

The measurement for temperature rise should be performed at the indoor coil inlet and near the outlet, but out of direct line of sight of the heater element or heat exchanger� For best results, measure air temperature at multiple points and average the measurements to obtain coil inlet and outlet temperatures�

ALTITUDE

(FEET)

Sea Level 1�08 6000 0�87

500

1000

2000

3000

4000

5000 0�90 20000 0�50

SENSIBLE HEAT

CONSTANT

(SHC)

1�07 7000 0�84

1�05 8000 0�81

1�01 9000 0�78

0�97 10000 0�75

0�94 15000 0�61

ALTITUDE

(FEET)

SENSIBLE HEAT

CONSTANT

(SHC)

Airﬂow Start-Up

23

START-UP

ST-A1226-08-00

Evacuation

Evacuation and Leak Testing

Evacuation Procedure

Evacuation is the most important part of the entire service procedure� The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air and moisture from the system�

Air or nitrogen in the system causes high condensing temperatures and pressure, resulting in increased power input and nonverifiable performance�

Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoric acid� This attacks motor windings and parts, causing breakdown�

• Gauges must be connected at this point to

IMPORTANT: Compressors

(especially scroll type) should never be used to evacuate the air conditioning system because internal electrical arcing may result in a damaged or failed compressor� Never run a scroll compressor while the system is in a vacuum or compressor failure will occur�

Final Leak Testing

After the unit has been properly evacuated and service valves opened, a halogen leak detector should be used to detect leaks in the system� All piping within the condenser, evaporator, and

• After the system has been leak-checked and

proven sealed, connect the vacuum pump and evacuate system to 500 microns and hold 500 microns or less for at least 15 minutes� The vacuum pump must be connected to both the high and low sides of the system by connecting to the two pressure ports� Use the largest size connections available since restrictive service connections may lead to false readings because of pressure drop through the fittings�

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�

check and adjust charge� Do not replace caps yet�

• After adequate evacuation, open both service

valves by removing both brass service valve

caps with an adjustable wrench. Insert a 3/16" [5 mm] or 5/16" [8 mm] hex wrench into the

stem and turn counterclockwise until the wrench stops�

24

Checking Refrigerant Charge

START-UP

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

WARNING:

compressor shell is hot� Touching the compressor top may result in serious personal injury�

The top of the scroll

IMPORTANT: Use factory-approved

charging method as outlined on the next page to ensure proper system charge�

NOTICE: The optimum refrigerant charge

for any outdoor unit matched with an indoor coil/air handler is affected by the application� Therefore, charging data has been developed to assist the field technician in optimizing the charge for all mounting configurations (UF – Upflow, DF – Downflow, LH – Left-Hand Discharge, and RH – Right-Hand Discharge)� Refer to the charging chart inside the access panel cover on the unit and choose the appropriate column for the specific application being installed or serviced�

Charging Units With R-410A Refrigerant

CAUTION:

approximately 60% higher (1�6 times) than R-22 pressures� Use appropriate care when using this refrigerant� Failure to exercise care may result in equipment damage or personal injury�

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

R-410A pressures are

IMPORTANT: Do not operate the

compressor without charge in the system� Addition of R-410A will raise high-side pressures

(liquid and discharge)�

NOTICE: System maintenance is to be

performed by a qualified and certified technician� The following method is used for charging systems

in the cooling mode� All steps listed should be performed to ensure proper charge has been set� For measuring pressures, the service valve port on the liquid valve (small valve) and suction valve (large valve) are to be used

Supply airflow must be between 320 and 450 cfm per rated cooling ton prior to adjusting system charge� If a humidification system is installed, disengage it from operation prior to charge

adjustment. Refer to the “Checking Airflow” section

of this manual for further instruction�

NOTICE: Verify system components

are matched according to the outdoor unit Specification Sheet�

Measurement Device Setup

1� With an R-410A gauge set, attach the high-

pressure hose to the access fitting on the liquid (small) service valve at the OD unit�

2�

Attach the low-pressure hose to the access fitting

on the suction (large) service valve�

3. Attach a temperature probe within 6" [15.2 cm]

outside of the unit on the copper liquid line (small line)� For more accurate measurements, clean the copper line prior to measurement and use a calibrated clamp-on temperature probe or an insulated surface thermocouple�

Charging by Weight

NOTICE:

weight for the straight length of the refrigerant line set� For a new installation, evacuation of inter-

connecting tubing and indoor coil is adequate;

otherwise, evacuate the entire system� Use the factory charge shown in “Electrical and Physical

Data” on page 5 of these instructions or on the

unit data plate� Note that the charge value includes

charge required for 15 ft. [4.6 m] of standard-size

interconnecting liquid line without a filter drier� Calculate actual charge required with installed

liquid line size and length using:

1/4" [6.4 mm] O.D. = .3 oz./ft. [8.5 g/.30 m] 5/16" [7.9 mm] O.D. = .4 oz./ft. [11.3 g/.30 m] 3/8" [9.5 mm] O.D. = .6 oz./ft. [17.0 g/.30 m] 1/2" [12.7 mm] O.D. = 1.2 oz./ft. [34.0 g/.30 m]

Add 6 oz� for field-installed filter drier�

Adjust the system charge by

Refrigerant

Confirm ID Airflow and Coils Are Clean

Confirm adequate indoor supply airflow prior to starting the system� See the Technical Specification Sheet for rated airflow for each ID/OD unit match� Air filter(s) and coils (indoor and outdoor) are to be clean and free of frost prior to starting the system�

25

START-UP

Checking Refrigerant Charge (cont�)

Refrigerant

With an accurate scale (+/– 1 oz. [28.3 g]) 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�

IMPORTANT: Charging by weight is

not always accurate since the application can affect the optimum refrigerant charge� Charging by weight is considered a starting point ONLY� Always check the charge by using the Charging Chart and adjust as necessary� CHARGING BY LIQUID SUBCOOLING MUST BE USED FOR FINAL CHARGE ADJUSTMENT�

With thermostat in the “Off” position, turn on

the power to the furnace or air handler and the condensing unit� Start the condensing unit and the furnace or air handler with the thermostat� Verify that the outdoor unit is operating and the indoor air mover is delivering the correct airflow for the system size�

Gross Charging by Pressures

1� Following airflow verification and charge weigh-

in, run the unit for a minimum of 15 minutes prior to noting pressures and temperature�

IMPORTANT: Indoor conditions

as measured at the indoor coil must be within

2°F [1.1°C] of the following during gross charge

(pressure) evaluation:

Cooling Mode: 80°F [26.7°C] Dry Bulb Heating Mode: 70°F [21.1°C] Dry Bulb

NOTICE:

or below this range, run the system to bring the temperature down or run the electric heat/furnace to bring the temperature within this range� System pressure values provided in the Charging Chart for outdoor dry bulbs corresponding to conditions outside of these ranges are provided as reference ONLY�

If the Indoor temperature is above

2� Note the Outdoor Dry Bulb Temperature,

ODDB° = _____°F [_____°C]� Unit charging is recommended under the following outdoor conditions ONLY:

Cooling Mode ONLY: 55°F [12.8°C] outdoor dry

bulb and above

3� Locate and note the design pressures� The

correct liquid and vapor pressures are found at the intersection of the installed system and the outdoor ambient temperature on the Charging Chart located inside the access panel cover�

Liquid Pressure: = ______psig; Vapor Pressure =

______psig

NOTICE:

are for gross charge check ONLY� These pressure values are typical, but may vary due to application� Evaporator load (indoor coil in cooling mode/outdoor coil in heating mode) will cause pressures to deviate� Note that all systems have unique pressure curves� The variation in the slope and value is determined by the component selection for that indoor/outdoor matched system� The variation from system to system seen in the table is normal� The values listed are for the applicable indoor coil match ONLY!

4� If the measured liquid pressure is below the

listed requirement for the given outdoor and indoor conditions, add charge� If the measured liquid pressure is above the listed requirement for the given outdoor and indoor conditions, remove charge�

The refrigerant pressures provided

Final Charge by Subcooling

1� After gross charging, note the designed

subcooling value� The correct subcooling value is found at the intersection of the installed system and the outdoor ambient temperature on the Charging Chart located inside the access panel cover�

SC° from Charging Chart = _____°F [_____°C].

IMPORTANT: Indoor conditions as

measured at the indoor coil are required to be

between 70°F [21.1°C] and 80°F [26.7°C] dry

bulb for fine-tuned unit charge adjustment� Unit charging is recommended under the following outdoor conditions ONLY:

Cooling Mode ONLY: 55°F [12.8°C] outdoor dry

bulb and above

26

Checking Refrigerant Charge (cont�)

START-UP

NOTICE: If the indoor temperature is

above or below the recommended range, run the system to bring the temperature down or run the electric heat/furnace to bring the temperature up� System subcooling values provided in the Charging Chart for outdoor dry bulbs corresponding to conditions outside of the above range are provided as reference ONLY�

2� Note the measured Liquid Pressure, Pliq =

______psig, as measured from the liquid (small) service valve� Use the Temperature Pressure Chart below to note the corresponding saturation temperature for R-410A at the measured liquid pressure�

Liquid Saturation Temperature, SAT°= _____°F

[_____°C].

3� Note the liquid line temperature, Liq° = _____°F

[_____°C], as measured from a temperature probe located within 6" [15.2 cm] outside of

the unit on the copper liquid line (small line)� It is recommended to use a calibrated clampon temperature probe or an insulated surface thermocouple�

4�

Subtract the liquid line temperature from the

saturation temperature to calculate subcooling� SAT°_____°F SC°_____°F

5�

Adjust charge to obtain the specified subcooling

value� If the measured subcool is below the listed requirement for the given outdoor and indoor

[_____°C]

- Liq°_____°F

[_____°C]

=

conditions, add charge� If the measured subcool is above the listed requirement for the given outdoor and indoor conditions, remove charge�

Finishing Up Installation

• Disconnect pressure gauges from pressure ports;

then replace the pressure port caps and tighten

adequately to seal caps� Do not overtighten.

• Replace the service valve caps finger-tight

and then tighten with an open-end wrench

adequately to seal caps� Do not overtighten.

• Replace control box cover and service panel and

install screws to secure service panel�

• Restore power to unit at disconnect if required.

• Configure indoor thermostat per the thermostat

installation instructions and set thermostat to desired mode and temperature�

NOTICE: Systems should not be fine-

tune charged below 40°F [4.4°C] outdoor dry bulb.

IMPORTANT: Excessive use of

elbows in the refrigerant line set can produce excessive pressure drop� Follow industry best practices for installation� Installation and commissioning of this equipment is to be performed by trained and qualified HVAC professionals� For technical assistance, contact

your Distributor Service Coordinator�

Refrigerant

TEMPERATURE PRESSURE CHART

SATURATION

TEMP

(Deg. F) [Deg.

C]

-150 [-101]

-140 [-96]

-130 [-90]

-120 [-84]

-110 [-79]

-100 [-73]

-90 [-68]

-80 [-62]

-70 [-57]

-60 [-51] 0�4 15 [-9] 70�2 80 [27] 235�6 145 [63] 576�0

-50 [-46] 5�1 20 [-7] 78�5 85 [29] 254�5 150 [66] 612�8

-40 [-40] 10�9 25 [-4] 87�5 90 [32] 274�3

-35 [-37] 14�2 30 [-1] 97�2 95 [35] 295�3

R-410A

PSIG

– -30 [-34]

– -25 [-32]

– -20 [-29]

– -15 [-26]

– -10 [-23]

– -5 [-21]

–

SATURATION

(Deg. F) [Deg.

10 [-12] 62�4 75 [24] 217�8 140 [60] 541�2

TEMP

C]

0 [-18] 48�4 65 [18] 185�1 130 [54] 476�5

5 [-15] 55�1 70 [21] 201�0 135 [57] 508�0

R-410A

PSIG

17�9 35 [2] 107�5 100 [38] 317�4

22�0 40 [4] 118�5 105 [41] 340�6

26�4 45 [7] 130�2 110 [43] 365�1

31�3 50 [10] 142�7 115 [46] 390�9

36�5 55 [13] 156�0 120 [49] 418�0

42�2 60 [16] 170�1 125 [52] 446�5

SATURATION

TEMP

(Deg. F) [Deg.

C]

R-410A

PSIG

SATURATION

TEMP

(Deg. F) [Deg.

C]

R-410A

PSIG

27

COMPONENTS AND CONTROLS

Compressor Crankcase Heat (CCH)

Components

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 refrigerant migration and to help eliminate any start up noise

or bearing “wash out.”

NOTE: A crankcase heater should be installed if:

• The system charge exceeds the values listed in

the adjacent tables,

• The system is subject to low voltage variations,

or

• When a low ambient control is used for system

operation below 55°F�

RA14 Charge Limit

ModelCompressorWithout Crankcase

Size Model Number Heat (1 Phase)

18 ZP14KAE 24 ZP20KAE 30 ZP24K5E 36 ZP29K5E 42 ZP34K5E 48 ZP39K5E 60 ZP49K6E

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 is on and wall thermostat is off�)

9.6

9.6 lbs.

9.6

9.6 lbs.

9.6

9.6 lbs.

9.6

9.6 lbs.

12

12 lbs.

12

12 lbs.

12

12 lbs.

28

High- and Low-Pressure Controls (HPC and LPC)

HPC and LPC are not installed on RA14**AJINA, but can be field installed using the followiing kit numbers: RXAB-A0z (high pressure control) and RXAC-A0Z (low pressure control)� These controls keep the compressor from operating in pressure ranges which can cause damage to the compressor� Both controls are in the low-voltage control circuit�

The high-pressure control (HPC) is an automaticreset which opens near 610 PSIG and closes near 420 PSIG�

The low-pressure control (LPC) is an automaticreset which opens near 15 PSIG and closes near 40 PSIG�

CAUTION: 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�

ACCESSORIES

WARNING: Turn o 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�

CAUTION:

SINGLE POLE COMPRESSOR CONTACTOR (CC):

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

Hard Start Components

Time Delay Control (Part No. RXMD-B01)

The time delay control 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�

Low Ambient Control (LAC) (Part No. RXAD-A08)

This component senses compressor head pressure and shuts the heat pump fan off when the head pressure drops to approximately 250 PSIG� This allows the unit to build a sufficient head pressure at lower outdoor ambient (down to 0°F

[-18°C]) in order to maintain system balance and

obtain improved capacity� Low ambient control should be used on all equipment operated below 70°F [21°C} ambient�

Accessories

Start components are not usually required with the scroll compressors used in RA14 condensing units, but are available for special cases and where start components are desirable to reduce light dimming�

29

DIAGNOSTICS

NO

YES

Thermostat

Problem?

Transformer

Problem?

Go to Mechanical Checks

for Cooling or Heating

Hi Pressure Cut-Out

Hot Gas Sensor

Compressor

Time-Delay

Unit Wiring and

Connections

Start Capacitor

Potential Relay

Compressor Internal

Overload Open

Unit Wiring and

Connections

Compressor Winding

Open

Unit

Running?

YES

Repair and

Recheck

YES

Repair and

Recheck

NO

Voltage on Compressor

Side of Contactor?

NO

YES

Run Capacitor

NO

Voltage on Line

Side of Contactor?

NO

Circuit Breakers or

Fuses Open

YES

Compressor Winding

Grounded

Outdoor Fan Motor

Grounded

Grounded Capacitor

Replace Fuses or Reset

Breakers and Recheck

System

YES

Compressor

Contactor

NO

Unit Wiring and

Connections

Electrical Checks Flowchart

Diagnostics

30

YES

NO

Pressure

Problems?

Low Liquid

Pressure

Low Suction

Pressure

High Head

Pressure

Go to Electrical

Checks Flowchart

Dirty Filters

Dirty Indoor Coil

Inadequate Indoor

Airow

Inoperative Indoor

Blower

Low on Charge

Open IPR

Valve

Low Ambient

Temperature

Bad

Compressor

Outdoor Check

Valve Closed

Restricted Indoor

Metering Device

Restricted Filter Drier

Dirty Outdoor

Coil

Inoperative Outdoor

Fan

Overcharge

Recirculation of

Outdoor Air

Noncondensibles

Higher Than Ambient Air

Entering Outdoor Coil

Wrong Outdoor

Fan Rotation

Inadequate Ducts

Outdoor Check

Valve Closed

Restricted Filter Drier

Outdoor Unit

Running?

Low on Charge

Restricted Indoor

Metering Device

Restriction in

System

Recirculation of

Indoor Air

Wrong Indoor

Blower Rotation

Cooling Mechanical Checks Flowchart

DIAGNOSTICS

Diagnostics

31

DIAGNOSTICS

General Troubleshooting Chart

Diagnostics

WARNING:

Disconnect all power to unit before servicing� Contactor may break only one side� Failure to shut off power can cause electrical shock resulting in personal injury or death�

SYMPTOM POSSIBLE CAUSE REMEDY

Unit will not run • Power o or loose electrical connection

• Thermostat out of calibration – set too high

• Defective control board

• Blown fuses/tripped breaker

• Transformer defective

• High-pressure control open

Low-pressure control open

• Miswiring of communications (communication

light on continuously)

Outdoor fan runs, compressor doesn't

Insucient cooling • Improperly sized unit

Compressor short cycles

Registers sweat • Low indoor airow • Increase speed of blower or reduce restriction.

High head, low vapor pressures

High head, high or normal vapor pressure – Cooling mode

Low head, high vapor pressures

Low vapor, cool compressor, iced indoor coil

High vapor pressure • Excessive load

Fluctuating head and vapor pressures

Gurgle or pulsing noise at expansion device or liquid line

• Run or start capacitor defective

• Contactor defective

• Loose connection

• Compressor stuck, grounded or open motor

winding, open internal overload�

• Low-voltage condition

• Improper indoor airow

• Incorrect refrigerant charge

• Air, noncondensibles, or moisture in system

• Bad ID TXV

• Incorrect voltage

• Defective overload protector

• Refrigerant undercharge

• Restriction in liquid line, expansion device, or lter drier

• Bad TXV

• Dirty outdoor coil

• Refrigerant overcharge

• Outdoor fan not running

• Air or noncondensibles in system

• Bad TXV

• Bad compressor

• Low indoor airow

• Operating below 65°F outdoors

• Moisture in system

• Closed ID circuit

• Defective compressor

• TXV hunting

• Air or noncondensibles in system

• Air or noncondensibles in system • Recover refrigerant. Evacuate and recharge.

• Check for correct voltage at line voltage connections in

condensing unit�

• Reset.

• Check control board diagnostic codes.

• Replace fuses/reset breaker.

• Check wiring. Replace transformer.

• Reset. Also see high head pressure remedy. The high-

pressure control opens at 610 PSIG�

• Check communication wiring.

• Replace.

• Check for correct voltage at compressor. Check and

tighten all connections�

• Wait at least 3 hours for overload to reset. If still open,

replace the compressor�

• Add start kit components.

• Recalculate load.

• Check. Should be approximately 400 CFM per ton.

• Charge per procedure attached to unit service panel.

• Recover refrigerant. Evacuate and recharge. Add lter

drier�

• Replace TXV

• At compressor terminals, voltage must be ± 10% of

nameplate marking when unit is operating�

• Replace. Check for correct voltage.

• Add refrigerant.

Replace air lter.

• Remove or replace defective component.

• Replace TXV.

• Clean coil.

• Correct system charge.

• Repair or replace.

• Recover refrigerant. Evacuate and recharge.

• Replace TXV.

• Replace compressor.

• Increase speed of blower or reduce restriction. Replace air lter.

• Add Low Ambient Kit.

• Recover refrigerant. Evacuate and recharge. Add lter

drier�

• Repair or replace ID coil

• Recheck load calculation.

• Replace.

• Check TXV bulb clamp. Check air distribution on coil.

Replace TXV�

• Recover refrigerant. Evacuate and recharge.

32

DIAGNOSTICS

Service Analyzer Charts

COMPRESSOR OVERHEATING

SYMPTOM POSSIBLE CAUSE CHECK/REMEDY

High superheat (greater than 15°F

[-9°C] at coil)

Low line voltage Loose wire connections

High line voltage Power company problem Have problem corrected�

Low charge Check system charge�

Faulty metering device Restricted cap tube, TEV (TXV)

Power element superheat out of adjustment internally

Foreign matter stopping ow

High internal load Hot air (attic) entering return

Heat source on; miswired or faulty control

Restriction in liquid line

Low head pressure Low charge

Suction or liquid line subjected to high heat source

Power company problem, transformer Have problem corrected before diagnosis continues�

Undersized wire feeding unit Correct and complete diagnosis�

Drier plugged�

Line kinked�

Operating in low ambient temperatures

Hot attic / insulate liquid line

Hot water line

Check wiring�

High head pressure

Short cycling of compressor

Overcharge Check system charge�

Dirty outdoor coil Clean coil�

Faulty or wrong size outdoor fan motor Replace fan motor�

Faulty fan blade or wrong rotation Replace fan blade�

Replace with correct rotation motor�

Recirculation of air Correct installation�

Additional heat source Check for dryer vent near unit�

Check for recirculation from other equipment�

Noncondensibles Recover refrigerant� Evacuate and recharge system�

Equipment not matched Correct mismatch�

Faulty pressure control Replace pressure control�

Loose wiring Check unit wiring�

Thermostat Located in supply air stream

Dierential setting too close

Customer misuse

TEV Internal foreign matter

Power element failure

Valve too small

Distributor tube/tubes restricted

Distributor tube Restricted with foreign matter

Kinked

I�D� reduced from previous compressor failure

Diagnostics

33

DIAGNOSTICS

Service Analyzer Charts

COMPRESSOR OVERHEATING (cont.)

SYMPTOM POSSIBLE CAUSE CHECK OR REMEDIES

Short cycling of compressor (cont�)

Faulty Compressor Valves

ELECTRICAL

SYMPTOM POSSIBLE CAUSE CHECK OR REMEDIES

Voltage present on load side of compressor contactor and compressor won't run

Voltage present on line side of compressor contactor only

Diagnostics

No voltage on line side of compressor contactor

Low charge Check system charge�

Low evaporator airow Dirty coil

Dirty lter

Duct too small or restricted

Faulty run capacitor

Faulty internal overload Replace compressor�

Fast equalization/Low pressure dierence Replace compressor and examine system to

Compressor start components Check start capacitor�

Run capacitor Check with ohmmeter

Internal overload Allow time to reset�

Compressor windings Check for correct ohms�

Thermostat Check for control voltage to contactor coil�

Compressor control circuit High-pressure switch

Blown fuses or tripped circuit breaker

Improper wiring Recheck wiring diagram�

Replace�

locate reason�

Check potential relay�

Low-pressure switch

Ambient thermostat

Solid-state protection control or internal thermal sensors

Compressor timed o/on control or interlock

Check for short in wiring or unit�

34

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�

FLOODED STARTS

SYMPTOM POSSIBLE CAUSE CHECK OR REMEDIES

Liquid in the compressor shell

Too much liquid in system

Faulty or missing crankcase heater Replace crankcase heater�

Incorrect piping Check piping guidelines�

Overcharge Check and adjust charge�

DIAGNOSTICS

Service Analyzer Charts

CONTAMINATION

SYMPTOM POSSIBLE CAUSE REMEDY

Moisture Poor evacuation on installation or during service In each case, the cure is the same� Recover refrigerant�

High head pressure Noncondensibles air

Unusual head and suction readings

Foreign matter –

copper lings

Copper oxide Dirty copper piping or nitrogen not used when

Welding scale Nitrogen not used during brazing

Soldering ux Adding ux before seating copper partway

Excess soft solder Wrong solder material

Wrong refrigerant or mixed refrigerants

Copper tubing cuttings

brazing

LOSS OF LUBRICATION

SYMPTOM POSSIBLE CAUSE REMEDY

Compressor failures Line tubing too large Reduce pipe size to improve oil return�

Low suction pressure Low charge Check system charge�

Refrigerant leaks Repair and recharge�

Cold, noisy compressor – Slugging

Noisy compressor Migration Check crankcase heater�

Cold, sweating compressor

Low load Reduced airow Dirty lter

Short cycling of compressor

Dilution of oil with refrigerant Observe piping guidelines�

Flooding Check system charge�

Thermostat setting

Faulty high- or low-pressure control Replace control�

Loose wiring Check all control wires�

Thermostat In supply air stream, out of calibration

Add lter drier, evacuate, and recharge.

Dirty coil

Wrong duct size

Restricted duct

Advise customer�

Customer misuse

Diagnostics

SLUGGING

SYMPTOM POSSIBLE CAUSE REMEDY

On start-up Incorrect piping Review pipe size guidelines�

TEV hunting when running

Faulty TEV Replace TEV�

35

DIAGNOSTICS

Service Analyzer Charts

FLOODING

SYMPTOM POSSIBLE CAUSE REMEDY

Poor system control

using a TEV

THERMOST A TIC EXPANSION V ALVES

SYMPTOM POSSIBLE CAUSE REMEDY

High Superheat, Low

Suction Pressure

(superheat over

15°F [-9°C])

Diagnostics

Valve feeds too much

refrigerant, with low

superheat and higher

than normal suction

pressure

Loose sensing bulb Secure the bulb and insulate�

Bulb in wrong location Relocate bulb�

Wrong size TEV Use correct replacement�

Improper superheat setting (less than 5°F [-15°C])

Moisture freezing and blocking valve Recover charge, install lter-drier, evacuate system,

Dirt or foreign material blocking valve Recover charge, install lter-drier, evacuate system,

Low refrigerant charge Correct the charge�

Vapor bubbles in liquid line Remove restriction in liquid line� Correct the refrigerant

Misapplication of internally equalized valve Use correct TEV�

Plugged external equalizer line Remove external equalizer line restriction�

Undersized TEV Replace with correct valve�

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

Charge migration from sensing bulb to power head (Warm power head with warm, wet cloth� Does valve operate correctly now?)

Moisture causing valve to stick open� Recover refrigerant, replace lter-drier, evacuate system,

Dirt or foreign material causing valve to stick open

TEV seat leak (a gurgling or hissing sound is

heard AT THE TEV during the o 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 straps, in 2:00 or 4:00

Low superheat adjustment Replace TEV�

Incorrectly installed, or restricted external equalizer line

Replace TEV�

recharge�

charge�

Remove noncondensible gases�

Size liquid line correctly�

Ensure TEV is warmer than sensing bulb�

and recharge�

Recover refrigerant, replace lter drier, evacuate system,

and recharge�

Replace the TEV�

position on suction line, with insulation�

Remove restriction, or relocate external equalizer�

36

Service Analyzer Charts

THERMOSTATIC EXPANSION VALVES (cont.)

SYMPTOM POSSIBLE CAUSE REMEDY

Refrigerant drainage from ooded evaporator Install trap riser to the top of the evaporator coil�

Compressor ood

back upon start-up

Superheat is low to

normal with low suction pressure

Superheat and

suction pressure

uctuate (valve is

hunting)

Valve does not

regulate at all

Inoperable crankcase heater or crankcase heater needed

Any of the causes listed under symptoms of Electrical problems on page 45

Unequal evaporator circuit loading Ensure airow is equally distributed through evaporator.

Low load or airow entering evaporator coil Ensure blower is moving proper air CFM�

Expansion valve is oversized Install correct TEV�

Sensing bulb is aected by liquid refrigerant or refrigerant oil owing through suction line

Unequal refrigerant ow through evaporator

circuits

Moisture freezing and partially blocking TEV Recover refrigerant, change lter-drier, evacuate system,

External equalizer line not connected or line plugged

Sensing bulb lost its operating charge Replace TEV�

Valve body damaged during soldering or by improper installation

Replace or add crankcase heater�

Any of the solutions listed under solutions of Electrical problems on page 45

Check for blocked distributor tubes�

Remove/Correct any airow restriction.

Relocate sensing bulb in another position around the circumference of the suction line�

Ensure sensing bulb is located properly�

Check for blocked distributor tubes�

and recharge�

Connect equalizer line in proper location, or remove any blockage�

Replace TEV�

DIAGNOSTICS

37

Diagnostics

DIAGNOSTICS

SYSTEM

PROBLEM

Overcharge

Undercharge

Liquid Restriction

(Drier)

Low Indoor Airﬂow

Dirty Outdoor Coil

Low Outdoor

Ambient Temperature

Inefﬁcient

Compressor

Indoor TXV Feeler Bulb Charge Lost

Poorly Insulated

Indoor Sensing Bulb

DISCHARGE

PRESSURE

COOLING MODE

TROUBLESHOOTING TIPS

INDICATORS

SUCTION

PRESSURE

High High Low High High

Low Low High Low Low

Low Low High High Low

Low Low Low Low Low

High High Low Low High

Low Low High High Low

Low High High High Low

Low Low High High Low

High High Low Low High

SUPERHEAT

Normal: 5°–15°F

[-15° – -9°C]

SUBCOOLING

Normal: See

Charging Chart

COMPRESSOR

AMPS

Diagnostics

38

For Single-Phase Models

WIRING DIAGRAMS

Wiring Diagrams

39

WIRING DIAGRAMS

For Three-Phase Models

Wiring Diagrams

40

NOTES

41

NOTES

42

NOTES

43

44

Rheem RA1460AJ1NA, RA1448AJ1NA, RA1442AJ1NA, RA1436AJ1NA, RA1430AJ1NA Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual