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Stellar Industries
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HDH018 - 60
User Manual
16 pgs2.57 Mb0

Stellar Industries HDH018 - 60, HDB012 - 76, HDE024 - 60 User Manual

CONTENTS
GENERAL
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2
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2
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2
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2
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2
LOCATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
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3
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3
UNIT PLACEMENT
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3
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4
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4
PIPING CONNECTIONS
. . . . . . . . . . . . . . . . . . . . . . . . . .
5
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5
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6
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6 & 7
GENERAL INFORMATION & GROUNDING
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8
FIELD CONNECTIONS POWER WIRING
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8
FIELD CONNECTIONS CONTROL WIRING
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8
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8
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9
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9
SYSTEM START-UP
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9
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9
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13
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13
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13
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13
INSTALLATION
INSTRUCTIONS
CAUTION:
READ ALL SAFETY GUIDES BEFORE
YOU BEGIN TO INSTALL YOUR UNIT.
SAVE THIS MANUAL
STELLAR
AIR CONDITIONING UNIT
SPLIT-SYSTEM COOLING
MODELS:
10 SEER
H*DB012 - 76
11 SEER
H*DE024 - 60
12 SEER
H*DH018 - 60
50 Hz
H*DA018-076
035-14562-000 REV A (
999) Form 550.38-N1Y (999)
®
550.38-N1Y
2
Unitary Products Group
GENERAL
This instruction covers the installation of the following Stellar
air conditioning units.
NOMENCLATURE
H
4 DB
030 S
06
Product Category
H = Condensing Unit
Product Generation
4 = Design Level
Product Identifier
DB = 10.00 SEER Condensing Unit
DE = 11.00 SEER Condensing Unit
DH = 12.00 SEER Condensing Unit
DA = 50 Hz Condensing Unit
Nominal Cooling Capacity
012 = 12,000 BTUH
036 = 36,000 BTUH
018 = 18,000 BTUH
042 = 42,000 BTUH
024 = 24,000 BTUH
048 = 48,000 BTUH
030 = 30,000 BTUH
060 = 60,000 BTUH
076 = 76,000 BTUH
Refrigerant Line Connections
S = Sweat-Connect
Voltage Code
06 = 208/230-1-60
46 = 460-3-60
78 = 230-1-50
25 = 208/230-3-60
58 = 575-3-60
50 = 380/415-3-50
These outdoor units are designed to be connected to a
matching UPG indoor coil with sweat connection lines. These
units are factory charged with refrigerant for a matching
indoor coil plus 15 feet of field supplied line. The outside unit
is designed to be placed alongside or at the back of the
home, remote from the indoor coil. The outdoor unit has been
factory run-tested and all components of the system are
ready for easy, immediate installation.
Matching evaporators contain an orifice liquid feed sized for
the most common usage. The orifice size and/or refrigerant
charge may need to be changed for some indoor-outdoor unit
combinations, elevation differences or total line lengths.
SAFETY
Use this instruction in conjunction with the instruction for the
appropriate indoor evaporator coil, variable speed air handler
or furnace and other accessories. Read all instructions before
installing the unit.
Installer should pay particular attention to the words: NOTE,
CAUTION and WARNING.
NOTES are intended to clarify or make the installation easier.
CAUTIONS are given to prevent equipment damage.
WARNINGS are given to alert the installer that personal
injury and/or equipment damage may result if installation pro-
cedures are not handled properly..
INSPECTION
As soon as a unit is received, it should be inspected for possi-
ble damage during transit. If damage is evident, the extent of
the damage should be noted on the carrier's freight bill. A
separate request for inspection by the carrier's agent should
be made in writing. See Form 50.15-NM for more information.
LIMITATIONS
The unit should be installed in accordance with all national
and local safety codes and the limitations listed below:
1.
Limitations for the indoor unit, coil and appropriate
accessories must also be observed.
2.
The outdoor unit must not be installed with any duct work
in the air stream. The outdoor fan is the propeller type
and is not designed to operate against any additional
external static pressure.
3.
The unit should not be operated at outdoor temperatures
below 45 °F.
4.
Indoor evaporator coil orifice
must be removed prior to
the installation of a TXV kit if the system match requires
a TXV.
This product must be installed in strict compliance
with the enclosed installation instructions and any
applicable local, state, and national codes including,
but not limited to, building, electrical, and mechanical
codes.
Incorrect installation may create a condition where the
operation of the product could cause personal injury
or property damage.
550.38-N1Y
Unitary Products Group
3
®
LOCATION
Before starting the installation, select and check the suitability
of the location for both the indoor and outdoor unit. Observe
all limitations and clearance requirements.
The outdoor unit must have sufficient clearance for air
entrance to the condenser coil, for air discharge and for ser-
vice access. See Figure 1.
If the unit is to be installed on a hot sun exposed roof or a
black-topped ground area, the unit should be raised suffi-
ciently above the roof or ground to avoid taking the accumu-
lated layer of hot air into the outdoor unit.
Provide an adequate structural support.
GROUND INSTALLATION
The unit may be installed at ground level on a solid base that
will not shift or settle, causing strain on the refrigerant lines
and possible leaks. Maintain the clearances shown in Figure
1 and install the unit in a level position. Isolate the base from
the structure to avoid noise or vibration transmission.
Isolate the unit from rain gutters to avoid any possible wash
out of the foundation.
Normal operating sound levels may be objectionable if the
unit is placed directly under windows of certain rooms (bed-
rooms, study, etc.).
ROOF INSTALLATION
When installing units on a roof, the structure must be capable
of supporting the total weight of the unit, including a pad, lin-
tels, rails, etc., which should be used to minimize the trans-
mission of sound or vibration into the conditioned space.
UNIT PLACEMENT
1.
Provide a base in the pre-determined location.
2.
Remove the shipping carton and inspect for possible
damage.
3.
Compressor tie-down bolts should remain tightened.
4.
Position the unit on the base provided.
5.
Sit unit on the (4) rubber elevating grommets if provided.
Use grommet kit 1SG0601 if not provided. These should
be positioned as shown in Figure 2 to reduce noise and
allow for proper drainage.
6.
Make a hole(s) in the structure wall large enough to
accommodate the insulated vapor line, the liquid line and
the wiring.
FIGURE 1: TYPICAL INSTALLATION
THERMOSTAT
TO
BLOWER
MOTOR
RELAY
TO POWER
SUPPLY
NEC CLASS 1
WIRING
NEC CLASS 2
WIRING
TO
COIL
NOTE: ALL OUTDOOR WIRING
MUST BE WEATHERPROOF
SEAL OPENING(S) WITH PERMAGUM OR EQUIVALENT
24” SERVICE
ACCESS CLEARANCE
REQUIRED
WEATHERPROOF
DISCONNECT
SWITCH
48” OVERHEAD
CLEARANCE
REQUIRED
12” REAR
AND SIDES
CLEARANCE
REQUIRED
Sit unit on
rubber
elevator
grommets
to reduce
noise and
allow for
proper
drainage.
®
550.38-N1Y
4
Unitary Products Group
FIGURE 2 :
POSITIONING GROMMETS
VERIFY INDOOR REFRIGERANT ORIFICE
Refer to the Tabular Data Sheet for the outdoor unit model
and installed evaporator coil. Determine the correct orifice for
that combination.
If the orifice sizes match, nothing further is required and the
refrigerant lines may be connected per the outdoor unit
instruction. However, if another orifice should be used,
change the orifice in the coil with the following procedure:
1.
First, relieve the holding charge by depressing the
Schrader valve located in the end of the liquid line.
2.
Remove the liquid line fitting using 3/4" wrenches, and
remove the pre-installed orifice with a small diameter
wire or paper clip.
3.
Remove the new orifice from the packet and verify that it
is the correct number required. Install this orifice with the
rounded end toward the coil and the flat end outward per
Figure 3 on page 4.
4.
Thread the liquid line fitting back in place on the coil.
Tighten the fitting hand tight and turn an additional 1/8
turn to seal.
NOTE:
This procedure should be done within 2 minutes to
keep air and contaminates from entering the coil. If the
orifice cannot be replaced and the coil resealed within
2 minutes, then it should be temporarily closed to air
using masking tape (short term delay) or plugging/cap-
ping (long term delay). There is no need to purge the
coil if this procedure is done within the time limit.
5.
Mark the data plate of the coil with the orifice installed.
INSTALLATIONS REQUIRING TXV
For installations requiring a TXV, the following are the basic
steps for installion. For detailed instructions, refer to the
Installation Instructions accompanying the TXV kit.
Install TXV kit as follows:
1.
First, relieve the holding charge by depressing the
Schrader valve located in the end of the liquid line.
FIGURE 3 :
ORIFICE INSTALLATION
UNIT
)
Coil is under 30 PSIG helium pressure. Relieve pres-
sure from schrader valve on liquid line side.
This fitting is a right-hand thread, turn counter-clock-
wise to remove.
Use 3/4" wrenches to turn fittings. Using pliers will
cause internal damage to the fitting.
BASE PAN
RUBBER ELEVATING GROMMETS (4 )
Note: D o N ot block drainage h o le s w ith g ro m m e ts .
UNIT BASE PAN
RUBBER ELEVATING GROMMETS (4 )
L IQ U ID L IN E SW IVEL CO UPLING (S ee C AU TIO N below
O R IF IC E
DISTRIBUTOR
550.38-N1Y
Unitary Products Group
5
®
2.
After holding charge is completely discharged, loosen
and remove the liquid line fitting from the orifice distributor
assembly. Note that the fitting has
right
hand
threads
.3.Remove the orifice from the distributor body using a
small diameter wire or paper clip.
Orifice
is
not used
when
the TXV assembly
is
installed.
4.
After orifice is removed, install the thermal expansion
valve to the orifice distributor assembly with supplied fit-
tings. Hand tighten and turn an additional 1/8 turn to
seal.
Do not overtighten fittings
.5.Reinstall the liquid line to the top of the thermal expan-
sion valve. Hand modify the liquid line to align with cas-
ing opening.
6.
Install the TXV equalizer line into the vapor line as follows:
a.
Select a location on the vapor line for insertion of the
equalizer line which will not interfere with TXV bulb
placement.
b.
Use an awl to punch through the suction tube and
insert the awl to a depth to achieve a 1/8 inch diam-
eter hole.
7.
Install TXV equalizer line in 1/8 hole previously made in
vapor line. Equalizer line can be bottomed out in vapor
line as end of equalizer line is cut on 45 degrees angle to
prevent blockage. Braze equalizer line making sure that
tube opening is not brazed closed.
All connections to be brazed are copper-to-copper and
should be brazed with a phosphorous-copper alloy material
such as Silfos-5 or equivalent. DO NOT use soft solder.
Install the TXV bulb to the vapor line near the equalizer line,
using the two bulb clamps furnished with the TXV assembly.
Ensure the bulb is making maximum contact. Refer to TXV
installation instruction for view of bulb location.
a.
Bulb should be installed on a horizontal run of the
vapor line if possible. On lines under 7/8" OD the
bulb may be installed on top of the line. With 7/8"
OD and over, the bulb should be installed at the
position of about 4 or 8 o'clock.
b.
If bulb installation is made on a vertical run, the bulb
should be located at least 16 inches from any bend,
and on the tubing sides opposite the plane of the
bend. On vertical bulb installations, the bulb should
be positioned with the bulb tail at the top, so that the
bulb acts as a reservoir.
c.
Bulb should be insulated using thermal insulation
provided to protect it from the effect of the surround-
ing ambient temperature.
PIPING CONNECTIONS
The outdoor condensing unit may be connected to the indoor
evaporator coil using field supplied refrigerant grade copper
tubing that is internally clean and dry. Units should be
installed only with the tubing sizes for approved system com-
binations as specified in Tabular Data Sheet. The charge
given is applicable for total tubing lengths up to 15 feet. See
Application Data Form 690.01-AD1V for installing tubing of
longer lengths and elevation differences.
NOTE:
Using a larger than specified line size could result in oil
return problems. Using too small a line will result in loss
of capacity and other problems caused by insufficient
refrigerant flow.
Slope horizontal vapor lines at least 1"
every 20 feet toward the outdoor unit to facilitate proper
oil return
.
PRECAUTIONS DURING LINE INSTALLATION
1.
Install the lines with as few bends as possible. Care must
be taken not to damage the couplings or kink the tubing.
Use clean hard drawn copper tubing where no apprecia-
ble amount of bending around obstruction is necessary.
If soft copper must be used, care must be taken to avoid
sharp bends which may cause a restriction.
2.
The lines should be installed so that they will not obstruct
service access to the coil, air handling system or filter.
3.
Care must also be taken to isolate the refrigerant lines to
minimize noise transmission from the equipment to the
structure.
The evaporator coil is under 30 psig pressure.
Dry nitrogen should always be supplied through the
tubing while it is being brazed, because the tempera-
ture required is high enough to cause oxidation of the
copper unless an inert atmosphere is provided. The
flow of dry nitrogen should continue until the joint has
cooled. Always use a pressure regulator and safety
valve to insure that only low pressure dry nitrogen is
introduced into the tubing. Only a small flow is neces-
sary to displace air and prevent oxidation.
In all cases, mount the TXV bulb after vapor line is
brazed and has had sufficient time to cool.
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