Nordyne R-410A User's Manual
Contents
1. Slab MOUND seieren eeen Cantilever Mount Roof MOUM Connecting Refrigerant Tubing Between the Indoor and Outdoor Unit General Filter Drier Installation Optional Electrical Connections Pre Electrical Checklist Wiring Diagram Schematic Line Voltage tede Outdoor Unit Connections Control Circuit Wiring sssssse Thermostat Connections Low Pressure Switch High Pressure Switch 9 Comfort Alert Diagnostics Module 10 24VAC Power Wiring 10 Thermostat Demand Wiring 10 Interpreting the Diagnostic LED s 10 LED Description 10 Two Speed Outdoor Fan Motor 11 Optional 11 Transformer Upgrade Kit 11 Startup amp Adjustments 11 Pre Start 112. ees Defrost Operation Operating the Heat Pump for Automatic Cooling and 5 Oper the Indoor Blower Continuously 5 Shutting the Heat Pump Off 5 System Maintenance 5 Regular 5 Before You Call a Technician 5 Troubleshooting 5 Warranty Information 5 INSTALLER INFORMATION Safety Information Pressures Within the System Labels Tags and Precautions Brazing General Information Outdoor Unit oc e Liquid and Suction Lines Field Connections for Electrical Power Site Unpacking the Equipment Inspect for Damage Preferred Location of the Outdoor Unit Facility Prerequisites Minimum Circuit Ampacity Maximum Fuse Circuit Breaker Size Installing the Indoor Unit Installing the Outdoor Unit
3. Add refrigerant when below rve 70 75 80 85 Liquid Temperature F Figure 5 Charging Chart for 3 Ton Units 14 90 95 100 105 110 115 120 125 Bo D 5 D A 3 Liquid Pressure psig A e o c1 o U Q I eo N 50 3 3 Oo o Cooling Charging Charts continued refrigerant when above curve Add refrigerant when below curve 70 75 80 85 90 95 100 105 110 115 120 125 Liquid Temperature F Figure 6 Charging Chart for 4 Ton Units Remove refrigeran t when above curve Add refrigerant when below curve 70 75 80 85 90 95 100 105 110 115 120 125 Liquid Temperature F Figure 7 Charging Chart for 5 Ton Units 15 16 0 Q i 5 a 2 5 E a Heating Charging Chart Remove refrigerant when above curve Add refrigerant when below curve 50 55 60 65 70 15 80 85 Liquid Temperature F Figure 8 Heating Charging Chart 90 TROUBLESHOOTING one EE Status LED Troubleshooting Information LED Description Green Module nes Supply voltage is present at module terminals POW
4. located internally on the suction line of the outdoor unit The switch is designed to protect the compressor from a loss of charge by interrupting the thermostat inputs to the unit If the suction pressure falls below 5 psig the switch will open and de energize the outdoor unit The switch will close again when the suction pressure increases above 20 psig NOTE When the switch opens and then closes there is a 3 minute short cycling delay before the outdoor unit will energize Under normal conditions the switch is closed High Pressure Switch A high pressure switch is factory installed and located internally on the compressor discharge line of the outdoor unit If the discharge pressure rises above 650 psig the switch will open and de energize the outdoor unit The switch will close Thermostat NOTE Jumper RW2C E Y1Y2 Wiw3 W1 amp 2 together o 0 Q9OO0900 9 99 for shorter staging time R 4 YODY 4 E Stat C O Y1Y2 o Air Handler Heat Pump OD Section Figure 2 Typical 2 Stage Heat Pump w Optional Outdoor Thermostat and Variable Speed Air Handler again after the discharge pressure decreases to 460 psig NOTE When the switch opens and then closes there will be a 3 minute short cycling delay before the outdoor unit will energize Under normal conditions
5. Thermostat st Lt EAE 11 Outdoor Unit esssssssess 11 Functional Checkout 11 GOOMING e 11 PAGANI eS 11 Indoor BlOWOLE reete ite ses 12 Short Cycle 12 Defrost Cycle Control 12 Defrost Test Procedure 12 Anti Short Cycle Timer Test 13 Heating 13 Cooling Mode 13 Optional 13 Adjustment of Refrigerant Charge 13 Charging R 410A Unit in AC Mode 13 Charging R 410A Unit in Heat Mode 13 Cooling Charging Charts 14 Heating Charging Chart 16 Troubleshooting 17 USER INFORMATION SAFETY INFORMATION IMPORTANT Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored WARNING indicates a potentially hazardous situation that if not avoided could result in personal injury or death CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or property damage ABOUT THE HEAT PUMP Your heat pump is a unique all weather comfort control appliance that will heat and cool your
6. codes Minimum Circuit Ampacity Electrical wiring to the equipment must be compatible and in compliance with the minimum circuit ampacity listed on the outdoor unit data label Maximum Fuse Circuit Breaker Size Circuit protection for the outdoor unit must be compatible with the maximum fuse circuit breaker size listed on the outdoor unit data label INSTALLING THE INDOOR UNIT The indoor unit air handler furnace etc should be installed prior to the routing of refrigerant piping Consult the Installation Instructions of the indoor unit for installation details INSTALLING THE OUTDOOR UNIT Slab Mount The site selected for a slab mount installation requires a stable foundation and not subject to erosion The slab should be level and anchored if necessary prior to installation on the slab Cantilever Mount The cantilever mount should be designed with adequate safety factor to support the weight of the equipment and for loads subjected to the mount during operation Installed equipment should be adequately secured to the cantilever mount and levelled prior to operation of the equipment 7 Roof Mount WARNING To avoid the risk of property damage personal injury or death it is the installer s responsibility to ensure that whatever means are used to move or lift the unit are safe and adequate Keep the unit in an upright position at all times The method of mounting should be designed so as
7. home year round and provide energy saving comfort It s an unknown fact that heat is always in the air even when the outside temperature is below freezing The heat pump uses this basic law of physics to provide energy saving heat during the winter months For example If the outdoor temperature is 47 F 8 C your heat pump can deliver approximately 3 5 units of heat energy per each unit of electrical energy used as compared to a maximum of only 1 unit of heat energy produced with conventional heating systems In colder temperatures the heat pump performs like an air conditioner run in reverse Available heat energy outside the home is absorbed by the refrigerant and exhausted inside the home This efficient process means you only pay for moving the heat from the outdoors to the indoor area You do not pay to generate the heat as with more traditional furnace designs During summer the heat pump reverses the flow of the heat absorbing refrigerant to become an energy efficient central air conditioner Excess heat energy inside the home is absorbed by the refrigerant and exhausted outside the home Fan System Temperature Mode Mode Selector Figure 1 Digital Thermostat OPERATING INSTRUCTIONS Please refer to the thermostat manufacturer s User manual for detailed programming instructions Cooling Operation Only 1 Set the thermostat s system mode to COOL or AUTO and change the fan mode to AUTO See Figu
8. not to overload roof structures or transmit noise to the interior of the structure Refrigerant and electrical lines should be routed through suitably waterproofed openings to prevent water leaking into the structure CONNECTING REFRIGERANT TUBING BETWEEN THE INDOOR amp OUTDOOR UNIT N CAUTION This system uses R 410A refrigerant with POE oil When servicing cover or seal openings to minimize the exposure of the refrigerant system to air to prevent accumulation of moisture and other contaminants General Information After outdoor and indoor unit placement has been determined route refrigerant tubing between the equipment accordance with sound installation practices Whenconnecting refrigerant linesets together itis recommended that dry nitrogen be flowing through the joints during brazing This will prevent internal oxidation and scaling from occurring Refrigerant tubing should be routed in a manner that minimizes the length of tubing and the number of bends in the tubing Refrigerant tubing should be supported in a manner that the tubing will not vibrate or abrade during system operation e Tubing should be kept clean of foreign debris during installation Every effort should be made by the installer to ensure that the field installed refrigerant containing components of the system have been installed in accordance with these instructions and soundinstallation practices to insure reliable syst
9. on the TEST pins e Ifthe Coiltemperature is above the Terminate Temperature selection setting the defrost cycle will be terminated reversing valve will de energized e Ifthe coil temperature is below the Terminate Temperature election setting the defrost cycle will continue for 14 minutes or until the coil temperature rises above the Terminate Temperature selection setting NOTE Short the TEST pins for 1 second or more to force the control out of defrost and back to heating mode reversing valve de energized Compressor will turn on immediately if the REMOVE FOR NO DELAY jumper is removed If the REMOVE FOR NO DELAY jumper is installed the compressor will energize immediately following a 30 second delay Note If the Y2 thermostat input is energized 2 stage system the second stage will turn on Ifthe above steps will notinitiate a defrost replace the defrost board Anti Short Cycle Timer Test The 3 minute time delay feature can be bypassed by shorting the TEST pins together Heating Mode When the TEST pins are shorted together for more than 1 second the control will switch between defrost mode and heating mode as described in the Defrost Test Procedure section Cooling Mode When the TEST pins are shorted together for more than 1 second the Anti Short Cycle Timer will be bypassed Optional Equipment A functional checkout should be performed in accordance with the checkout procedures supplied w
10. setpoint temperature until the outdoor unit and indoor blower de energize 3 Immediately lower the setpoint temperature of the thermostat to its original setting and verify that the indoor blower is energized and that the outdoor unit remains de energized 4 After approximately 3 minutes verify that the outdoor unit energizes and the temperature of the air supplied to the facility is cooler than ambient temperature Defrost Cycle Control The defrost cycle is controlled by an Adaptive Demand Defrost algorithm that monitors coil temperature and ambient temperature Other features of the of the demand defrost board include e 4 Field selectable defrost termination temperatures 50 F 80 F coil temperature Field selectable compressor delay feature High pressure and low pressure switches Sensing of second stage compressor demand Test speed up capability Anti short cycle timer 3 minutes for compressor protection On board diagnostics with flashing LED for quicker troubleshooting See Table 2 Diagnostic Description LED Status Control Fault No Power Cono Fault ore Normal Normal Operation ASCD Delay Active 1 Flash with compressor gemand Table 2 Control Diagnostic 12 Control is uncalibrated when power is applied Calibration occurs after a defrost cycle The control initiates this sacrificial defrost after 34 minutes of accumulated compressor run time in heating with
11. the switch is closed Comfort Alert Diagnostics Module The Comfort Alert Diagnostics Module is a breakthrough innovation for troubleshooting heat pump and air conditioning system failures The module installs easily in the electrical box of the outdoor unit near the compressor contactor By monitoring and analyzing data from the Copeland scroll compressor and the thermostat demand the module can accurately detect the cause of electrical and system related failures without any sensors A flashing LED indicator communicates the ALERT code anda diagnostic key is also imprinted on the side of the module to quickly direct the technician to the root cause of a problem See Figure 3 NOTE This module does not provide safety protection The Comfort Alert Diagnostics Module is amonitoring device and cannot control or shut down other devices 24 VAC Power Wiring The Comfort Alert module requires a constant nominal 24 VAC power supply The module cannot be powered by the C terminal on a defrost board or other control board without experiencing nuisance alerts NOTE The wiring to the module s R amp C terminals must be routed directly from the indoor unit or thermostat If the constant 24 VAC R wire is not present in the outdoor unit use one of the spare wires in the thermostat cable to bring power to the module Connect the other end of the spare wire to R at the indoor unit or thermostat Thermostat Demand Wiring T
12. ER power ER 9 P Compressor protector is open Check for high head pressure Check compressor supply voltage Outdoor unit power disconnect is open Compressor circuit breaker or fuse s is open Broken wire or connector is not making contact Low pressure switch open if present in system Compressor contactor has failed open Thermostat demand signal Red TRIP Y is present but compressor is not running Low refrigerant charge Evaporator bloweris not running Check blower relay coil and contacts Check blower motor capacitor Check blower motor for failure or blockage Check evaporator blower wiring and connectors Check indoor blower control board Check thermostat wiring for open circuit Evaporator coil is frozen Check for low suction pressure Long Run Time Check for excessively low thermostat setting Yellow ALERT Compressor is Checkevaporator airflow coil blockages or return airfilter Flash Code 1 running extremely Check ductwork or registers for blockage long run cycles Faulty metering device Check TXV bulb installation size location and contact Check if TXV fixed orifice is stuck closed or defective Condenser coil is dirty Liquid line restriction filter drier blocked if present in system Thermostat is malfunctioning Solenoid plug not connected Y2 not wired at Comfort Alert Check thermostat sub base or wiring for short circuit Check thermostat installation locat
13. Outdoor Heat Pump User s Manual Installation Instructions Two Stage R 410A Split System E A TM Mibi TAA LL Premium Model Shown IMPORTANT Please read this information thoroughly and become familiar with the capabilities and use of your appliance before attempting to operate or maintain this unit Keep this literature where you have easy access to it in the future If a problem occurs check the instructions and follow recommendations given If these suggestions don t eliminate your problem call your NORDYNE Servicing Contractor Service PRO These instructions are primarily intended to assist qualified individuals experienced in the proper installation of this appliance Some local codes require licensed installation service personnel for this type of equipment Please read all instructions carefully before starting the installation DO NOT DESTROY PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE USER INFORMATION Safety Information About the Heat Pump Operating Instructions Cooling Heating Operation Emergency Heat
14. WARNING indicates a potentially hazardous situation that if not avoided could result in personal injury or death CAUTION indicates a potentially hazardous situation that if not avoided may result in minor or moderate injury or property damage Read the following instructions completely before performing the installation Unqualified individuals should not attempt to interpret these instructions or install this equipment The installer should comply with all local codes and regulations which govern the installation of this type of equipment Local codes and regulations take precedence over any recommendations contained in these instructions Consult local building codes and the National Electrical Code ANSI CI for special installation requirements N WARNING These units are fully charged with R 410A refrigerant and ready for installation When a system is installed according to these instructions no refrigerant charging is required If repairs make it necessary for evacuation and charging it should only be attempted by qualified trained personnel thoroughly familiar with this equipment Some local codes require licensed installation service personnel to service this type of equipment Under no circumstances should the homeowner attempt to install and or service this equipment Failure to comply with this warning could result in equipment damage personal injury or death N CAUTION This unit uses
15. coil temperature below 35 F The defrost cycle terminates if coil sensor reaches selected termination temperature or after 14 minutes defrost Defrost function is disabled if coil temperature is above 35 F If Ambient sensor is detected as open orshorted demand defrost will not operate and control will revertto time temperature defrost operation If the outdoor coil sensor is detected as open or shorted the control will not perform demand or time temperature defrost operation NOTE When the defrost cycle initiates there will be a 30 second compressor delay going into and out of the defrost cycle This delay may be removed by removing P6 connector onthe board This 2 stage unit will defrost in second stage regardless of the stage called for by the thermostat NOTE All units are shipped from the factory with the default termination temperature set at 70 F Defrost Test Procedure 1 Terminals R C must have 18 30VAC present between them in order for defrost sequences to be initiated 2 With heat mode thermostat demand Y connected to R short and hold the TEST pins together This will energize reversing valve to initiate a forced defrost NOTE This will bypass the ASCD and allow the high stage compressor to come on immediately if the REMOVE FOR NO DELAY jumper at P6 is removed If the REMOVE FOR NO DELAY jumper at P6 is installed the compressor will energize immediately following a 30 second delay 3 Remove the short
16. ed liquid refrigerant pressure determined in step 4 then there is too much charge in the system Remove refrigerant and repeat steps 1 through 3 until the system is correctly charged 5 f the pressure measured in step 1 is less than the required liquid refrigerant pressure determined in step 4 then there is too little charge in the system Add refrigerant and repeat steps 1 through 3 until the system is correctly charged System Charge R 410A oz 185 272 272 272 Tonnage 2 Ton 3 Ton 4 Ton 5 Ton Table 3 Split System Heat Pump Charge Charging an R 410A Unit in Heating Mode 1 Evacuate the refrigerant system 2 Weigh in the proper charge per Table 3 using the Heating Charging Chart Figure 8 page 16 as a guide Unit charge MUST be verified in cooling season 3 Verify the unit is operating properly as outlined in the functional checkout heating section on page 11 13 Cooling Charging Charts eo LL a aa refrigerant when above curve BS D D A 3 E d Add refrigerant when bel 70 75 80 85 90 95 100 105 110 Liquid Temperature F Figure 4 Charging Chart for 2 Ton Units refrig erant above curv 115 BOR e Liquid Pressure psig C2 O 32
17. em operation and longevity e Themaximumrecommendedinterconnecting refrigerant line length is 75 feet and the vertical elevation difference between the indoor and outdoor sections should not exceed 20 feet If precise forming of refrigerant lines is required a copper tubing bender is recommended Avoid sharp bends and contact of the refrigerant lines with metal surfaces Filter Drier Installation A filter dryer is provided with the unit and must be installed in the liquid line of the system If the installation replaces a system with a filter dryer already present in the liquid line the filter dryer must be replaced with the one supplied with the unit The filter dryer must be installed in strict accordance with the manufacturer s installation instructions Optional Equipment Optional equipment such as liquid line solenoid valves twinning kit low ambient etc should be installed in strict accordance with the manufacturers installation instructions ELECTRICAL CONNECTIONS N WARNING Shut off all electrical power to the unit before performing any maintenance or service on the system Failure to comply may result in personal injury or death Pre Electrical Checklist Verify that the voltage frequency and phase of the supply source are the same as those specified on the unit rating plate Verify thatthe service provided by the utility is sufficient to handle the additional load imposed by this equipme
18. emental heat electric resistance heating will be used as a source of heat Sustained use of electric resistance heat in place of the heat pump will result in an increase in electric utility costs Defrost Operation During cold weather heating operation the outdoor unit will develop a coating of snow and ice on the heat transfer coil This is normal USER INFORMATION and the unit will defrost itself This unit features Adaptive Demand Defrost that monitors ambient and coil temperatures to regulate the defrost function accordingly At the beginning of the defrost cycle both the outdoor condenser fan and compressor will turn off After approximately 30 seconds the compressor will turn on and begin to heat the outdoor coil causing the ice and snow to melt NOTE While the ice and snow is melting some steam may rise from the outdoor unit as the warm coil causes the melting frost to evaporate When defrost is completed the outdoor fan motor will start and the compressor will turn off again In approximately 30 seconds the compressor will start up again and continue normal operation Operating the Heat Pump for Automatic Cooling and Heating 1 Set the thermostat system switch to AUTO and the thermostat fan switch to AUTO See Figure 1 Note Thermostats will vary Some models will notinclude the AUTO mode and others will have the AUTO in place of the HEAT and COOL and some will include all three 2 Setthe thermostat te
19. ent sensing holes displayed incorrectly Open e Verify the Y terminal is connected to 24VAC at contactor Circuit Open Start Circuit or coil Open Run Circuit Verify voltage at contactor coil falls below 0 5VAC when off ALERT Flash Code 6 Open Start Circuit displayed for Verify the compressor run and start wires are routed Code 7 Open Run Circuit or through the correct module sensing holes vice versa Determine if module s Y terminal is connected Verify Y terminal is connected to 24VAC at contactor coil Verify 24VAC is present across Y amp C when thermostat demand signal is present If not R and C are reversed wired Verify voltage at contactor coil falls below 0 5VAC when off Review Thermostat Demand Wiring page 10 for Y amp C wiring ALERT Flash Code 8 displayed incorrectly Welded Contactor Table 5 Module Wiring Troubleshooting 19 INSTALLER PLEASE LEAVE THESE INSTALLATION INSTRUCTIONS WITH THE HOMEOWNER Bian aw uu wh PERFORMANCE m CERTIFIED w ENERGY STAR Liste o COMPLETE COMFORT GENUINE VALUE 1 without notice t incurring obligations O Fallon MO 708868A Printed in U S A 10 09 708868A Replaces 7088680 Specifications and illustrations subject to change
20. g If heating equipment furnace air handler is provided with the system lower the thermostat setpoint temperature to the lowest temperature setting and change the thermostat s function mode to HEAT The outdoor unit should stop running andthe indoor blower will shut off afterthe preprogrammed delay Increase the thermostat s setpoint temperature to the maximum setting Verify the heating equipment and the indoor blower energize after a short period of time Feel the air being circulated by the indoor blower and verify thatitis warmerthan ambienttemperature Listen for any unusual noises If unusual sounds occur determine the source of the noise and correct as necessary NOTE Other sources for heating electric furnace fossil fuel furnace air handler with electric heat options etc that interface with the heat pump should be functionally checked to 11 verify system operation and compatibility with the heat pump Refer to the installation instructions for this equipment and perform a functional checkout in accordance with the manufacturer s instructions Indoor Blower 1 Turn the fan mode to ON Verify that the indoor blower is operating and that airflow is not restricted 2 Set the fan mode back to AUTO Blower will operate at a decreased speed on continuous fan Short Cycle Protection 1 With the system operating in COOLING mode record the setpoint temperature setting of the thermostat 2 Gradually raise the
21. he Comfort Alert module requires a thermostat demand signal to operate properly The thermostat demand signal input labeled Y on the module should always be connected to the compressor contactor coil NOTE When the coil is energized the demand signal input is 24 VAC When the coil is not energized the demand signal input should be less than 0 5 VAC NOTES e Factory installed modules have different thermostat demand signal wiring Always follow manufacturer wiring instructions when replacing the module e After the thermostat demand signal is connected verify that 24 VAC across Y amp C when demand is present Interpreting the Diagnostic LED s When an abnormal system condition occurs the Comfort Alert module displays the appropriate ALERT and or TRIP LED will flash a number of times consecutively pause and then repeat the process To identify a Flash Code number count the number of consecutive flashes Eachtime the module powers up the last ALERT Flash Code that occurred prior to shut down is displayed for one minute The module will continue to display the LED until the condition returns to normal or if 24 VAC power is removed from the module LED Description e POWER LED Green indicates voltage is presentatthe power connection ofthe module ALERT LED Yellow communicates an abnormal system condition through a unique flash code NOTE The ALERT LED will flash consecutively pause and then repeat
22. if voltage at disconnect is low Check wiring connections Flash code number corresponds to a number of LED flashes followed by a pause and then repeated Trip and alert LED s flashing at same time means control circuit voltage is too low for operation 18 Table 4 LED Diagnostics Continued TROUBLESHOOTING CONTINUED Miswired Module Indication Recommended Troubleshooting Action Green LED is not on module Determine if both amp C module terminals are connected does not power up Verify voltage is present at module s R amp C terminals Green intermittent module Nod up only when compressor runs Determine if R amp Y terminals are wired in reverse Verify modules R and C terminals have a constant source Verify Y terminal is connected to 24VAC at contactor coil Verify voltage at contactor coil falls below 0 5VAC when off Verify 24VAC is present across Y amp C when thermostat demand signal is present If not R amp C are reversed wired Trip LED is on but system and compressor check OK TRIP EEE and ACERT LER Verify R and C terminals are supplied with 19 28VAC flashing together ALERT Flash CODE displayed Verify Y terminal is connected to 24VAC at contactor coil incorrectly Compressor short Verify voltage at contactor coil falls below 0 5VAC when cycling off Verify the compressor run and start wires are routed ALERT Flash Code 5 6 or 7 through the module s curr
23. ion level Comfort Alert failure High head pressure System Pressure Check high pressure switch if present in system Trip Check if system is overcharged with refrigerant Check for non condensable in system d Condenser coil poor air circulation dirty blocked damaged Yellow ALERT Flash Code 2 Condenser fan is not running pressure out of Check fan capacitor limits Check fan wiring and connectors Check fan motor for failure or blockage Return air duct has substantial leakage compressor overloaded flow pressure switch present in system check Flash Code 1 information Table 4 LED Diagnostics 17 TROUBLESHOOTING CONTINUED Status LED Status LED Status LED Troubleshooting Information Short Cycling Thermostat demand signal is intermittent Yellow ALERT Flash Code 3 Yellow ALERT Flash Code 4 Yellow ALERT Flash Code 5 Yellow ALERT Flash Code 6 Yellow ALERT Flash Code 7 Yellow ALERT Flash Code 8 Yellow ALERT Flash Code 9 Compressor is running only briefly Locked Rotor Open Circuit Open Start Circuit Current only in run circuit Open run circuit Current only in start circuit Welded Contactor Compressor always runs Low Voltage Control circuit lt 17VAC Low line voltage contact utility if voltage at disconnect is low Excessive liquid refrigerant in compressor Compressor bearings are seized Run capacito
24. is unit has been designed and tested for capacity and efficiency in accordance with Standards This unit will provide many years of safe and dependable comfort providing it is properly installed and maintained With regular maintenance this unit will operate satisfactorily year after year Abuse improper use and or improper maintenance can shorten the life of the appliance and create unsafe hazards To achieve optimum performance and minimize equipmentfailure itis recommended that periodic maintenance be performed on this unit The ability to properly perform maintenance on this equipment requires certain mechanical skills and tools Please consult your dealer for maintenance information and availability of maintenance contracts Please read all instructions before installing the unit Outdoor Unit Each outdoor unit is shipped with a refrigerant charge adequate to operate the outdoor section with an indoor matching coil or air handler These units include the proper amount of refrigerant for an additional 15 ft of refrigerant lines the same size as the valve fittings NOTE DO NOT USE ANY PORTION OF THE CHARGE FOR PURGING OR LEAK TESTING Matching coils and air handlers may be shipped with a small holding charge to pressurize them to keep out contaminants To release the pressure read the indoor section installation instructions carefully Liquid and Suction Lines Refrigerant grade copper tubing should be used
25. ith the equipment ADJUSTMENT OF REFRIGERANT CHARGE N CAUTION Split system equipment contains liquid and gaseous refrigerant under pressure Adjustment of refrigerant charge should only be attempted by qualified trained personnel thoroughly familiar with the equipment Under no circumstances should the homeowner attempt to install and or service this equipment Failure to comply with this warning could result in equipment damage personal injury or death NOTES The unit must be charged while both first and second stages are operating To achieve rated capacity and efficiency the compressor must be exposed to refrigerant for at least 24 hours prior to running and then must be run for a minimum of 12 hours e The following Refrigerant Charging Charts are applicable to listed assemblies of equipment and at listed airflows for the indoor coil Assemblies of indoor coils and outdoor units not listed are not recommended Charging an R 410A Unit in AC Mode at Outdoor Temperatures Above 65F 1 With the system operating at steady state measure the liquid refrigerant pressure in psig at the service valve 2 Measure the liquid refrigerant temperature in Fahrenheit at the service valve 3 Forthe temperature measured determine the required liquid refrigerant pressure from the appropriate charging charts in Figures 4 7 pages 14 amp 15 4 If the pressure measured in step 1 is greater than the requir
26. itinstalled in a proper location Verify air filters are clean and in place prior to operating the equipment Verify the outdoor coil and top of the unit are free from obstructions and debris and all equipmentaccess control panels are in place a 2 ee Thermostat Set the thermostat s system mode to OFF the fan mode to AUTO and adjust the temperature setpoint to its highest setting Outdoor Unit Prior to applying electrical power to the outdoor unit verify that the unit has been properly and securely grounded and that power supply connections have been made at both the facility power interface and outdoor unit Verify the outdoor coil and top of the unit are free from obstructions and debris and all equipment access control panels are in place FUNCTIONAL CHECKOUTS N CAUTION These units have a crankcase heater factory installed Wait 24 hours prior to performing a function checkoutto allow for heating ofthe compressor crankcase Failure to comply may result in damage and could cause premature failure of the system Cooling Gradually lower the thermostat temperature setpoint below the actual room temperature and observe that the outdoor unit and indoor blower energize Feel the air being circulated by the indoor blower and verify that it is cooler than ambient temperature Listen for any unusual noises If unusual sounds occur determine the source of the noise and correct as necessary Heatin
27. mperature to the desired heating and cooling temperature level s The outdoor unit and the indoor blower will then cycle on and off in either the heating or cooling mode of operation as required to automatically maintain the indoor temperature within the desired limits Operating the Indoor Blower Continuously The continuous indoor blower operation is typically used to circulate the indoor air to equalize a temperature unbalance due to a sun load cooking or fireplace operation Set the thermostat fan mode to ON Figure 1 The indoor blower starts immediately and will run continually until the fan mode is reset to AUTO The continuous indoor blower operation can be obtained with the thermostat system mode set in any position including OFF Shutting the Heat Pump Off Change the thermostat s system mode to OFF and the fan mode to AUTO See Figure 1 NOTE The system will not operate regardless of the temperature selector setting SYSTEM MAINTENANCE N CAUTION Shut off all electrical power to the unit before performing any maintenance or service on the system Failureto comply may result in personal injury or death Proper maintenance is mostimportantto achieve the best performance from the appliance and should be performed by a qualified service technician at least once a year Follow the maintenance schedule and the instructions below for years of safe trouble free operation Regular Cleaning Clean or re
28. n instructions provided with the equipment Optional Equipment low ambient control hard start kits etc should be installed in strict accordance with the manufacturer s installation instructions Transformer Upgrade Kit Ifthis 2 stage heat pumpis installed in conjunction with a gas furnace and fossil fuel kit the furnace transformer MUST be upgraded to one with a 60 VA rating or using the transformer upgrade kit 904077 To upgrade the transformer e Remove the existing transformer and install the new 60 VA transformer e Removethe3ampfuseonthe furnace control board and install the 5 amp fuse provided NOTE The new transformer may be larger than the existing transformer that is mounted in the furnace If this happens mount the 60 VA transformer using one of the mounting holes in the furnace panel On the other side either drill a 0 149 hole in the panel and use the existing fastener or use a self drilling fastener to secure the other side of the transformer STARTUP AND ADJUSTMENTS Pre Start Checklist Thefollowing check list should be observed prior to starting the unit Is the unit level Y Is the wiring correct according to the wiring diagram and electrical codes Inspect wiring for evidence of open shorted and or improperly wired circuits Are all the wiring connections tight Check the condenser fan to make sure it turns freely Is the overcurrent protection properly sized Isthe thermostat wired correctly Is
29. nt For minimum circuit ampacity and maximum overcurrent protection see unit rating plate 2 2_ Wiring Diagram Schematic A wiring diagram schematic is located on the inside cover of the electrical box of the outdoor unit The installer should become familiar with the wiring diagram schematic before making any electrical connections to the outdoor unit Line Voltage Electrical power wiring must comply with the current provisions of the NEC ANSI NFPA 70 and with applicable local codes having jurisdiction Provide powersupplyforthe unitin accordance with the unit wiring diagram and the unit rating plate Connect the line voltage leads to the terminals on the contactor inside the control compartment e Use only copper wire for the line voltage power supply to this unit Table 1 Use proper code agency listed conduit and aconduit connector for connecting the supply wires to the unit Use of rain tight conduit is recommended e See the unit wiring label for proper high and low voltage wiring Make all electrical connections in accordance with all applicable codes and ordinances e Useaseparate branch electrical circuit for this unit A means of electrical disconnect must be located within sight of and readily accessible to the unit This switch shall be capable of electrically de energizing the outdoor unit e Overcurrent protection must be provided atthe branch circuit distribution panel and sized as shown on
30. place the indoor air filter at the start of each heating and cooling season and when an accumulation of dust and dirt is visible on the air filter Remove any leaves and grass clippings from the coil in the outdoor unit being careful not to damage the aluminum fins Check for obstructions such as twigs sticks etc TROUBLESHOOTING If the unit fails to operate check the following The thermostat is properly set See Cooling Operation for air conditioning or Heating Operation for furnace or air handler e Theunitdisconnectfuses are in good condition and the electrical power to the unit is turned on WARRANTY INFORMATION A warranty certificate with full details is included with the heat pump Carefully review these responsibilities with your dealer or service company The manufacturer will not be responsible for any costs found necessary to correct problems due to improper setup improper installation adjustments improper operating procedure on the part of the user etc Some specific examples of service calls which are not included in the limited warranty are Correcting wiring problems in the electrical circuit supplying the heat pump Resetting circuit breakers or other switches e Adjusting or calibrating of thermostat INSTALLER INFORMATION SAFETY INFORMATION IMPORTANT Safety markings are used frequently throughout this manual to designate a degree or level of seriousness and should not be ignored
31. r has failed Low line voltage contact utitlity if voltage at disconnect is low Check wiring connections Excessive liquid refrigerant in compressor Compressor bearings are seized Measure compressor oil level Outdoor unit power disconnect is open Compressor circuit breaker or fuse s is open Compressor contactor has failed open Check compressor contactor wiring and connectors Check for compressor contactor failure burned pitted or open Check wiring and connectors between supply and compressor Check for low pilot voltage at compressor contactor coil High pressure switch is open and requires manual reset Open circuit in compressor supply wiring or connections Unusually long compressor protector reset time due to extreme ambient temperature Compressor windings are damaged Check compressor motor winding resistance Run capacitor has failed Open circuit in compressor start wiring or connections Check wiring and connectors between supply and the compressor S terminal Compressor start winding is damaged Check compressor motor winding resistance Open circuit in compressor run wiring or connections Check wiring and connectors between supply and the compressor R terminal Compressor run winding is damaged Check compressor motor winding resistance Compressor contactor has failed closed Thermostat demand signal not connected to module Control circuit transformer is overloaded Low line voltage contact utility
32. re 1 2 Set the temperature selector to the desired temperature level The outdoor fan compressor and blower motor will all cycle on and off to maintain the indoor temperature at the desired cooling level NOTE If the temperature level is re adjusted or the system mode is reset the fan and compressor in the outdoor unit may not start immediately A protective timer circuit holds the compressor and the outdoor fan off for approximately three minutes following a previous operation or the interruption of the main electrical power Heating Operation Only 1 Set the thermostat s system mode to HEAT or AUTO and change the fan mode to AUTO See Figure 1 2 Set the temperature selector to the desired temperature level The compressor outdoor fan and blower motor will cycle on and off to maintain the indoortemperature atthe desired heating level NOTE If the temperature level is re adjusted or the system mode is reset the fan and compressor in the outdoor unit may not start immediately A protective timer circuit holds the compressor and the outdoor fan off for approximately three minutes following a previous operation or the interruption of the main electrical power Emergency Heat Some thermostats may include a system mode called EM HT or AUX HT etc This is a back up heating mode that should only be used if a problem is suspected With the mode set to EM HT etc the compressor and outdoor fan will be locked off and suppl
33. refrigerant R 410A DO NOT under any circumstances use any other refrigerant in this unit Use of another refrigerant will damage the unit Pressures within the System This equipment contains liquid and gaseous refrigerant under high pressure Installation or servicing should only be performed by qualified trained personnel thoroughly familiar with this type equipmentand related system components Under no circumstances should the Homeowner attempt to install and or service the equipment Labels Tags and Precautions When working with this equipment follow all precautions in the literature on tags and on labels provided with the equipment Read and thoroughly understand the instructions provided with the equipment prior to performing the installation and operational checkout of the equipment Brazing Operations Installation of equipment may require brazing operations Safety codes must be complied with Safety equipment safety glasses work gloves fire extinguisher etc must be used when performing brazing operations N WARNING Verify all electrical power to the unit is off prior to installing or servicing the equipment Failure to shut off power may cause personal injury or death GENERAL INFORMATION Split System Heat Pump units are designed for use with a wide variety of fossil fuel furnaces electric furnaces air handlers and evaporator coil combinations equipped with variable speed blowers Th
34. the process The number of consecutive flashes referred to as the Flash Code correlates to a particular abnormal condition Detailed descriptions of these ALERT Flash Codes are listed in Table 4 page 14 TRIP LED Red indicates a demand signal is received from the thermostat but current to the compressor is not detected by the module The TRIP LED typically indicates if the compressor protector is open or the compressor has no power The scroll compressor s R run C common and S start wires are routed through the holes in the Comfort Alert module marked R C and S NOTE The common wire does not need to be routed through the module for it to operate POWER LED Green Diagnostics Key ALERT LED Yellow TRIP LED Red Figure 3 Comfort Alert Diagnostics Module 10 Outdoor Fan Motor If unit utilizes a 2 speed condenser fan motor this motor will operate on low speed when in low cooling and on high speed when in high cooling A relay within the control area switches the fan motor from low to high speed using the call for high cooling as the trigger Other models that utilize BLDC fixed torque variable speed fan motors will not require a relay Optional Equipment Optional equipment requiring connection to the power or control circuits must be wired in strict accordance with current provisions of the NEC ANSI NFPA 70 with applicable local codes having jurisdiction and the installatio
35. the unit rating label and according to applicable local codes Outdoor Unit Connections The outdoor unit requires both power and control circuit electrical connections Refer to the unit wiring diagram schematic for identification and location of outdoor unit field wiring interfaces Control Circuit Wiring The outdoor unit is designed to operate from a 24 VAC Class II control circuit The control circuit wiring must comply with the current provisions of the NEC ANSI NFPA 70 and with applicable local codes having jurisdiction Thermostat Connections Thermostat connections should be made in accordance with the instructions supplied with the thermostat and with the instructions supplied with the indoor equipment A typical residential installation with a heat pump thermostat and air handler are shown in Figure 2 COPPER WIRE SIZE AWG 1 Voltage Drop Supply Wire Length Feet Supply Circuit Ampacity ojal Alejo A O1 oj o1 OoO O 200 ZA Wire Size based on N E C for 60 type copper conductors Table 1 Copper Wire Size Grounding N CAUTION The unit must have an uninterrupted or unbroken electrical ground to minimize personal injury if an electrical fault should occur This ground may consistof electrical wire or approved conduit when installed in accordance with national or local codes Low Pressure Switch A low pressure switch is factory installed and
36. when installing the system Refrigerant suction line tubing should be fully insulated Field Connections for Electrical Power Supply All wiring must comply with current provisions of the National Electrical Code ANSI NFPA 70 and with applicable local codes having jurisdiction The minimum size of electrical conductors and circuit protection must be in compliance with information listed on the outdoor unit data label SITE PREPARATION Unpacking the Equipment Remove the shipping carton and User s Manual from the equipment Take care notto damage the tubing connections when removing the carton Inspect for Damage Inspect the equipment for damage prior to installing the equipment at the job site Verify coil fins are straight If necessary comb fins to remove flattened or bent fins Preferred Location of the Outdoor Unit Survey the job site to determine the best location for mounting the outdoor unit Overhead obstructions poorly ventilated areas and areas subject to accumulation of debris should be avoided The outdoor unit should be installed no closer than 18 inches from the outside walls of the facility and in an area free from overhead obstructions to ensure unrestricted airflow through the outdoor unit Facility Prerequisites Electrical power supplied to the unit must be adequate for proper operation of the equipment The system must be wired and provided with circuit protection in accordance with local building
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