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HomeMy WebLinkAbout40389-Z A+�,4�gUFFOI,�co _ Town of Southold 3/30/2016 i''.S'� ;Alt, P.O.Box1179 ;o - �' cf, 53095 Main Rd ,,�y0l * *,„ Southold,New York 11971 "r roar CERTIFICATE OF OCCUPANCY No: 38189 Date: 3/30/2016 THIS CERTIFIES that the building AS BUILT ALTERATION Location of Property: 640 Skippers Ln, Orient SCTM#: 473889 Sec/Block/Lot: 24.-1-10 Subdivision: Filed Map No. Lot No. conforms substantially to the Application for Building Permit heretofore filed in this office dated 12/11/2015 pursuant to which Building Permit No. 40389 dated 1/6/2016 was issued, and conforms to all of the requirements of the applicable provisions of the law. The occupancy for which this certificate is issued is: "as built"basement alterations and"as built"first floor bathroom alteratiion in an existing one family dwelling as applied for. The certificate is issued to Rowe,Clive&Elizabeth of the aforesaid building. SUFFOLK COUNTY DEPARTMENT OF HEALTH APPROVAL ELECTRICAL CERTIFICATE NO. 40389 2/23/2016 PLUMBERS CERTIFICATION DATED 8/25/2015 George Fredricks Aut fed gn itre svFFoj�c® TOWN OF SOUTHOLD BUILDING DEPARTMENT o t o . TOWN CLERK'S OFFICE SOUTHOLD, NY BUILDING PERMIT (THIS PERMIT MUST BE KEPT ON THE PREMISES WITH ONE SET OF APPROVED PLANS AND SPECIFICATIONS UNTIL FULL COMPLETION OF THE WORK AUTHORIZED) Permit#: 40389 Date: 1/6/2016 Permission is hereby granted to: Rowe, Clive 640 Skippers Ln PO BOX 310 Orient, NY 11957 To: legalize "as built" alterations (boiler/bathroom) to an existing single family dwelling as applied for. At premises located at: 640 Skippers Ln, Orient SCTM # 473889 Sec/Block/Lot# 24.-1-10 Pursuant to application dated 12/11/2015 and approved by the Building Inspector. To expire on 7/7/2017. Fees: AS BUILT- SINGLE FAMILY ADDITION/ALTERATION $400.00 .•. ERATION TO D =- _ 1 G $50.00 Total: $450.00 Building •s.ector Form No.6 TOWN OF SOUTHOLD BUILDING DEPARTMENT TOWN HALL 765-1802 APPLICATION FOR CERTIFICATE OF OCCUPANCY This application must be filled in by typewriter or ink and submitted to the Building Department with the following: A. For new building or new use: 1. Final survey of property with accurate location of all buildings,property lines, streets,and unusual natural or topographic features. 2. Final Approval from Health Dept. of water supply and sewerage-disposal(S-9 form). 3. Approval of electrical installation from Board of Fire Underwriters. 4. Sworn statement from plumber certifying that the solder used in system contains less than 2/10 of 1% lead. 5. Commercial building, industrial building,multiple residences and similar buildings and installations, a certificate of Code Compliance from architect or engineer responsible for the building. 6. Submit Planning Board Approval of completed site plan requirements. B. For existing buildings (prior to April 9, 1957) non-conforming uses,or buildings and "pre-existing" land uses: 1. Accurate survey of property showing all property lines,streets,building and unusual natural or topographic features. 2. A properly completed application and consent to inspect signed by the applicant.If a Certificate of Occupancy is denied,the Building Inspector shall state the reasons therefor in writing to the applicant. C. Fees 1. Certificate of Occupancy-New dwelling$50.00,Additions to dwelling$50.00,Alterations to dwelling$50.00, Swimming pool$50.00,Accessory building$50.00,Additions to accessory building$50.00,Businesses$50.00. 2. Certificate of Occupancy on Pre-existing Building- $100.00 3. Copy of Certificate of Occupancy-$.25 4. Updated Certificate of Occupancy- $50.00 5. Temporary Certificate of Occupancy-Residential$15.00, Commercial$15.00 Date. — �P New Construction: r Old or Pre-existing Building: (check one) I/' Location of Property: CQ 0 S(L[ ,pfYre� La t4 Q Ul(-&� r IHamle 0, (("l�� House No. t't Owner or Owners of Property: t Suffolk County Tax Map No 1000, Section 16.0 044. . .B(c k Lot Subdivision Iv • Filed Map. Lot: Permit No. 403 1 Date of Permit. Applicant: Health Dept.Approval: Underwriters Approval: Planning Board Approval: Request for: Temporary Certificate Final Certificate: (check one) 56 Fee Submitted: $ (30 Applicant Signature V ,/, I,��� iii 1*pf S0045,• • ,, �® Telephone(631)765-1802 Town Hall Annex �� 54375 Main Roadlig Fax(631)765-9502 P.O.Box 1179 �� Southold,NY 11971-0959 �, y® II roger.richertRtown.southold.ny.us ,r).,_ ..‘z- ... o's BUILDING DEPARTMENT TOWN OF SOUTHOLD CERTIFICATE OF ELECTRICIAL COMPLIANCE SITE LOCATION Issued To: Clive Rowe Address: 640 Skippers Lane City: Orient St: New York Zip: 11957 Building Permit#• 40389 Section: 24 Block: 1 Lot: 10 WAS EXAMINED AND FOUND TO BE IN COMPLIANCE WITH THE NATIONAL ELECTRIC CODE Contractor: "AS BUILT" DBA: License No: SITE DETAILS Office Use Only Residential X Indoor X Basement X Service Only Commerical Outdoor X 1st Floor X Pool New Renovation 2nd Floor Hot Tub Addition Survey X Attic Garage INVENTORY Service 1 ph Heat GAS Duplec Recpt Ceiling Fixtures HID Fixtures Service 3 ph Hot Water GFCI Recpt 1 Wall Fixtures 1 Smoke Detectors Main Panel A/C Condenser 2 Single Recpt Recessed Fixtures 1 CO Detectors Sub Panel NC Blower 2 Range Recpt Fluorescent Fixture Pumps Transformer Appliances Dryer Recpt Emergency Fixtures Time Clocks Disconnect Switches 3 Twist Lock Exit Fixtures TVSS Other Equipment "AS BUILT"- "ELECTRICAL SURVEY" - "NO VISUAL DEFECTS" Certificat Covers Gas Furnace,2-Central A/C Units, 1-Bathroom Renovation. Notes: Inspector Signature: Date: February 23, 2016 Electrical 81 Compliance Form xls �ho�. _ Hplo,., C Town Hall Annex 'title �,'\-'; + ` Telephone(631)765-1802 • 54375 Main Road Fax(631)765-9502 P.O.Box 1179 ;�;G �.%Y' �~ �1 O Southold,NY 11971-0959 `4'Qly' '• t�+F,�, C_Q(j�'r{' BUILDING DEPARTMENT TOWN OF SOUTHOLD LLy. CERTIFICATION Date: 8/ 2`S- �/5 Building Permit No. _ Owner: C..,0/7/C/c / "ocv.e (Please print) Plumber: 6 eU' ( _ .-?1)1..."_C/LP- (Ca- 466/0 P/()Mb) '• (Please print) �J I certify that the solder used in the water supply system contains less than 2/10 of 1% lead. ill •94,440/'- (Plumbers Signature) Sworn to before me this ) day of ,i,,iib,_,t ' , 20 l . 1 — titt4ak • I Notary Public, County __ BONNIE J.DOROSKI - _ Notary Public,State Of New York No. 01D06095328,Suffolk ,. Term Expires July 7,20 ih 009 �ryolo,; 41 • TOWN OF SOUTHOLD BUILDING DEPT. 765=1802 INSPECTION' [ ] FOUNDATION 1ST [ ] ROUGH PLUMBING [ ] FOUNDATION 2ND [ ] IN ULATION [ ] FRAMING /STRAPPING [ FINAL [ ] FIREPLACE & CHIMNEY [ ] FIRE SAFETY INSPECTION [ ] FIRE RESISTANT CONSTRUCTION [ ] FIRE RESISTANT PENETRATION [ ] ELECTRICAL (ROUGH) [ ] ELECTRICAL (FINAL) [ ] CODE VIOLATION [ ] CAULKING REMARKS: fi '-, �-- 42-, a1. 6;1, '''4e'-"r7° DATE ®fAA INSPECTOR " 1'1°67 ,,,,,,,,,,,,, ho��OF SO(/T�6e.` * :ss * OQ 1 i , i TOWN OF SOUTHOLD BUILDING DEPT. 765-1802 INSPECTION [ ] FOUNDATION 1ST [ ] ROUGH PLUMBING [ ] FOUNDATION 2ND [ ] 1N ULATION [ ] FRAMING / STRAPPING [ FINAL [ ] FIREPLACE & CHIMNEY [ ] FIRE SAFETY INSPECTION [ ] FIRE RESISTANT CONSTRUCTION [ ] FIRE RESISTANT PENETRATION [ ] ELECTRICAL (ROUGH) [ ] ELECTRICAL (FINAL) [ ] CODE VIOL/7.10N [ ] CAULKING REMARKS: /. DATE p3A3A INSPECTOR FIELD mewl=.KENO r DATBCO ,NTS G • 'UUND,AnON(1ST) , • . .. - , • . -. i ' .. ;. I , CP • ,4 , ... '.t .; . 1" • .....:. •1 . . . .. I . ; .. . ' . . . .. . `^ FOUNDATION(2ND) 1�-.•,-r--*--- c. O I� ROUGH FRANI:14'1G& ._:.__..,,_,._ Jla ii PLUMBTN'G .._._,._:— , , . . _ r G • . '. y INSULATION'PEA N.Y. • • STATE BNERGY CODE . , , • .,. . . • . ...... .....am.41. ). 4, "41-97,47z-Ps / ..10 , • •- , ./ • , / 4, „ i :7:-. L mss•' . / c1" /#1*1040 .. . • ..' ' ' • 0 a 0 �r ' '.0. :4-1,16.4 �i 1 • ( w ) i-obU10 e rc31) r1Pl9 ?i -/1e. �2�C P 15,�;`�- 1d4 . . . . , . • . • \ 2 . .. . . . �{ . . , . ,. 4 ` . . .. ,, .. . _ . , • • ,. . , „ , . .. , . TOWN OF SOUTHOLD BUILDING PERMIT APPLICATION CHECKLIST BUILDING DEPARTMENT Do you have or need the following,before applying? TOWN HALL oard of Health SOUTHOLD, NY 11971 4 ets of Building Plans TEL: (631) 765-1802 Pl nning Board approval FAX: (631) 765-9502 z - urrvey SoutholdTown.NorthFork.net PERMIT NO. ick Septic Form — ^--_ — N.Y.S.D.E.C. �.1 `; �� r;};, j Trustees ,[7.721 (/C�O.Application Flood Per&mit Searate le Examined ,20 -I 1 '( g p DECEC 1 1 2015 I orm-Water Assessment Form `R� — ._-_j Contact: 31 ;JEF' Approved ,20 Disapproved a/c Phone: ( �� 3/ 1 Expiration (--)/ ,2043-- Building Inspector APPLICATION FOR BUILDING PERMIT Date , 20 INSTRUCTIONS a. This application MUST be completely filled in by typewriter or in ink and submitted to the Building Inspector with 4 sets of plans, accurate plot plan to scale. Fee according to schedule. b. Plot plan showing location of lot and of buildings on premises, relationship to adjoining premises or public streets or areas, and waterways. c. The work covered by this application may not be commenced before issuance of Building Permit. d. Upon approval of this application, the Building Inspector will issue a Building Permit to the applicant. Such a permit shall be kept on the premises available for inspection throughout the work. e.No building shall be occupied or used in whole or in part for any purpose what so ever until the Building Inspector issues a Certificate of Occupancy. f. Every building permit shall expire if the work authorized has not commenced within 12 months after the date of issuance or has not been completed within 18 months from such date. If no zoning amendments or other regulations affecting the property have been enacted in the interim, the Building Inspector may authorize, in writing,the extension of the permit for an addition six months. Thereafter, a new permit shall be required. APPLICATION IS HEREBY MADE to the Building Department for the issuance of a Building Permit pursuant to the Building Zone Ordinance of the Town of Southold, Suffolk County,New York, and other applicable Laws, Ordinances or Regulations, for the construction of buildings, additions, or alterations or for removal or demolition as herein described. The applicant agrees to comply with all applicable laws, ordinances,building code,housing code, and regulations, and to admit authorized inspectors on premises and in building for necessary inspections. (Signature of applicant or name, if a corporation) 6.o. t aK 52)b 0 Mme, *c, L�STh (Mailing address of applicant) State whether applicant is owner, lessee, agent, architect, engineer, general contractor, electrician, plumber or builder Name of owner of premises (-( I Va- f? .1-. C4r1A21C VUf/VK` i2t i (As on the tax roll or latest deed) If applicant is a corporation, signature of duly authorized officer (Name and title of corporate officer) Builders License No. Plumbers License No. Electricians License No. Other Trade's License No. 1. Locg/ation� of land on which I/r// �(�/ �(/ l_\ oposed work will) hb//py dopy:.,'/; ; 6n/ , "7y House Number Street I" 1)1'' Hamlet County Tax Map No. 1000 Section (-(' Block I Lot no Subdivision Filed Map No. Lot 2. State existing use and occupancy of premises and intended use and occupancy of proposed construction: a. Existing use and occupancy b. Intended use and occupancy 3. Nature of work(check which applicable): New Building Addition Alteration Repair Removal Demolition Other Work 1270(tti(._--t-1 ( . (Description) 4. Estimated Cost Fee 4y"1/I (To be paid on filing this application) 5. If dwelling, number of dwelling units Number of dwelling units on each floor If garage, number of cars 6. If business, commercial or mixed occupancy, specify nature and extent of each type of use. 7. Dimensions of existing structures, if any: Front Rear Depth Height Number of Stories Dimensions of same structure with alterations or additions: Front Rear Depth Height Number of Stories 8. Dimensions of entire new construction: Front Rear Depth Height Number of Stories 9. Size of lot: Front Rear Depth 10. Date of Purchase Name of Former Owner 11. Zone or use district in which premises are situated 12. Does proposed construction violate any zoning law, ordinance or regulation? YES NO X 13. Will lot be re-graded? YES NO % Will excess fill be removed from premises? YES NO 14. Names of Owner of premises Address Phone No. Name of Architect Address Phone No Name of Contractor Address Phone No. 15 a. Is this property within 100 feet of a tidal wetland or a freshwater wetland? *YES NO * IF YES, SOUTHOLD TOWN TRUSTEES &D.E.C. PERMITS MAY BE REQUIRED. b. Is this property within 300 feet of a tidal wetland? * YES NO * IF YES, D.E.C. PERMITS MAY BE REQUIRED. 16. Provide survey, to scale, with accurate foundation plan and distances to property lines. 17. If elevation at any point on property is at 10 feet or below, must provide topographical data on survey. 18. Are there any covenants and restrictions with respect to this property? * YES NO X * IF YES, PROVIDE A COPY. STATE OF NEW YORK) SS: COUNTY OF iNK_ ) l:f 4�I0 0 being duly sworn, deposes and says that(s)he is the applicant (Name of individual signing contract) above named, (S)He is the (Contract r,Agent Corporate Officer, etc.) of said owner or owners, and is duly authorized to perform or have performed the said work and to make and file this application; that all statements contained in this application are true to the best of his knowledge and belief; and that the work will be performed in the manner set forth in the application filed therewith. Sworn to before me this TRACEY L. DWYER 11 -- day of T2CmI9eJL 20!5NOTARY PUBLIC,STATE OF NEW-YORK N0.01 DW6306900 JI)9 �Q . QUALIFIED IN SU6OLK COUNTY 40-/U Cn • at��} NO. EXPI CS JUNE 90, -40-/U v Notary Public (f „ ,Signature of Applicant o." iii____• o Town Hall Annex ; � +`. , Telephone(631)765-1802 1 54375 Mai n Road �, +,•'; __i `- ::, az(0"3 i]Zell P_O_ Box 1179 ; + • ��� roger_richert town-souel d_ny_us Southold,NY 11971-0959 \% Z1i1' -4. '�C011 t'{,\\c'' I. • BUILDING DEPARTMENT TOWN OF SO.6JTBIOLD- APPLICATION FOR ELECTRICAL INSPECTION - ! 71.((j2 REQUESTED BY: ' - -'�--• Date: I - (� - ) C - ICompany Name: r' -Name: - i - s• License No_: j- Address: - - - ---- - - - --- -- - --- Ph-one•No_:: - " - - 1 : - - r • JOBSITE INFORMATION:(*Indicates-requir-edd information) - - *Name: 1 7 �e I 2 L - ( • -� get G4- tGk (N r _ ar" - _ , *Address: (lit1 ->c,V`S - l--of,'v*e : - (O&1 - *Cross Street: \jt I,\q,., - it J - - *Phone No_: 31 r7 i 1 I I - Permit No.: Tax-Map District: • 1000 Section: 21-' - Block: I Lot: J a - *BRIEF DESCRIPTION OF WORK(Please Print Clearly) - _ - 11) ( L_ C,12..- AC, / /3 6-77'/(2a)1-, - . / .(Please Circle All That Apply) _ - - *Is job ready for inspection: ��NO- Rough In Final - *Do-you need a Temp Certificate: YES/ NO - - Temp Information (If needed) - . *Service Size: 1 Phase 3Phase 100 150 200 300 350 400 Other *New Service: Re-connect Underground Number of Meters Change of Service Overhead - Additional Information: PAYMENT DUE WITH APPLICATION - - PILA jz,i) 611;,. 0 I 82-Request for Inspection Form / f- f' r In - / N Ni 0 SURVEY OF PROPERTY / �oy� AT ORIENT 1., ti4 // sss, ' TOWN OF SO UT F.IOLD .,�°c // `��'; L '' �'<< SUFFOLK COUNTY, N. Y. o . / rL -14i< 1000-24-01-10 // 90-94,� � 4i,/ SCALE:MARCH 10, 2000, // i°,y4) SEPT. 6, 2007 (CERTlFlCATION) / �A„,.. / F,QSy/t / lv // TEST j0� 05DATA 0 06. .D�Q (/ l�y9�o 3,S)�e BROWN SILTY LOAN OL �VA N N 4 % - __ '•y - - '- - !rte -, ;-- - j.`-�. ,- - - _ --- --- - - -„--- - --- -_'- -- t Ys= r , DA-2_,s- . ----7000 _ ;� _ , -/v TOWN OF ;-SOUTHOLD ' PROPERTY RECORD- CARD (o j _ OWNER _ STREET / 'j 0 VILLAGE DIST. SUB. LOT `t .za&fli_.GacrIL-k:•VI1011'/ee' D .Sk1 ft. ,0e,-J !a e ���1, . . _ FORMER N ' E ACR. �,�, � OWNER � ,^ 1�="Ir�-r-2. Fiet ii :L L ... , t f u ii1 t I i.- ,-` �.4'2(V.i ivr-C r r't Y 111, 4 !,2M1 I: 1 0 K1-C'K Ir v,ru1 r S `• _ , ,, W -' TYPE,'QF BUILDING'2_.e,-:- /-- e_C Ad d- '.!� -F-i, , Rae rd 9( V_�t�ir-pelridne--/t �hoz›lell ,a,,. IU �� k1,L/i . ' / 72 e,-:- � lvG-z R � to S S. VL. FARM COMM. CB. MISC./ Mkt. Value ' LAND IMP. TOTAL DATE REMARKSr/,2/w-G ,//jozHale,.: kL_2,9yIL- )7 A9,e',-4,i 7 Ca :,ei e,ry 100 ;17c9A9 2.s'Oo 1 /13# -� 1- lZa9 ,oS31/- aCke Ora 1. f”' / , 4 ( 4th' �r5 ���.:4-� / e o .... dC 3 ?o® ,/ //f/? �3�' �lu1 — 14n rte $L ac -e It r-rlo, i,s 11 e--..& , \7h� Q ' 0 . 7(oo I 2/ /o ib1/ -7-- L 11530 p e i2 - /PAicL:q 1!r ` 6466),N iloo , (ezon Soin. / :-?-1 13/49-9 ''Dt.. ccaA.,wi y \A clAk_ k...t...,n s....tt._ „314.. ( t..,‘,,,..k.- 2_10_12.9 ,:57/3oYozi - L ' 1 tC© rC.. e rt I /i ,o ti c...- AGE BUILDING CONDITION NEW NORMAL BELOW ABOVE l; FARM Acre Value Per Value Acre Tillable 1 Tillable 2 51- .. _ f �a a I Tillable 3 • ,/ a 6 / 6,>-5----,-,-_____ ../7 ® p Woodland /3�r •G.- 7-,m-✓ / � '�s . Swampland FRONTAGE"ON)A ER / ' c� Brushland FRONTAGE-ON ROAD 5 /j---- . House Plot 11\c_ \1p0(0 k taco d DEPTH ) ( (-------- 2.- S-O ` BULKHEAD Total ' / POCK s3=. r • , , i , •%.,i'fie',;e -i4.:—:el,,',V1;;4., -',1:1,1e41.0 .A, . - i In.)k&A.AP--.4,-re l',..t3 , ; , ,g1,L*":',::i6z:'4 :k f,.:14.::',.,;•-f•fp I. -3i----0;efic,4q,A44i, 1 1- 111111.111111111111191111111111• 11.11.111111111111.11 , ^ .'_}.1,v. '..4."..4-, .0,, ...AI-„,,,,,, .U•44., 1,A,„_ ‘,. .:„„, ,..:,,,,,_-__-,--._____• 1..4‘.. "..%*:.-Iq'• . N•'.V7, }Z:....;c4"-vort tr.--,,:,-,t-°,1,'A-.1V :77:',. a ".'4',.,;.-IF R 11111111111111111 , IIIMELINEE11111MMIIIIMMENIIIMI i , : ,..- - •;:,7;..-,',...,7',::, .-,,.;,?.., .0 „, ,,- .- , - 1 , ,,,, ._,,._-el.%::,,,,,r,., .. MitilriEir1111111111.111111.11111.1111111111.11 '41% --",s1.- ',*''.'.,-; , ,,:'•,,'" -',-t- ' , 2.,-: :----: 7---...-7—'—'''' ..— ;.-.t 1111111111111111 .;1:‘,1,-' -,. • ',,, 111•11.11111.11.111111111111.1111111.111 .kt7 ,i.'-- ' ,,,,, .1:—"-•-I 1111r-::-;_fr - :',f'.-,:' i,, . ' f I EINEM 1111111111•111111111.11N111111111111111111111111MO -.-,—._ ...._t---- 1_, __________-----5,,v„. ..., 1 , '11 -:'-'-'4.— '' '' ... s' -1 ' — ' MINER • 111111111111111ENIIMMIIMINI11111•111 ..-T - , ,_..,_-.--- k, 7;:'•---, --,--t---- ...-,... F' * -- - '--:f---L' ; 1 EIMIIIIIMEN 11111111111.111111.1111111111.11.1111.111 kot;':::."fr•=;5k-:,(4,4,:..0-• ,,-,,c,11.4., i;-"746.107101,1,ir,,,,A- ... -^ : ,‘ ,-.., 2,,,4(An.',,i,1,1-,,,,-, *!.),44'*'-'"- VITZW9Itf• NIMEINMINIE EIMINIIIIIIIIIIMNIIIIIIIIIMIIME ;41'q - 4 k 11111.111111 EillIIIIIIRMIIIIII11111111111111111111111 :"'...t. 1. t,..?,- ' , ,..VT',54 §,,,'-e.7-4,'-0,A, .k fl- 4,k1., .7,,, .-i,e, . • .t.t .,...v . _ .. ,.1,.. 24.-1-10 9/09 ' MIIIIIMMIIIIIII 11•1111111111111111•1•11111111111111111111111 , -- 1111111111111111111 INIIIIIIIIIMIIINIIIIIIMIEMIIIIIIIIIMIN .. ' 401: irt4.4.,VV.r...''.,•:0;.• '%::''''' , '‘47.71kr 1011.111111111111 IMIIIMIIIEIIIMMMIIIMIIIEIIIIMIIIEIIIII ---.--5 ') • M. Bldg. #., -3 C / r,--0 e) Foundation 4=int„€._ Bath / Dinette ; e,6 , — ? r,, --- ,., , Floors K. Extension 0 X /6 .., I/A) / .2-,s'''' / ' ' Basement Paia f 0-ry \2415•;, l Mo Extension 78" X // .. i / 1 Ext. Walls X:1---, ---t-e " Interior Finish L R. - Extension / )._ -1(-->.-1-- : 1 ckti ,,24-1/ ‘ .._.,/) 9:„.2,-,v Fire Place /76) Heatiat7---- DR. /o9; .:.-,' 6-0 I42 Type Roof 611-m-- b i-e...., Rooms 1st Floor • BR. Porch 0 t „,,__, \ %%IC)?4,30,,s4'r 1 ,"io, Recr.eatian Room Rooms 2nd Floor % FIN. B. , cd ..,{ cas. /Q'. / ..,._ 7 69 CP-- j17 Porch Dormer Breezeway - A-(-, Driveway E,%1--- laangl Garage 2,6--- gd-1-(e214-= r6ruo \ _ 72.0 Patio '7vco-t,_ 0. B. ;1"-- -/YtH\.LlAZI sco, t oo(e.a__ 7,v!r. .,, , , Total 7/>'''a -r 6 2.6Z (---. - 1 1 ' f'---- , , -) \,,..., _ 0- . . INSTALLATION INSTRUCTIONS 13 SEER SERIES R-22 CUBE CONDENSING UNITS 11/2 - 5 TONS G✓;j'�, y_ • -c--+.-: p'ty{';r:�`>�:•);:`};�}\"yam'• '0 i :%''' This product is shipped with a nitrogen holding charge that must be vented prior to evacuation and charging. I J This product is only intended for r� r; condensing change-out in existing R-22P" I' systems ° >�-� LL- This product must be charged with R-22 ^ �� `' { �' v refrigerant meeting AHRI 700 purity stan L�!_� dard. -_--- NOTE:Appearance of unit may vary. A RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION! AWARNING C �L US THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED, LICENSED SERVICE PERSONNEL FOR PROPER LISTED INSTALLATION, ADJUSTMENT AND OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY BEFORE o "E�`g ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOL- � - LOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER .� 0 B INSTALLATION, ADJUSTMENT, SERVICE OR MAINTENANCE Amsditcd qthe a.A m System POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK, ISO 9001:2008 'PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. . Certificate Number 30164 DO NOT DESTROY THIS MANUAL PLEASE READ CAREFULLY AND KEEP IN A SAFE PLACE FOR FUTURE REFERENCE BY A SERVICEMAN 92-21354-47-12 SUPERSEDES 92-21354-47-10 TABLE OF CONTENTS 1.0 SAFETY INFORMATION 3 2.0 GENERAL 4 21 Checking Product Received 4 • 2 2 Application .4 2.3 Dimensions . . 5 2.4 Electrical and Physical Data . . .6 3.0 LOCATING UNIT - 6 3 1 Corrosive Environment . . .. . . . . . . . . . 6 3 2 Condenser Location 7 3.3 Operational Issues 7 3 4 For Condensers With Space Limitations . . 7 3.5 Customer Satisfaction Issues - . 8 3.6 Unit Mounting. . . - 8 3 7 Factory-Prepferred'Tie-Down Method . . . . . . • . 8 4.0 REFRIGERANT CONNECTIONS 8 5.0 REPLACEMENT UNITS 8 6.0 INTERCONNECTING TUBING 9 61 Vapor and Liquid Lines . . . 9 6 2 Maximum Length of Lines .. . . 9 6.3 Outdoor Unit Installed Above Indoor Coil 9 6.4 Outdoor Unit Below Indoor Cod .. . . . . . 10 6.5 Tubing Installation . ... . 10 6 6 Tubing Connections. . . . . . 10 6 7 Leak Testing . . . . . . . . . 11 7.0 EVACUATION PROCEDURE - 11 8.0 START UP PERFORMANCE 13 ' 9.0 CHECKING AIRFLOW " 13 10.0 CHECKING REFRIGERANT CHARGE 13 10 1 Charging By Liquid Pressure . . 14 10.2 Charging By Weight 14 10.3 Final Leak Testiing. . . . . . . . 14 11.0 ELECTRICAL WIRING - 14 11 1 Grounding . . . . . . . . . . . . . . . . . . . . . . . 14 11.2 Power Wiring. .. . . . . . . . . . . 14 11.3 Control Wiring .. . . . . . . . . . . . . . . . . . . . . . . 15 12.0 FIELD INSTALLED ACCESSORIES 15 12 1 Compressor Crankcase Heat 15 12 2 Time Delay Control(TDC).. . . 16 12.3 Low Ambient Control(LAC) . _ . . . 16 " 12 4 High and Low Pressure Controls(HPC or LPC) . . . . . . . . . . 16 13.0 SERVICE - - 16 13.1 Operation. . . . . . . . . . . . .. . . . . . . . . . 16 13.2 Single-Pole Compressor Contactor. . . . . . . .. . . . . -. 16 14.0 TROUBLE SHOOTING - 17 14.1 Electrical Checks Flow Chart . . . . . . . 17 14.2 Mechanical Checks Flow Chart . . . . . . . . . . . . . . . . . . . .. . . . . 18 14.3 Superheat Calculation . 19 14.4 Subcooling Calculation . 19 14.5 General .. . . . . . .. . . . . . . . . . . . 20 15.0 WIRING DIAGRAMS 21-22 2 1 :0 SAFETY INFORMATION • . A WARNING • _ THESE INSTRUCTIONS ARE INTENDED AS AN AID TO QUALIFIED LICENSED _ SERVICE PERSONNEL FOR PROPER INSTALLATION, ADJUSTMENT AND . OPERATION OF THIS UNIT. READ THESE INSTRUCTIONS THOROUGHLY - - - ' BEFORE ATTEMPTING INSTALLATION OR OPERATION. FAILURE TO FOL- LOW THESE INSTRUCTIONS MAY RESULT IN IMPROPER INSTALLATION, - ADJUSTMENT, SERVICE OR MAINTENANCE POSSIBLY RESULTING IN FIRE, ELECTRICAL SHOCK,'PROPERTY DAMAGE,PERSONAL INJURY OR DEATH. ; - A WARNING. '' THE MANUFACTURER'S WARRANTY DOES NOT COVER ANY DAMAGE OR ' DEFECT TO THE HEAT PUMP-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 UNAU= THORIZED COMPONENTS, ACCESSORIES OR DEVICES MAY ADVERSELY AFFECT THE OPERATION OF THE HEAT PUMP AND MAY ALSO ENDANGER LIFE AND PROPERTY.THE MANUFACTURER DISCLAIMS ANY RESPONSIBIL- ITY FOR SUCH LOSS OR INJURY RESULTING FROM'THE USE OF SUCH UNAUTHORIZED COMPONENTS,ACCESSORIES OR DEVICES. •-' • = , . A-WARNING " _ ' DISCONNECT ALL POWER TO UNIT BEFORE STARTING'MAINTENANCE. - FAILURE TO DO SO CAN CAUSE ELECTRICAL L-SHOCK RESULTING IN - - SEVERE PERSONAL INJURY OR-DEATH. . A 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. 'A WARNING` _ ,_ ' , ' . ' • " THE UNIT MUST-BE PERMANENTLY GROUNDED. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING-IN-SEVERE PERSONAL INJURY OR DEATH. . - , ' . :A'WARNING- - . - ` - ' ' - _ , ' TURN.OFF ELECTRIC POWER AT THE,FUSE BOX OR SERVICE PANEL ' BEFORE MAKING ANY ELECTRICAL CONNECTIONS. •' ' -- - -ALSO,THE GROUND CONNECTION MUST BE-COMPLETED BEFORE MAKING - • • - LINE VOLTAGES CONNECTIONS. FAILURE TO DO SO CAN RESULT IN ELEC-• - ' TRICAL SHOCK,SEVERE PERSONAL INJURY OR DEATH. 3 AWARNING 2.0 GENERAL • THE MANUFACTURER'S WAR- - The information contained in this manual has been prepared to assist in the proper RANTY DOES NOT.COVER ANY installation, operation and maintenance of the air conditioning system. Improper DAMAGE OR DEFECT TO THE installation, or installation not made in accordance with these instructions, can result AIR CONDITIONER CAUSED BY in unsatisfactory operation and/or dangerous conditions, and can cause the related THE ATTACHMENT OR USE OF warranty not to apply. ANY COMPONENTS. ACCES- Read this manual and any instructions packaged with separate equipment required, TORIES OR DEVICES (OTHER B THAN THOSE AUTHORIZED BY to make up the system prior to installation. Retain this manual for future reference.- THE MANUFACTURER) INTO, To achieve optimum efficiency and capacity, the indoor cooling coils listed in the ONTO OR IN CONJUNCTION condensing unit specification sheet should be used. WITH THE AIR CONDITIONER. YOU SHOULD BE AWARE THAT IMPORTANT: We recommend replacement of any HVAC equipment that has been THE USE OF UNAUTHORIZED subjected to flooding in order to avoid any risk of injury or harm COMPONENTS, ACCESSORIES IMPORTANT: Use all available safety precautions during the installation and servic- OR DEVICES MAY ADVERSELY . ing of any HVAC equipment. AFFECT THE OPERATION OF THE AIR CONDITIONER AND 2,1.CHECKING PRODUCT RECEIVED MAY ALSO ENDANGER LIFE - AND PROPERTY.THE MANUFAC- Upon receiving unit, inspect it for any shipping damage Claims for damage, either TURER DISCLAIMS ANY apparent or concealed, should be filed immediately with the shipping company. - RESPONSIBILITY FOR SUCH Check condensing unit model number, electrical characteristics and accessories to LOSS OR INJURY RESULTING determine if they are correct and match the original order from the local distributor. FROM THE USE OF SUCH Check system components (evaporator cod,'condensing unit, evaporator blower, UNAUTHORIZED COMPONENTS, etc.)to make sure they are properly matched ACCESSORIES OR DEVICES. 2.2 APPLICATION Before installing any air conditioning equipment, a duct analysis of the structure and a heat gain calculation must be made. A heat gain calculation begins by measuring all external surfaces and openings that gain heat from the surrounding air and quantifying that heat gain. A heat gain calculation also calculates the extra heat load caused by sunlight and by humidity removal. There are several factors that the installers must consider: • Outdoor unit location , • Proper equipment evacuation • System refrigerant charge - • Indoor unit airflow • Indoor unit blower speed • Supply and return air duct design and sizing • System air balancing • Diffuser and return air grille location and sizing • 4 2.3 (SEE FIGURE 1) FIGURE 1 / -W gAIR DISCHARGE: ALLOW DIMENSIONS 60" MINIMUM CLEARANCE. / g. \W-"-":"ii-WN-S4)) ,,, L ,//i, 111�� AIR INLETS 'i VIfk.(•_______„...:-..1/7 - (LOUVERED � � PANELS) �, `,_%�,%�/ 7< ALLOW 6 � �-=/ MINIMUM _ '„ CLEARANCE SERVICE ACCESS ALLOW 24"CLEARANCE H Y „ \ , . , , ••INOTE:GRILLE APPEARANCE \ . 4frif MAY VARY. SEE DETAIL A 1 . LOW VOLTAGE ' 71s"[22 mm]HOLE DIAMETER HIGH VOLTAGE 111/32"[34 mm] HOLE DIAMETER , (r ) (= -= ) (- ) • ' SERVICE 1111^ /�� o .... _ o FITTING ��,� 411741( �� ���Ii SERVICE —k �aLilli FITTING .r� � �iQl �� DETAIL A - ., 1 BASERAIL LIQUID LINE VAPOR LINE o CONNECTION CONNECTION DIMENSIONAL DATA Model Size 18,24 30 364842, 60 n ( BASE PAN(BOTTOM VIEW) Height"H"(in.)[mm] 24'14 24'14 2715/16 3575/16 DO NOT OBSTRUCT DRAIN HOLES [616] [616] [710] [913] (SHADED) Length"1"(in.)[mm] 235/6 275/6 315/6 315/6 [600] [702] [803] [803] Width"W"(in.)[mm] 235/6 275/6 315/6 315/6 [600] [702] [803] [803] 5 2.4 ELECTRICAL & PHYSICAL DATA(SEE TABLE 1) TABLE 1 - ELECTRICAL AND PHYSICAL DATA Electrical Data Physical Data Compressor Fan Motor Minimum Fuse or HACR Outdoor Coil Weight Refrig. Model Phase Circuit Breaker Number Frequency(Hz) Rated Load Locked Rotor Full Load Circuit Per g (Volts) Amperes Amperes Amperes Ampacity Face Area No CFM Circuit Net Shipping Voltage P P (FLA) Amperes Minimum Maximum Sq Ft[m2] Rows [Us] Oz[g] Lbs.[kg] Lbs[kg] (RLA) (LRA) Amperes Amperes 18 1-60-208/230 7 7/7 7 40 3 1 11/11 15/15 15/15 843' 1 1900- 67 150 158 [0 78] [897] [1899] [68] [71 7] 24 1-60-208/230 10 4/10 4 54 0 6 14/14 2020 2020 11 06 1 1700 77 155 163 [1 03] [802] [2183] [70 3] [73 9] 30 1-60-208/230 14 1/141 68 0 8 19/19 25/25 30/30 13 72 1 2325 98 175 185 [1 27] [1097] [2778] [79 4] [83 9] 36 1-60-208/230 14 4/14 4 78 0 8 19/19 25/25 30/30 16 39 1 2800 108 200 212 [1 52] [1321] [3062] [90 7] [96 2] 42 1-60-208/230 19 2/19 2 105 0 8 25/25 30/30 -40/40 16 39 1 2800 121 205 217 [1 52] [1321] [3430] [93] [98 4] 48 1-60-208/230 211211 115 12 28/28 35/35 45/45 1639 1 3300 123 210 222 [1 52] [1557] [3487] [95 3] [100 7] 60 1-60-208/230 25 325 3 150 1 2 33/33 40/40 50/50 21 85 1 3575 191 247 258 [2 03] [1687] [5415] [112] [117] NOTE Units are shipped with a nitrogen holding charge Refrigerant charge shown is for 15 ft of standard lineset System must be charged with R-22 in the field Electrical Data Physical Data Compressor Weight Model Calc.Fuse Sizes Outdoor Refrigerant Number Phase I Comp Motor Coil Coil CFM Per 13ACA Frequency(Hz) LRA FLA Area Sq Ft Rows [Us] Circuit' Net Shipping Voltage(Volts) Comp RLA Comp LRA Lbs[kg] Lbs[kg] Min Max [m9 (Oz.)[g] 36 3-60-208/230 10 3 88 0 8 14/14 20/20 2020 11 06 1 2800 108 184 5 196 5 [1 03] [1321] [3062] [83 7] [89 1] 42 3-60-208/230 13 5 89 0 8 18/18 25/25 30/30 13 72 1 2800 121 178 5 190 5 [1 27] [1321] [3430] [80 9] [88 4] 48 3-60-208/230 141 _ 95 1 2 19/19 25/25 30/30 16 39 1 3300 123 184 196 [1 52] [1557] [3487] [83 5] [88 0] l 60 3-60-208/230 17 3 123 1 2 23/23 30/30 40/40 21 85 1 3575 191 228 5 239 5 [2 03] [1687] [5415] [103 6] [108 6] NOTE Units shipped with nitrogen holding charge Refrigerant quantity shown is for 15 ft of standard lineset - - Electrical Data Physical Data Compressor Weight Model - - Calc Fuse Sizes Outdoor Refrigerant Phase Number Comp Motor Coil Coil CFM Per 13ADA Frequency(Hz) LRA FLA Area Sq Ft Rows [Us] Circuit* Net Shipping Voltage(Volts) Comp RLA Comp LRA Min Max [mz] (Oz.)[g] Lbs [kg] Lbs.[kg] - 36 3-60-460 5 8 45 0 4 - 8 15 15 21 85 2 2800 108 194 206 - [2 03] [1321] [3062] [88 0] [93 4] 42 3-60-460 6 4 45 0 4 9 15 15 - 21 85 2 2800 121 184 196 [2 03] [1321] [3430] [83 5] [88 9] 48 3-60-460 7 1 45 0 6 10 15 15 21 85 2 3300 123 188 200 [2 03] [1557] [3487] [85 3] [90 7] 60 3-60-460 8 4 70 0 6 12 15 15 21 85 2 3575 191 241 252 [2 03] [1687] [5415] [109 3] [114 3] NOTE Units shipped with nitrogen holding charge Refrigerant quantity shown is for 15 ft of standard lineset - 3.0 LOCATING UNIT MATCH ALL COMPONENTS: 3.1 CORROSIVE ENVIRONMENT • OUTDOOR UNIT The metal parts of this unit may be subject to rust or deterioration if exposed to a • INDOOR COIL/METERING DEVICE corrosive environment. This oxidation could shorten the equipment's useful life • INDOOR AIR HANDLER/FURNACE 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 conta- • REFRIGERANT LINES minants 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 prob- - lem, special attention should be given to the equipment location and exposure. 6 • 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 water- front. • Shielding provided by a fence or shrubs may give some protection, but cannot violate minimum airflow andiservice access clearances • Elevating the unit off its slab or base enough to allow air circulation will help avoid holding water against the basepan Regular maintenance will reduce the build-up of contaminants and help to protect the unit's finish. A WARNING DISCONNECT ALL POWER TO UNIT BEFORE STARTING MAINTENANCE. FAILURE TO DO SO CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH. • Frequent washing of the cabinet,fan blade and coil with fresh water will remove most of the salt or other contaminants that build up on the unit • Regular cleaning and waxing of the cabinet with an automobile polish will pro- vide some protection. • A liquid cleaner may be used several times a year to remove matter that will not wash off with water. Several different types of protective coatings are offered in some areas. These coatings may provide some benefit, but the effectiveness of such coating materials cannot be verified by the equipment manufacturer. 3.2 CONDENSERLOCATION Consult local and national building codes and ordinances for special installation requirements. Following location information will provide longer life and simplified ' servicing of the outdoor condenser. NOTE: These units must be installed outdoors No ductwork can be attached, or other modifications made, to the discharge grille. Modifications will affect perfor- mance or operation. 3.3 OPERATIONAL ISSUES • IMPORTANT: Locate the condenser in a manner that will not prevent, impair or compromise the performance of other equipment horizontally installed in prox- imity to the unit. Maintain all required minimum distances to gas and electric meters, dryer vents, exhaust and inlet openings. In the absence of National Codes, or manaufacturers' recommendations, local code recommendations and requirements will take presidence • Refrigerant piping and wiring should be properly sized and kept as short as possible to avoid capacity losses and increased operating costs. • Locate the condenser where water run off will not create a problem with the equipment. Position the unit away from the drip edge of the roof whenever pos- sible. Units are weatherized, but can be affected by water pouring into the unit from the junction of rooflines,without protective guttering 3.4 FOR CONDENSERS WITH SPACE LIMITATIONS In the event that a space limitation exists,we will permit the following clearances* Single Unit Applications:One condenser inlet air grille side may be reduced to no less than a 6-inch clearance. Clearances below 6 inches will reduce unit capacity and efficiency. Do not reduce the 60-inch discharge, or the,24-inch service clear- ances. Multiple Unit Applications: When multiple condenser grille sides are aligned, a 6- inch per unit clearance is recommended, for a total of 12 inches between two units. Two combined clearances below 12 inches will reduce capacity and efficiency. Do not reduce the 60-inch discharge, or 24-inch service,clearances 7 - 3.5 CUSTOMER SATISFACTION ISSUES ._ • The condenser should be located away from the living, sleeping and recreation, ' al spaces of the owner and those spaces on adjoining property. ' - • ' - • To,_prevent noise transmission, the mounting pad for the outdoor unit should ' - not be connected to the structure, and should be located sufficient distance - ' above grade to'prevent ground water from entering the unit ' 3.6 UNIT MOUNTING . . ' _ If elevating the condensing_unit,_either oma-flat roof or on a slab, observe the - _ , - - following guidelines . - • The base pan provided elevates the condenser coil 3/4"above the base pad. ' • , ' •• If elevating a unit on a flat roof, use 4"-x 4"-(or equivalent) stringers positioned , , to distribute Unit weight evenly and prevent noise arid-vibration - _ - 3.7 FACTORY-PREFERRED TIE-DOWN.METHOD . - INSTRUCTIONS: . , - " - - - ' IMPORTANT:These instructions are intended as a guide to securing equipment for wind- - - . , ' - , - _ Joad ratings of"120 MPH sustained wind load"and"3-second, 150 MPH gust."While.this ,- ' - - - procedure isnot mandatory,the Manufacturer does recommend that equipment be prop- - - - erly secured in areas where high wind damage may occur. • STEP 1•Before installing,clear pad of any dirt or debris. - ' - IMPORTANT:The pad must be constructed of industry-approved materials,and - - - , must be thick enough to accommodate the concrete fastener ' -.STEP 2 Center basepan on pad,ensuring it is level STEP 3' Using metal straps as guides,mark spots on concrete where 4 holes will be drilled(See Figure 2): - - , - REQUIRED PARTS LIST ' .' NOTE:ALL PARTS AVAILABLE THROUGH LOCAL HARDWARE SUPPLY - ' - - ' , - DESCRIPTION , QUANTITY . - 1/4"x 2"Hex Washer Head Concrete Screws-- 4 - , • 1/8"x 1 1/2"x W-(width of-unit+-4") Metal straps - 2 - - 3/8"Washers - - 28 - - STEP 4.Drill four pilot holes ih pad,ensuring that the hole is at least 1/4"deeper than the • - - concrete fastener being used - - _ STEP 5'Gauge the amount of'washers needed by stacking washers and metal strap in - place;as shown in Figure 2, Detail A Typical installation requires 6 to 7 Wash- - - , - ers. - ' , _ STEP 6:Insert-concrete fastener into hole in metal strap,insert washers over end of fas- • , ' _ tener,and then insert into hole drilled into concrete - - STEP 7 Tighten concrete fastener - - - - - - -NOTE:Do not over-tighten the concrete,fastener Doing so can weaken the integrity of the concrete fastener and cause it to break ' ' - - STEP 8. Finish unit assembly per unit's installation instructions. - - - - - ' - 4.0-REFRIGERANT CONNECTIONS _ , • - v.All units are factory charged with a nitrogen holding charge All Models'are supplied with service valves. Keep tube ends sealed until-connection is to be made to pre- - ' V . vent system contamination. - - - • - . 5.0 REPLACEMENT -UNITS , .. -' - . . ' To prevent failure of a new.condensing unit, the existing evaporator tubing system - - must be correctly sized and cleaned-or replaced.'Care must be-exercised that the -- - expansion device is not plugged. Test the oil for acid. If positive, a suction line filter, ' drier is,mandatory:For new-and replacement units, a liquid line filter drier should be - installed and refrigerant tubing should be properly sized p 9 • 8 - - . FIGURE 2 TIE-DOWN KIT ASSEMBLY , J o AI r� J / \ 0•,- -"k 11 ,,41 p/ eip7 EE DETAIL A • • DETAIL A (4)#10 X 1/2"Screws ���� (4)Straps. See Detail B (4) 1/4 X'1 3/4"Hex Washer Head Concrete Screws DETAIL A SCALE 0 300 (3/16"Pilot HoLe Needed.Pilot Hole t/4"deeper Than The Fastener Embedment)• - 6.0 INTERCONNECTING TUBING 6.1 VAPOR AND LIQUID LINES Keep all lines sealed until connection is made. Refer to Line Size Information in Tables 2 through 4 for correct size and multipliers to be used to determine capacity for various vapor line diameters and lengths of run. The losses due to the lines being exposed to outdoor conditions are not included. IMPORTANT: Units are shipped with a nitrogen holding charge.Open service valves to vent the nitrogen before connecting the suction and liquid lines to the service valves. Lines must be connected immediately after nitrogen is vented to prevent con- tamination of system. Do not leave the system open to the atmosphere more than 15 minutes. - The nameplate refrigeration charge in the outdoor unit is sufficient for 15 feet of interconnecting lines.The factory refrigeration charge in the outdoor unit is sufficient for the unit and 15 feet of standard size interconnecting liquid and vapor lines. For different lengths, adjust the charge as indicated below 1/4"± 3 oz. per foot 5/16"±.4 oz per foot 3/8"±.6 oz. per foot • 1/2"±1.2oz per foot 6.2 MAXIMUM LENGTH OF LINES The maximum length of interconnecting line is 150 feet. Always use the shortest- length possible with a minimum number of bends Additional compressor oil is not required for any length up to 150 feet. NOTE: Excessively long refrigerant lines cause loss of equipment capacity. 6.3 OUTDOOR UNIT INSTALLED ABOVE INDOOR COIL Keep the vertical separation between coils to a minimum. However,the vertical dis- tance can be as great as 120 feet with the condensing unit ABOVE the indoor coil. Use the following guidelines when installing the unit' 9 1. DO NOT exceed 120 feet maximum vertical separation. 2 Expansion Valve Coil. a. The vertical separation can be greater than the value in Table 3,-but no more than 120 feet b. No changes are required for expansion valve coils 3. Always use the smallest liquid line size permitted to minimize the system charge. 4. Table 3 may be used for sizing horizontal runs. 6.4 OUTDOOR UNIT BELOW INDOOR COIL Keep the vertical separation to a minimum. Use the following guidelines when installing the unit: - 1. DO NOT exceed the vertical separations as indicated on Table 4 2. Always use the smallest liquid line size permitted to minimize system charge 3. Table 4 may be used for sizing horizontal runs 6.5 TUBING INSTALLATION - Observe the following when installing correctly sized type "L" refrigerant tubing between the condensing unit and evaporator coil. • If a portion of the liquid line passes through a hot area where liquid refrigerant can be heated to form vapor, insulating the liquid line is required - • Use clean, dehydrated, sealed refrigeration grade tubing.- • Always keep tubing sealed until tubing is in place and connections are to be made. • Blow out the liquid and vapor lines with dry nitrogen before connecting to the outdoor unit and indoor coil. For an air conditioning system, any debris in the line set could end up plugging the expansion device - • As an added precaution, a filter drier is recommended to be installed in the liq- - uid line. • If tubing has been cut, make sure ends are deburred while holding in a position to prevent chips from falling into tubing. Burrs such as those caused by tubing cutters can affect performance dramatically, particularly on small liquid line sizes - - - • For best operation, keep tubing run as short as possible with a minimum num- ber of elbows or bends. • Locations where the tubing will be exposed to mechanical damage should be avoided If it is necessary to use such locations, the copper tubing should be housed to prevent damage. • If tubing is to be run underground, it must be run in a sealed watertight chase. • Use care in routing tubing and do not kink or twist Use a tubing bender on the vapor line to prevent kinking. • The vapor line must be insulated to prevent dripping (sweating) and prevent performance losses. Armaflex and Rubatex are satisfactory insulations for this purpose Use 1/2" minimum insulation thickness, additional insulation may be required for long runs. - • Check Table 2 for the correct vapor line size. Check Tables 4 and 5 for the cor- rect liquid line size 6.6 TUBING CONNECTIONS - Indoor evaporator coils have only a holding charge of dry nitrogen. Keep all tube ends sealed until connections are to be made. i • Use type "L" copper refrigeration tubing. Braze the connections with accepted industry practices. • Be certain both refrigerant service valves at the outdoor unit are closed. • Clean the fittings before brazing • Remove the cap and schrader core from service port to protect seals from heat damage. ' • Use an appropriate heatsink material around the copper stub and the service valves before applying heat • IMPORTANT: Do not braze any fitting with the TEV sensing bulb attached. 10 TABLE 2 VAPOR LINE LENGTH SIZE AND CAPACITY MULTIPLIER R-22 System 1%Ton 2 Ton 21/2 Ton 3 Ton -31/2 Ton 4 Ton 5 Ton Capacity Model 54Opt. 5/8 Opt '5/8 Opt: ,3/44opt:, 3/4Opt. 7/8;Opt: '7/8 Opt. Suction Line Run ieer 3/4"Std 3/4*Std:, 3/4'-Std. 7/8'•Std: 7%8'Std. 11/e'Std. W Std; ,7/8 Opt7/8 Opt: _- '1'/:Opt.,. .... Opt. .99 .99 .98 .99 .99 .99 .99 • 25' Std. 1.00 1.00 1.00 1.00 1.00 1.00 1.00 Opt. WA WA 1.00 WA 1.00 - WA WA - _ Opt. .97 .96 .96 • .98 .97 .98 .97 50' Std. .99 .99 .98 ' , .99 .98 .99 .99 - - Opt. WA .99 .99 WA 1.00 WA , N/A Opt. .94 .92 .94 .95 .93 .95 .95 100' Std. .96 .96 .96 .96 .96 .98 .98 Opt. N/A .97 .97 WA .98 WA WA Opt.- .99 .89 .92 •93 .92 .93 .93 = ' 150' Std. .93 .93- .93 .94 .94 .96 .96 Opt. WA .95 .95 WA .96 WA WA NOTES. • *Standard line size • • Braze the tubing between the outdoor unit and indoor coil. Flow dry nitrogen into a service port and through the tubing while brazing. • After brazing - use an appropriate heatsink material to cool the joint and remove any flux residue. - - 6.7 LEAK TESTING • - Pressurize line set and coil through service fittings with dry nitrogen to 150 psig maximum. Leak test all joints using liquid detergent. If a leak is found, repair and repeat leak,test procedures. AWARNING 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. 7.0 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 line set and indoor coil' Air in the system causes high condensing,temperatures and pressure, resulting in increased power,input and non-verifiable performance. _ Moisture chemically reacts with the refrigerant and oil to form corrosive hydrofluoric and hydrochloric acids.These attack motor windings and parts,causing breakdown. After the system has been leak checked and proven sealed, connect the vacuum pump and evacuate system to 500 microns. The vacuum pump must be connected - to both the high and low sides of the system through adequate connections. Use - the largest size connections available since restrictive service connections may lead , to_false"readings because of pressure drop through the fittings.' • IMPORTANT: Compressors(especially scroll type)should never be used to evacu- ate'the air conditioning system because internal electrical arcing'may result in a , damaged or failed compressor. ' NOTE: Unit is shipped with a nitrogen holding chargé. Service valves must be , opened prior to evacuation to allow condensing unit to be evacuated along with the line set and indoor coil - 11 TABLE 3 LIQUID LINE SIZE-OUTDOOR UNIT ABOVE INDOOR COIL Liquid Line Size Outdoor Unit Above Indoor Coil System Line Size Line Size (Cooling Only-Does not apply to Heat Pumps) Capacity Connection Size (Inch O.D.) Total Equivalent Length-Feet (Inch I.D.) 25 50 75 100 125 150 Minimum Vertical Separation-Feet 1/4 0 0 0 18 31 44 11/2 Ton 3/8" 5/16 0 0 0 0 0 0 3/8* 0 0 0 - 0 0 0 1/4 0 5 - 27 48 69 91 2 Ton 3/8" 5/16 0 0 0 0 0 0 3/8* 0 0 0 0 0 0 1/4 0 34 69 N/A N/A N/A 21/2 Ton 3/8" 5/16 0 0 0 0 9 18 3/8* 0 0 0 0 0 0 3 Ton 3/8" 5/16 0 0 0 6 17 28 3/8* 0 0 0 0 0 0 31/2 Ton 3/8" 5/16 0 0 0 13 28 43 3/8* 0 0 0 0 0 0 4 Ton 3/8" 3/8* 0 0 0 0 0 0 1/2 0 0 0 0 0 0 5 Ton 3/8" 3/8* 0 0 0 0 0 9 1/2 0 0 0 0 0 0 NOTES: *Standard Line Size N/A-Application not recommended TABLE 4 LIQUID LINE SIZE-OUTDOOR UNIT BELOW INDOOR COIL Liquid Line Size Line Size Cooling Only With Outdoor Unit Below Indoor Coil System Line Size Connection Size Total Equivalent Length-Feet Capacity (Inch I.D.) (Inch OD) 25 50 75 100 125 150 Maximum Vertical Separation-Feet 1/4 21 8 N/A N/A N/A N/A 11/2 Ton 3/8" 5/16 25 27 24 21 17 14 3/8* 25 40 39 38 37 35 - 1/4 16 N/A N/A N/A N/A N/A 2 Ton 3/8" 5/16 25 26 21 15 10 5 3/8* 25 38 36 35 33 - 31 1/4 0 N/A N/A N/A N/A N/A 21/2 Ton 3/8" 5/16 25 17 8 0 N/A N/A 3/8* 25 37 - 34 31 29 26 3 Ton 3/8" 5/16 25 15 4 N/A N/A N/A 3/8* 25 30 26 23 19 16 31/2 Ton 3/8" 5/16 25 17 2 N/A N/A N/A 3/8* 25 37 32 28 23 18 4 Ton 3/8" 3/8* 25 33 27 21 15 9 1/2 25 43 42 40 39 38 5 Ton 3/8 3/8* 25 25 17 - 8 0 N/A 1/2 25 39 37 36 34 32 NOTES: *Standard Line Size N/A-Application not recommended 12 • The service valves are not backseating valves. To open the valves, remove the valve cap with an adjustable wrench Insert a 3/16" or 5/16"'hex wrench into the stem Back out counterclockwise until it stops. • Replace the valve cap finger tight then tighten an additional 1/8 of a turn for a metal-to-metal seal. 8.0 START UP AND PERFORMANCE After system evacuation, charge system with the amount of R-22 shown on the nameplate and in Table 1 on page 6 BEFORE the system is started for the first time The charge must then be checked to the charge table attached to the service panel and adjusted, if required. Allow a minimum of 5 minutes running Before ana- lyzing charge, see the instructions on the unit service panel rating plate for marking the total charge. • The senlice valves are not backseating valves. To open the valves, remove the valve cap with an adjustable wrench Insert a 3/16" or 5/16" hex wrench into the stem Back out counterclockwise until it stops • Replace the valve cap finger tight then tighten an additional 1/8 of a turn for a metal-to-metal seal. 9.0 CHECKING AIRFLOW The air distribution system has the greatest effect. The duct system is totally con- trolled 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, effi- ciency, 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, and causes 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 350 and 450 cubic feet of air per minute(CFM), or 400 CFM nominally. Duct design and construction should be carefully done.System performance can be - lowered dramatically-through bad planning or workmanship Air supply diffusers must be selected and located carefully.They must be sized and positioned to deliver treated air along the perimeter of the space. If they are too small for their intended airflow, they become noisy. If they are not located properly, they cause drafts Return air grilles must be properly sized to carry air back to the blower. If they are too small,they also cause noise The installers should balance the air distribution system to ensure proper quiet air- - flow 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 resi- dential or,light commercial system Electric resistance heaters can use - - CFM= volts x amps x 3.414 0 1.08 x temp rise Gas furnaces can use BTUH CFM OT x 1.08 An air velocity meter or airflow hood can give a more accurate reading of the sys- tem CFM. 10.0 CHECKING REFRIGERANT CHARGE Charge for all systems should be checked against the Charging Chart inside the • access panel cover. 13 10.1 CHARGING BY LIQUID PRESSURE The liquid pressure method is used for charging systems in the cooling mode. The service port on the liquid (small valve)and suction (large valve) is used for this pur- pose. Verify that the outdoor unit is running and the indoor air mover is delivering the cor- rect airflow for this system size Read and record the liquid pressures at the ports on the liquid and suction valves. If refrigerant lines are 15 feet long, the correct liquid pressure is found at the inter- section of the suction pressure and the outdoor ambient. 1. Remove refrigerant charge if the liquid pressure is above the chart value. 2 Add refrigerant charge if the liquid pressure is below the chart value If the refrigerant lines utilized extend 15 feet, add 4 psi to the liquid pressure values shown in the chart. 1. Remove refrigerant charge if the liquid pressure is above the chart value. 2. Add refrigerant charge if the liquid pressure is below the chart value 10.2 CHARGING BY WEIGHT Evacuate the entire system. Be sure to open both service valves prior to evauca- tion. Use the factory charge shown in Table 1 of these instructions or unit data plate. Note that charge value includes charge required for 15 ft. of standard size interconnecting liquid line. Calculate actual charge required with installed liquid line size and length using 1/4"O.D.=.3 oz./ft. 5/16" 0 D. =.4 oz./ft. 3/8"O.D = hoz/ft 1/2"0.D =1 2 oz./ft. With an accurate scale(+/—1 oz.)or volumetric charging device, adjust charge dif- ference 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 calculat- ed charge. - 10.3 FINAL LEAK TESTING After the unit has been properly evacuated and charged, a halogen leak detector should be used to detect leaks in the system. All piping within the condensing unit, evaporator, and interconnecting tubing should be checked for leaks. If a leak is detected, the refrigerant should be recovered before repairing the leak. The Clean Air Act prohibits venting refrigerant into the atmosphere. AWARNING 11 .0 ELECTRICAL WIRING . TURN OFF ELECTRIC POWER AT Field wiring must comply with the National Electric Code (C.E C. in Canada) and THE FUSE BOX OR SERVICE any applicable local code. PANEL BEFORE MAKING ANY ELECTRICAL CONNECTIONS. 11.1 GROUNDING ALSO, THE GROUND CONNEC- A grounding lug is provided near the contactor for a ground wire. TION MUST BE COMPLETED BEFORE MAKING LINE VOLTAGE A WARNING - CONNECTIONS. FAILURE TO DO SO CAN RESULT IN ELECTRICAL THE UNIT MUST BE PERMANENTLY GROUNDED. FAILURE TO DO SO SHOCK, SEVERE PERSONAL CAN CAUSE ELECTRICAL SHOCK RESULTING IN SEVERE PERSONAL INJURY OR DEATH. INJURY OR DEATH. 11.2 POWER WIRING It is important that proper electrical power from a commercial utility is available at the condensing unit contactor. Voltage ranges for operation are shown in Table 5. Power wiring must be run in a rain-tight conduit. Conduit must be run through the connector panel below the access cover(See Figure 1) and attached to the bottom of the control box Connect power wiring to contactor located in outdoor condensing unit electrical box. (See wiring diagram attached to unit access panel.) 14 Check all electrical connections, including factory wiring within the'unit and make sure all connections are tight. _ . • DO NOT connect aluminum field wire to the contactor terminals • - - - ' TABLE 5 ' - ' . VOLTAGE RANGES(60 HZ) - Operating Voltage Range at Copeland Nameplate Voltage , ' - Maximum Load Design Conditions for - - Compressors - ' - - 208/230(1 Phase)' -, ' 197-253 - -- 208/230(3-Phase) - - - 187-253 - - 460(3-Phase - - - - - ` '" 414-506 11.3 CONTROL WIRING „ ' (See Figure 3) >.- , . - - - If the low voltage control wiringis run in conduit with the power supply, Class I Insu- - lation is required Class II insulation•is,required if run separate. Low voltage wiring, - may be run through the insulated bushing provided'in the 7/8 hole in the base • panel, up to and attached-to the pigtails from the bottom of the control box. Conduit .' - can be run to the base panel if desired by removing the insulated bushing , - A thermostat and a 24 volt, 40 VA minimum transformer are required for the control ' • ' • ' circuit of the condensing unit.;The furnace or the air handler transformer may be• , ' • used_ if sufficient; See the'wiring diagram for reference. Use 18-gauge thermostat • • - wire only - . _ . , j . TABLE 6 . _ - • • MAXIMUM SYSTEM CHARGE VALUES • - ' ' ' Model Compressor Compressor Model - Charge Limit Without '` - Size ' Manufacturer ' Number Crankcase Heat* - ' 18_ ` ' Bristol - H21J14BABCA _ '7,lbs _ - _ ', - 18, - Copeland ZR16KA/K5-PFV, , 24 • Bristol ' H21J19BABCA' • • ' 7lbs • _ .• ` • . 24 Copeland ZR21 KA/K5-PFV 30 Bristol H21J24BABCA 7 Ib s 30 Copeland ZR26KA/K5-PFV ' ' " - ' 36 ,, Bri'stol' , ' H21J30BABCA , - --` 9lbs. - - 36 Copeland - - - ZR32KA/K5-PFV -' 36 - Copeland • . ZR32K5-TF5-622 _ • 9 lbs 36 Copeland 'ZR32K5-TFD-622 , ' , 9 lbs 42 Copeland 'ZR38K5-TF5-622 .'_ • 8lbs _ - - 42 , - Copeland_ • ., _ZR38K5-TFD-622 - , 8 lbs - 42 Danfoss HRM038U1 LP6 8 lbs - • . . - 42 Copeland ZR38KA/K5-PFV - ' - ' 48 - , Danfoss , HRM042U1LP6 - 8lbs ' - 48 Copeland ZR42KA/K5-PFV - - . _ ' . 48 ' Copeland • . ZR42K5-TF5-622 ' 8 lbs - ' 48 Copeland .ZR42K5-TFD-622 8,Ibs - • • = ' ' . - - - • • 60 Danfoss - HRM054U1 LP6. 12 lbs' • - ' - . 60 Copeland ZR54KA/K5-PFV , - - - 60 - Copeland - , ZR54K5-TF5-622 - 12 lbs 60 Copeland -ZR54K5-TFD-622 - , ' .12 lbs - ' - _ *All other models come with the crankcase heater-factory-installed. ' , 12.0 FIELD INSTALLED ACCESSORIES ` ' . - - ' 12.1 COMPRESSOR CRANKCASE HEAT(CCH) ' - While scroll compressors usually•do not require'crankcase heaters, there are instances when a heater should be added Refrigerant migration during the off cycle' - can result in a noisy start up. Add-a crankcase heater to minimize refrigerate migra- . - tion,and to help eliminate any start up noise or bearing''wash out" ' NOTE:The installation of a crankcase heater is recorrimended&if the system"charge- ' exceeds the values listed in Table 6. - -' , - ' - " ' 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. , • . - 15 FIGURE 3 ' CONTROL WIRING FOR GAS OR ELECTRIC HEAT TYPICALTHERMOSTAT TYPICALTHFANOSTAT ' ' 'FOR TYPICAL GAS OR OIL HEAT SUBBASE'' FOR TYPICAL ELECTRIC HEAT SUBBASE ' 19 n © G1 (1) i SOH 7 , : ' BR=BROWN WIRE YL-YELLOW WIRE , X-WIRE CONNECTION L BR•BROWN WIRE -R•BEDTIME - YL-YELLOW WIRE WOK-WHITE WIRE WITH BLACK STRIPE _ GIBK-GREEN WIRE WITH BLACK STRIPE , ' •PU-PURPLE WIRE(NOT USED) 'TYPICAL ELECTRIC HEAT ' TYPICAL OAS OR '%'WIRE CONNECTION LOW VOLTAGE JUNCTION BOX , OIL FURNACE , X a. fl X, wn3K , TYPICAL CONDENSING 0 - TYPICAL CONDENSING• X GIBK, + WRY.' 0 UNIT , X YL ^ —YL . . 0 . YL X ' ep; BR X X BR. PO At initial start-up or after extended shutdown periods, make sure-the heater is ener- gized for at least 12 hours before-the compressor is started '(Disconnect=switch on 'and wall thermostat off.) . 12.2 TIME DELAY'CONTROL-(TDC) - . The.time-delay (TDC) is in the low voltage control circuit. When the compressor . shuts off due to a power failure or thermostat operation, this control keeps it off at least 5 minutes which allows the system pressure to equalize, thus not damaging -- - the compressor or blowing fuses on start-up - - ' ' 12.3 LOW AMBIENT CONTROL'(LAC) -- This component senses compressor head pressure and shuts the,condenser fan off . , when the head pressure drops to approximately 150 PSIG. This allows the unit to -- build a sufficient head pressure at lower ambient in order to maintain system bal- , • - ance and obtain improved capacity Low ambient control should be used-on all - equipment operated below 70°F ambient ' - " _ 12.4 HIGH AND LOW PRESSURE CONTROLS (HPC OR LPC)- . - , , 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 cir- - cult.' ' - ' - _ - High pressure control (HPC)is a manual ieset which_opens near 450 PSIG. . - The low pressure control-(LPC) is an automatic• reset which opens near 15 PSIG - ' - and closes near 40 PSIG. - ' 13.0 SERVICE. 13.1 OPERATION _ -- - - ' - - , - 'Single phase units are operated_PSC (no starting components). It is important that - - . such systems be off for a minimum of 5 minutes before restarting to allow equalize- - ' ' - ' ' - ' - -tion of pressure.The thermostat should not be moved-to cycle unit without.waiting 5 - - -'„ ' minutes -To do so may cause the compressor to go off on an automatic overload - - device br blow a fuse. Poor electrical service can also cause'nuisance tripping on ' - , - - -overloads, trip a breaker, or cause light dimming This generally can be corrected- ' _ , ' - - by adding start components. Check with factory-for recommended start compo- nents, if required . , , - , , 13-.2 SINGLE-POLE COMPRESSOR CONTACTOR (CC) ' , - - ' • Single-pole contactors are used on all standard single phase units up through 5 tons. Caution must be exercised when servicing as only one leg of the power sup- , - - " 16, _ , 14.0 TROUBLE SHOOTING - In diagnosing common faults in the,air conditioning system, it is useful to present the logical pattern of thought that is used by experienced technicians. The charts • _which follow-are'not intended to be an answer-to.all problems, but only to,guide ' your thinking as-you attempt to,decide on your course of action Through a series of yes and no answers, you will follow the logical path to a likely conclusion. - Use these charts as you would a road map, if you are a beginning technician As you gain,experience, you,will learn where to'establish the,shortcuts. Remember that the chart will help clarify the logical path to the problem.'' . '14.1 ELECTRICAL CHECKS FLOW CHART- - ' ' Unit Running? . . i NO _ :YES' , " - - . - •- 'Thermostat Problem? _ - = ' Go to . - - - Mechanical Checks ' YES " NO - • Repair and Recheck-• ' , - ` - • t - ' • - Transformer Problem? - I YES , - ' ' - NO ' - ' 'Repair and Recheck ' .. " - • . . , - , Voltage on Compressor - - , • - - - - Side of Contactor? - YES - NO Run,Capacitor ,Voltage on Line- . ' - I - Side of Contactor? , - • Start Capacitor I . - I , t NO YES Potential Relay - ' _ , ' Circuit Breakers Compressor Contactor or Fuses Open - Compressor Internal - - I - . Overload Open , - - , ' YES - Hi Pressure Control" ' Compressor Winding Open - Compressor Winding Lo Pressure Control . Unit Wiring and Grounded ' Connections - , , I Compressor Time-Delay - ' - Condenser Fan' - - I - Grounded - - - ' - Unit Wiring and Connections Grounded Capacitor - ' -Replace Fuses - - ' - ' or Reset Breakers and Recheck - 17 14.2 MECHANICAL CHECKS FLOWCHART - Unit Running? YES NO Pressure problems? Go to Electrical Checks Flow Chart High Head Pressure Low Head Pressure Low Suction Pressure Dirty Condenser Coil Low on Charge Dirty Filters Inoperative Outdoor Fan - Open IPR Valve , Dirty Evaporator Overcharge Low Ambient Temperature Inadequate Airflow Recirculation of Inoperative Compressor - Broken Indoor " Condenser Air - Valves . Blower Belt Non-condensibles Restricted Filter-drier Inoperative Indoor Blower Higher than Ambient Restriction in System Low on Charge Air Entering Condenser - S Wrong Condenser Fan Rotation Indoor Metering - Faulty Metering Device ' Device Stuck Closed Indoor Metering Device - Restriction in System Stuck Open - Restricted Filter-drier Recirculation of Evaporator Air Wrong Evaporator - Blower Rotation Inadequate Ducts • 18 - - TABLE 7 14.3 SUPERHEAT CALCULATION - - TEMPERATURE PRESSURE CHART 1 Measure the suction pressure at the suction line service valve ` - .'"TEMP ' R=22'-"=22' 2, Convert the suction pressure to saturated temperature. See Table 7. (Deg.F), PSIG; _ 150 *29.4 3. Measure the temperature of the suction line at the suction line service valve. 140'`;` 'L *29.1P:A 4. Compare the temperature of the suction line to the saturated temperature. _ -130 *28.5 5. The difference between saturated temperature and suctln line temperature is the ' --120- `*27:7 ' superheat.Superheat normal range 12°to 15°. M 11026.6 14.4 SUBCOOLING CALCULATION -100 *25:1, - 90 '23.0 1. Measure the liquid pressure at the liquid line service valve. , 780. - '*202 2. Convert the liquid line pressure,to saturated temperature. See Table 7. -70 16.6 3. Measure the liquid line temperature at the liquid line service valve. i -760-:.', - -_-*-11:9 4 Compare the liquid line temperature to the saturated temperature. X50 *6.11 5. The difference between saturated temperature and liquid line temperature is the ti =40: '' , - 'O.fi' subcooling. Subcooling normal range 9°to 12°. -35 2.6 - ' -3Q:j.^ -4:9 TABLE 8 -25 . 7.5 AIR CONDITIONING SYSTEM TROUBLESHOOTING TIPS _._. - 0-., , ^ i 10.2; .. .. : . ... . .. , . - AIR'CONDITIONING_SYSTEM` . -15 J 6 13 2 T__R_OUBLESHOOTING-TIPS', . -10;"._ 16:5. - - - _INDI_CATORS_� -_•_ - -5 20 1 SYSTEM PROBLEM DISCHARGE `SUCTION. 'COMPRESSOR, -• - SUPERHEAT SUBCOOLING: _ --0, -; ' 24:0 - _, • _ 2 PRESSURE PRESSURE, ._ , _, _- ,, AMPS: 5 _ 28 3_ Overcharge High High Low High High Undercharge Low Low High Low Low ~32`8 _ Liquid Restnction(Drier) Low Low High High Low _` M 15 37.8__ Low Evaporator Airflow Low . Low Low Low -Low �20 _ - 43.1 , - Dirty Condenser High High Low - Low High 25 48.8 Low Outside Ambient Temperature Low• Low High High Low 30 A ' -54.9 - Inefficient Compressor Low High High High -Low _ _35 61.5 TXV Feeler Bulb Charge Lost Low Low High High Low 40,- ; - 68.5 Poorly Insulated Sensing Bulb High High Low - Low. - High 45 76.1 - '50 -` 84.1' 55 92.6 - X60. 1016 , , 65 '111.3 " - - 70-,i - 121.4' 75 �__...�132_2-~- .,ar.i _ `80; ' �'- 143.7 , 85155.7 _..w 90,----- -- 16_4_ 95 ;181.8 - . 100•- - 196.0: 105210.8 - - !'110-_ , -:226.44.^' 115242:8 120-'---' _ •• -260.0' 125' - - 278.1 130' 297!0~• . 135 : 316.7 LL 140<.: ', ,.: 337.4' - 145 359.1 ` _ ` _150,- - 381:7' , 19 14.5 GENERAL TROUBLE SHOOTING CHART AWARNING 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 off or loose electrical connection • Check for correct voltage at contactor in condensing unit •Thermostat out of calibration-set too high • Reset • Defective contactor • Check for 24 volts at contactor coil-replace if contacts are open • • Blown fuses/tripped breaker • Replace fuses/reset breaker - •Transformer defective • Check wiring-replace transformer • High pressure control open(if provided) • Reset-also see high head pressure remedy-The high pressure control opens at 450 PSIG Outdoor fan runs,compressor • Run or start capacitor defective • Replace doesn't •Start relay defective • Replace • Loose connection - • Check for correct voltage at compressor • - check&tighten all connections •Compressor stuck,grounded or open motor winding, • Wait at least 2 hours for overload to reset open internal overload. " If still open,replace the compressor. • Low voltage condition - • Add start kit components Insufficient cooling • Improperly sized unit • Recalculate load • Improper indoor airflow • Check-should be approximately 400 CFM per ton • Incorrect refrigerant charge Charge per procedure attached to unit service panel •Air,non-condensibles or moisture in system • Recover refrigerant,evacuate&recharge,add filter drier Compressor short cycles • Incorrect voltage • At compressor terminals,voltage must be±10%of nameplate marking when unit is operating • Defective overload protector • Replace-check for correct voltage • Refrigerant undercharge • Add refrigerant Registers sweat • Low indoor airflow • Increase speed of blower or reduce restriction-replace air filter High head-low vapor pressures • Restriction in liquid line,expansion device or filter drier • Remove or replace defective component - • Flowcheck piston size too small • Change to correct size piston • Incorrect capillary tubes - • Change coil assembly High head-high or normal vapor • Dirty outdoor coil • Clean coil pressure-Cooling mode • Refrigerant overcharge • Correct system charge •Outdoor fan not running • Repair or replace •Air or non-condensibles in system - • Recover refrigerant,evacuate&recharge Low head-high vapor pressures • Flowcheck piston size too large • Change to correct size piston • Defective Compressor valves • Replace compressor • Incorrect capillary tubes • Replace coil assembly Low vapor-cool compressor- • Low indoor airflow • Increase speed of blower or reduce restriction-replace air iced indoor coil filter •Operating below 65°F outdoors • Add Low Ambient Kit • Moisture in system _ • Recover refrigerant-evacuate&recharge-add filter drier High vapor pressure • Excessive load • Recheck load calculation •Defective compressor • Replace Fluctuating head&vapor •TXV hunting • Check TXV bulb clamp-check air distribution on coil-replace pressures- TXV • Air or non-condensibles in system • Recover refrigerant,evacuate&recharge Gurgle or pulsing noise at • Air or non-condensibles in system • Recover refrigerant,evacuate&recharge expansion device or liquid line 20 1-5.0 WIRING DIAGRAMS- FIGURE'4 - ; SINGLE-PHASE WIRING DIAGRAM ' '- - WIRING DIAGRAM - WIRING SCHEMATIC, ELECTRICAL BOX(LEFT SIDE/ c ELECOMPONENCTRITSCAL OUTSBOXIDE ` ELECTRICAL BOX RIGHT SIDE) I© - I CHC CCH IS /47 ^ _ - ih,11_111 CC OND ,Iiiie), Irlirli).- © lag SC MBEwrs J COMP 1 ^ ,R2Y—--' CWP BOX © , TOC.RI--BR" BK (OPT) Y2-Y� BK - VI -BR _ � ,I RBK-_ 0 �� —... . -II - RC -I ,R �� I BK—x4 ONO ` ,;. ,_O _ .•• BOR I , _ , - - - ` . •I I PR-12 11 • _ , SR I' L: T3 i '-_- -- _ �BK-• 5 IOPTI - ` - _ CC COIL O © I I - : :'c+ PR I • , - - O .ul 1 - .- , , • . " I•'' I I HPC . , R -- CCH •' GNO. 1 I I WIRE NUT i-A(DPT)I ' 1. �.. SL - - _ - - . (L_—_ .BK —= Corr Box�_ �i ISI d ❑ .HGS 7r',-BK — Mal `I• /OPT) _ - ( -; - _ I LPC•: , • - 1 Y _ �OELECTRICAL BOX D� L I I I , COMPONENT CODE NOTES:, " , , - - _ L CONNECTORS SUITABLE FOR USE WITH COPPER CONDUCTORS ONLY. - ' V - CC COMPRESSOR CONTACTOR • - 2 MOTOR COMPRESSOR THERMALLY.PROTECTED AW ALL 3 PHASE ARE - - - CCH CRANKCASE HEATER PROTECTED UNDER PRIMARY SINGE PHASE CONIITIONS. _ CHC CRANKCASE HEATER CONTROL • 3 CONNECT FIELD WIRING IN GROUNDED RAINTIGHT CONDUIT TO'EB ' ' COMP,COMPRESSOR HERTZ'DISCONNECT.VOLTAGE AND, PHASE PER RATING PLATE - ' - -GNO GROUND,CHASSIS USE�'C WIRE. _ ` - HPC- HIGH PRESSURE CUT-OUT CONTROL 4•LOW VOLTAGE CIRCUIT 40 BE N.E.C.CLASS 2 WITH A CLASS 2 ' LAC LOW AMBIENT COOLING CONTROL .TRANSFORMER 24 VOLT,fiB HERTZ. ' _ V - - LPC- LOW PRESSURE,CUT-OUT CONTROL - ' OFM OUTDOOR FAN MOTOR- 5.TO THERMOSTAT SUB-BASE,REFER TO SYSTEM SCIEMATICS OR ^ - „ - OPT OPTIONAL' SCHEMATICS ON INDOOR SECTION FOR LOW. VOLTAGE CONTROL WIRING., RC- RUN CAPACITOR - - - - ' ` - SC START CAPACITOR - - SR START RELAY - - ' ` - - TDC TIME OELAY CONTROL - , ' _ - HGS `HOT.GAS SENSOR ' PTCR POSITIVE TEMPERATURE COEFFICIENT RELAY - WIRING,INFORMATION _-: WIRE-COLOR CODE • ,• LINE`VOLTAGE " BK_ BLACK D___ORANGE , - -FACTORY STANDARD BR__BROWN __ ' ' • _ - -FACTORY OPTION - --- BL__BLUE V R__ RED - ' - _ -FIELD INSTALLED G___GREEN W___WHITE ' . - -LOW-VOLTAGE. GY• __GRAY_ _ _ Y___YELLOW _ - '-FACTORY•STANDARD - - --FACTORY OPTION ----- - ' • - • - ' '-FIELD INSTALLED - , - , - - - _ - REPLACEMENT WIRE - .•WIRING` DIAGRAM ` -MUST BE THE SAME SIZE AND TYPE OF - V. ' INSULATION AS ORIGINAL(105 C MIN.) . ' ' REMOTE AIR CONDITIONER WARNING ' ^ _ -CABINET MUST BE PERMANENTLY ' 208/230 VOLT.,SINGLE PHASE •• - - GROUNDED AND CONFORM TO LE.C.,N.E.C., V ' - ' C.E.C.AND LOCAL CODES AS APPLICABLE. - -- OR.BY JHB APP.BY 00"6 DWG.NO.90-101229-01 REV 01• 21 - FIGURE 5 - " THREE-PHASE WIRING DIAGRAM -- - WIRING DIAGRAM WIRING SCHEMATIC , - I'© I AUG I GIY I I ISN--34Jr N ,__)� m _ 0.`s{J L (7I7 / /./ GND CC GNO CC CCH4.---.—.---°BK---.—...-----1 TI GPT - - - -— ���11�p- OPT "J 0 - T1 0 6A." I • slm ®A clnt — rela Rct— �-. `,. l ml CORP• • 5(n) — PR F. •• RCT3) R(nl (R) • ��'F 1 BK TOC R!• Po• p n(OPT ,I , Y _ _ _Y—_ BK - - LAC BR LRCI • (OPT) + LRLI.1r ILIEI Y f—--7 — BK—- Urn -LAA Y - ® Y -I I - Y . • (OPT) . . Y- „1 I 01111170 •� , j BK I TDC (OPT) i� ks • BK BK TB(OPT) I HPC . .HOS LPC• ®& Om - BR , I I . COMPONENT CODE- NOTES: - CC COMPRESSOR CONTACTOR I.CONNECTORS SUITABLE FOR USE WITH COPPER CONDUCTORS ONLY. ' ' CCH CRANKCASE HEATER , 2.COMPRESSOR MOTOR THERMALLY PROTECTED AND ALL 3 PHASE ARE COMP COMPRESSOR , PROTECTED UNDER PRIMARY SINGLE PHASE CONDITIONS. , GNO GROUND.CHASSIS - HGS HOT GAS SENSOR 3.CONNECT FIELD WIRING IN GROUNDED RAINTIGHT CONDUIT TO _ HPC HIGH PRES.CUT-OUT CONTROL LAC LOW AMBIENT COOLING CONTROL FUSED DISCONNECT,VOLTAGE.HERTZ AND PHASE PER RATING- LPC LOW PRESSURE CONTROL - PLATE. ' OFM OUTDOOR FAN MOTOR , 4.LOW VOLTAGE CIRCUIT TO BE N.!C.CLASS 2 WITH A CLASS 2 ' - OPT OPTIONAL TRANSFORMER 24 VOLT.50 OR 60 HERTZ. - RC RUN CAPACITOR ' --MEG - RESISTOR 5.TO THERMOSTAT SUB-BASE,REFER-TO SYSTEM SCHEMATICS OR . - SC START CAPACITORSR START RELAY SCHEMATICS ON INDOOR SECTION FOR LOW VOLTAGE-CONTROL WIRING. ' TB TERMINAL BLOCK. - TOC TIME DELAY CONTROL - WIRING INFORMATION WIRE-COLOR CODE - LINE VOLTAGE - BK_ BLACK O___ORANGE . -FACTORY STANDARD • BR_ BROWN PR_PURPLE - - - ' -FACTORY OPTION —-—- BL__BLUE R___REO ' '-FIELD INSTALLED — — — — G___GREEN W___WHITE LOW VOLTAGE GY__GRAY - Y___YELLOW , -FACTORY STANDARD - . -FACTORY OPTION —-—- - ` •-FIELD INSTALLED — — — — - • REPLACEMENT WIRE ELECTRICAL WIRING DIAGRAM - . • • -MUST BE THE SAME SIZE AND TYPE OF ' INSULATION AS ORIGINAL 1105 C MIN.1 - „ WARNING - REMOTE',AIR CONDITIONER ' _ -GROUNDED AND CONFORM TO LE.C.,N.E.C., - '- ` - C.E.C.AND LOCAL CODES AS APPLICABLE. • OR.BY APP.BY DATE DWG.NO. REV , JHB 6-01-07 90-101229-11 05 - 22 - - " It 1I U . w. 40as cl C ?/L iSP • ke-fr- * - jt "," I l'1S-121- :' ' r c 4.,,,,,,,:),‘ .-- - ,.. ,,,,„ Q `P( ri,1 "$ o I - (-rip-- ._1. --,-• ' 1 tt-,i-pv.I4-%44. rwanz 74 I 1,f,-,P 6- -=1 ,,.;,:-.?:;'-_ -j4;sZ s J I ,I Oma �yd�R �. j rA# > .� I .2 PISTE . fm i 1-• (<_,,41_1,y__Li."44.4.0,k % di . tit'l ceigaieleg- "ili • sf,a CL ` Lr . t( -k- -' - _ a= vy..!ott,T5 ` 1.2 I ai 3IAJ ,` --4 i § : -'�` t N I � _ 4Yi' II9 ' dig �'aIPI4 �T " LL ili -(43.7t p II p S. if ,r'. -,0,4 6p40,044.er 1 - I =F' roc- 1-1 S4 ' l L- AL — fir; rl, - N \ r ,. ; . . 040:c0. ... * r72 ri) >4 11-----c . . 4179414; qvAr-e• r _1- _L. 14-. .--- 1---.' - 1 - - -to woollriz-14 A ' a R ult:4146,-11,44041, lu ag ,, oscarops —? , .-1 4 J613 -14-P 4401.0.9,4j_44;4. 1 yO ` \ b b I L'7 a� P t 1 ,iaM_ ! 60 I - I I•I .Aki• Q PL%1 STH i g . $1-4 gOE . 1124.-icri-leAL, Ell 4 . rI-s- r1 �--tom, iz, _ei ,.. i4W uIFIA 1; E Ic ,FIPIt oIA I �k--- z x: 1�'-3" - w is, U so fl EXISTING CELLAR g/fi� Pr4 04 __11_4'____1=---1'-10"_- _ Cr, so g _ --_- STEPH MO ARCHITECT DATE ENERGY CODE COMPLIANCE: PER NYC ENERGY CONSERVATION CONSTRUCTION CODE (NYCECCC) 2014 `� PROFESSIONAL STATEMENT PER NYCECC 101.5 31. TO THE BEST OF MY KNOWLEDGE BELIEF AND PROFESSIONAL JUDGEMENT, THIS APPLICATION,'DRAWINGS AND SPECIFICATIONS ARE IN COMPLIANCE WITH THE CURRENT 2014, NYC ENERGY CONSERVATION CODE. . • • 1 PFG= Commercial Boiler Weil-McLain - '., Gas (4P ; G MBH:305-427 Combustion Eff.:81% Net Load Range Hot Water COMMERCIAL GAS BOILER 215,000 to 301,000 BTU/Hr. ® COMPACT DESIGN AND HIGH EFFICIENCY , ® EASY TO INSTALL AND SERVICE OO MADE WITH WEIL-McLAIN QUALITY r a t APPLICATIONS INCLUDEr4.„ Large Residential Homes Apartment Buildings Commercial Buildings ••--,r ( i Institutional Buildings �E��MOH , Multiple Boilers 4 _, Indirect-fired Water Heating —And Much More t ,,, .4,..'^-71 :..,'',', r?' ' 1!," " It or,, F t!' \ 1. trii h I- ,,w$; - y a► , l lit 1 WEll mc LAIN www.weil-mclain.com otsia*ink, MADE IN THE `� .Ratin s oW I DOEFA- Ho .*, 9 .Ai:m CERTIFIED_• � tel I Model I C.SAInput I 'C.SA I Nett=B=R I I=B=R I Approx Add"SPN"forstammngpilotor"PIN"iorintermittent Ignition. (MBH)' 'Gross Water Rating Chimney Shipping , Output (MBH)** Size Weight(Lbs) NetAHRlratingsabsionnetiflstalIcadiatIOfl of sufficient (MBH) quantity for the requirements of the building and nothing need be added lot normal piping"and pickup.Ratings am based Ona piping and pickup PFG-6- I 305 I 247 I 215 18" I.D.X 20' I 575 allawanceof115.Anadditional allowance stmuldbenide forunusual ' PFG-7-A I 366 I 296 I 257 I '9"1D.X'20' I 635 piping'andpicoulbads:Ratiingsshowriare for elerraticnsupto2,000 feel For elevationsabove 2,000 feet,ratings should be reduced at the PFG-8R• I 400 I 324 1 282 I 9"I.D.x 20' 1 695 rate of4itfor eadhlpoofeet above seelevel. 131FG-8=PIN I 427 I 346 I 301 1 9"1. —Redticed Input: [).X20' I 695 iuorE:Boilers testedfor50P.S1working pressure;C.SAdesign certified for installation on non-combustible flooring only Dimensions I Dimensions In inches I-Number&Size I I Outside Dimension of Crate I .Model I A I B I 0 I W I Model I Flows I Returns I Gas Connection I Draft Hood I Length I Width I'Height PFG-6- 1171/q ,l 27 1/16" I 8 I 2011/15" Size Natural Outlet PFG-7-A 1191/2 I 30 3/a, I 9 23 11/18" &Propane PFG=8R+ I 25 I 357/8 I g 1 26.11/1x° PFG-6- 1-2" 11-2" I 3%q' i 8" 138 3 /g 25" 1331 J2" PFG-7-.A 11-2"• 1 172" I 3/4' I .9° I, 383/8 131" I'331 /2' PFG- 8 I 25 1357/8 1 9 1 2611/16" PFG-8F1A 11-2" 11-2" I 1" I 9" 1 383/8 31" 1331/2' PFG-8-PIN 11-2" I 1-2" I 1" I '9" 138 3/g'I 31" I'331/2,' r-D ,D' . •MANUAL MAIN SHUT-OFF GJASI 8 •TAPPING FOR ME `/ EXPANSION TANK A y'c, iF-•2"SUPPLY i� I - 4 NPT __ (LEFT END ri SECOON ONLYPLUGGED) 1 � i 4 ,l GAS u '+sow SUPPLY 2TSSd tI.4ki tD Nn2'RETURN DRIP aLEG 'o, �� lots er V S i+- 34SY -i' W GROUND 3114e LEFT END VIEW FRONT VIEW t JOINT UNION RIGHT END VIEW Standarand Additional Equipment Standard Equipment: Additional Equipment: , Factory Tested Aluminized Steel Burners Intermittent Electronic Ignition Insulated Extended Jacket Combination Relay Receptacle and Pilot System for PFG-6 and 7 Built-in Air Separator 40 VA Transformer (standard for PFG-B Only) Vertical Draft Hood(packed separately) Electronic Junction Box Automatic Vent Damper for Radiation Plates Plug=in Circulator Relay - PFG;6 thru 8 . Corimbination-Gas Valve for 24 Volt r R_olloutlhern al Fuse Element - - - Gas Conversion Kits,- - Constant Burning,Thermally Supervised (PFG-5 only) , Pilot System and Thermocouple High-limit Temperature Control=. ,- , , (PFG-6 and 7 only) 30 PSI ASME Relief Valve(Boiler- - _ -- ° Intermittent Electronic Ignition System' sections tested for50 PSI working (PF ___ - . ..- G 8 Only) Pressure)Packed Separately , . , - ' • .- (' v Non-Linting Pilot Burner Combination Pressure=Temperature -- - ., Gauge(packed separately) - ' ^5• -;:(.;:f.,;,°,' • -__- I - `'' .sa: Drain'Valve Packed Searatel '--'''''''..:';$-:�� �WEIL■miLJN_ `" I •i -,. A �a 1 hz,,ryi-,,':,i4',1. .''r `4, .,'` °',..-,---°-, ,i,.,..,-% .. ,'''--:-.,,,7-?--- '. .,3 'r .....i-et.6: ' Intheinterest"ofcontin'Ualimp'�aiemeMsfnp+ralucfaitd'performance;IhleilMcLaini2servestherighttorciiangespecificationsvudfiou(roti e_ _ t.:*�-'.' , _ i,. •C-513(0812)8 t « ; 0.,q.. °; '-;. • `I ''; c'i,, i rm °„t r } :' off. b, ..- LI", ""%a-,Z. ,14,741:_."-.4.:' _. ' l ri;„", a' _. 7,.� 4 . ti' r. ' • I .b�'. 'J ' 1{ .s r b{ -t.+'�t' a+ is j '�='.: IJ'i� a IIC' 'ti(`�z' i'1.'11';N d _7i. ' n 7� .'i�,.. � 1 • �d.._. ., ,,,_ ,,..K.,_ ...v.__; Gas-fired WEIL•mI LAIN11:10 FG water boiler MODEL PFG Series 7 Control Supplement Universal Control Systems (UCS) To complete boiler installation, e�,-� .'"'.`�"•� follow: _ = •General Information 2 (0, 1 `. • ▪ ; i • Boiler Wiring 3-5 ¢i ag •Vent Damper Installation 6 • • Check-out Procedure 7 ▪1110,44 • Operating Instructions 8-10 F 'r > -,; k For additional help, see: E] _ •Troubleshooting - 11-15 • 14( I` a. • Parts List 16 SR C[NTIFI[O DESIGN .0 Controls must only be installed by and Control Supplement used by a qualified installer/service technician. Read all instructions before installing.Failure to follow-all instructions in proper order can cause severe personal injury,death crAvrm0 or substantial property damage. Part No.550-110-643/0605 A s PFG SERIES 7 GAS-FIRED WATER BOILER — UNIVERSAL CONTROL SYSTEMS GENERAL INFORMATION: This system is used on natural gas-fired boilers with or without dampers as shipped from the factory. WARNING This system is not offered for retrofit, -or conversion-from standing pilot systems.Any attempt to apply the system components to boilers shipped for use with a different control system will not be covered under boiler warranty and can cause severe personal injury,death or substantial property damage. IMPORTANT: When calling or writing about the boiler,, PLEASE GIVE THE MODEL listed on the boiler rating label AND THE CP NUMBER found next to the rating label. The following defined terms are used throughout this manual. They bring attention to the presence of hazards of various risk levels, or to important information concerning the life of the product. - - DANGER indicates presence of hazard which will cause severe personal,injury, death or substantial property damage if ignored. WARNING indicates presence of hazard which can cause severe personal injury, death or substantial property damage if ignored. CAUTION indicates presence-of hazard which will or can cause minor personal injury or property damage if ignored. NOTICE indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards. • 2 - - Part Number 550-110-643/0605 PFG SERIES 7 GAS-FIRED WATER BOILER— UNIVERSAL CONTROL SYSTEMS MIMI Section A: Installation 1. Bring supply wiring to boiler.Must be 14 ga.or heavier.See pages listed below each Figure for appropriate wiring diagram. 2. Proceed to page 6. DAMPER DAMPER 1' —DRAFT HOOD (OPTIONAL) "W DRAFT HOOD i = . SPILL SWITCH DAMPER DAMPER— �(PFG-5 ONLY) HARNESS HARNESS N @ - �DAMPER HARNESS v DAMPER HARNESS DAMPER HARNESS z i, RECEPTACLE DAMPER HARNESS- PLUG - `, i PLUG l • LIMIT ` ■ ,i ■ .r` Th N I f IGNITION _ -iul IGNITION WIRING �11 v CONTROL �,t 4��� LIMIT 1� n CONTROL HARNESS � WIRING �r HARNESS OC )TRANSFORMER/ TRANSFORMER/ -a, f,' +''""'"" i RELAY j RELAY DRAIN = DRAIN GAS VALVE VALVE ��� GAS VALVE VALVE ■ 6434 ROLLOUT TFE PILOT PILOT (PFG-5 ONLY) - PFG 5 Boiler PFG 6 thru 8 Boilers - Figure 1, Figure 2, see page 4 V V - see page 5 Part Number 550-110-643/0605 — 3 immoll PFG-5 I . , I . SCHEMATIC WIRING DIAGRAM LADDER WIRING DIAGRAM 11 •P UMWa00I-C1 ORM $"CRL ti, '--•--, GI RtI Y DTRiLiY'Lit'wSiR'411 MEWIRT 8 7 r `-a 0...i....--(c,.. [4�OtidRf3 tit11�A Gta�tY� MOM L�71 � � f1�C7i (', {�fE71' i � (-777 � nttssi�lsrJRs ,_ .__ ,��.. -__ cli eTA:B tslacus{ r , x - .... as VC t1 51 RI •ty j t an t �a ..Y.. L 4' tLirTA33E it IL c mum reki5V TMI ---L. iNSSJ�1l 615S9t TRBICSTR7 2i11OCL •t CRB \ 0 C"13t1�aYls GRED FMAltYtwRt r----1 ? —..�- tet`119P Iff1k s'8 t8 r , W.+ar` �.� Q 11in _ f . —_L�,� ,.a . - -- - 0 FbC SY t TRU4 IMFR —MI MAIM r'' AILICCITAL '? tTDai d 24YtC+RII1 a MI R MUri -M y GI "S A Y tT? '--.. Cat 1--' ........ ..-.- -E.-a.H �Iv7W0i titM= m tA N an& =OE Clla i6 F. V 7}sl\ J1 --sl-� �` 4 nil ,�► G g WAS f ewer MT eau to �it1iJ�T \ AMU*Silt •'� I �' ergt - c her y mat: magus t?i ' B I P 1 ••__Jt m at a COMER ' P 5 a jJ-- c• c� wimpy N _ IQ o c> «x-yes`' �4 J '�43 ems. .....-= w C ! 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TABLE Y It V1PLAZSPHICC m - a1FICA .11O.FCRAPOt FE lM MTN11104=11f1RiLR13lEC ARaa. 6A#VAzvC 'd6 'fF' 1C' C R N c R FOR ki11 l DONEE 4MSlitagOZOIFEAWLSCitC AC4CR HWE!WW.V lI2 4,1/10 4 MV?I'V MV IV r A!D?l 1+JCT t CORe1'.YTt+I. �trtt4 . `�11fi$sf0 _74' t $ C) Cr 1411:5-MR ThL tt RD3 T3Fr*W72km C tit r 0 01 mut TOMO�FCRATN MrNRIAL s MCfO17Y A:W'If * Z,1 o e.t wA'P i u u Um ar,-.mREDe r�REA, x _. T. S' t 0401/s1D. 0 o e PI=LEA [�AP MIT FEW AILE.FEFIACE.WT. •I n2Pct vim z N., Attada•dYIF t ®F ' ! c. z PFG 6 thru 811 1:1. . - . _. .._. ..fiWil.,."-- -140,11.1:e.,-1 M 01 SCHEMATIC WIRING DIAG53 RAM LADDER WIRING DIAD M N J o AMMO= t,J11 - al o IAYR= 1:001. 1 la trMIPL°0) NC) CL-Mitt Rams:r, -- r I r�t9D 4, dQa .-o -- -a ! 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C�6NM3A-CSh"C22.1 CAJa m.%EttLTICGAL=MB PPM 1 ANDASY MUM CID Cl) NATIC!fA-.v�4Oaw 40RLOCAL=OsFtIGUI1!MCt4TB, 025Y1ttL1; 41%UJ o 2.A3LCO?4m is eaCw r Will701JT PIN R rf fteELP CONDIEON. LAM N _, i4L. C]R103 1 IPOfaCiit ROLLOUT[3[WARR SWP�L!#T�ITHMB?PPV�'=UUU TITL'RIIPt�, 717E200°C1A11MORFT8CI ITWI CTML�YBEU! .IFCITH�tOJLC1NALYR. .FAS o ar -a� Cl A.=WrOI?NCAU.&'EOEMClSTBEREJ'IAC8U,TYPE1010ORR8ECLCALENTviJSTEEUEE'L N35L R 'aK .�.-.--A.- +fit A 41 *�C M7C1 OONIROLEC IP RENT 114$TIiLJCT1D3 8 PA8IED USSTH HOLES F itA1 PL&{:AiTiO 4 F'II11f+I 1D [QLY�fDI TYIfla�nap HAHVCF AL1E MELD allAti 3RL 11K S.71' 3fA%•FCRSL1Yai� SYSTEMS. 13t1tB09TATANitCI> -5ET31NDIBi4fT1R44iP$. LOW mime IMITECI FOR RRJI.TTPLEMAE SYSTEMS[t8J!fO=O E ValiSSCAIC TO BETVRI TO C'O9/PQNENT Vita11R1CITIRERS Ra a Ns F��t WU N3Ntto HA3HVOLTA 1E MELDFP4TOY - V7 € EMCe• Ti-rr•31CL'1B t'{ .HLIFT3[LTtiL NCS fClh7gatiNNC�tfiLftwowwww 1 003TALLIEDDIMPEWLSSMANUAL @ L_K0.0,/'OiFOU3FA4HLlLfE: wire*moon. 6 , T. qDINDTE8 min la {uLFD chtCmama �� •irtormitttwP6' � ��� • a KAT tLEAMMItZ ARIDWY MD FOSPLACeATILE.RE RAM PIOTAft3t6eLv IV IFICCES.Mly. - Mac=•Number Si.. ttivua( C t4 410.= I - Part Cr 650-223-811/0402 s . mom An moil - - PFG SERIES 7 GAS-FIRED WATER BOILER — UNIVERSAL CONTROL,SYSTEMS - Section B: Damper Installation- ,These boilers must have vent dampers: Where screws,or rivets are used,to secure damper to draft •PFG 5 (U.S. only) hood,they must not interfere with free movement of damper _ These boilers may,have vent dampers: blade. •PFG 6-8(U.S. only) ' 5. Install damper harness between damper actuator and knock- , • PFG 5-7 (Canadian) out in jacket top panel. Use strain relief connectors and ` locknuts to secure both ends of damper harness. See Figure These boilers must not have vent damper : 1 or 2. - '•PFG 8(Canadian) . If not installing-damper;proceed to page 7. CAUTION Keep wiring harness clear of all hot surfaces. 1' NOTICE Once damper is installed on boiler, . - boiler will not operate without WARNING damper installed. NEUP KEYWAY WHEN Only dampers listed on page 16 are CONNECTING PLUGS. WARNING approved foruse on PFG Series 6&, 7 boilers.Any other damper installed - FORCING A MISMATCH _ . can cause severe personal injury or HAZARDOUS CONDITION death.. - _� 2. Effikal and Johnson dampers-install plug(packed in damper ] a� carton of 4"thru 8"dampers)in hole in damper blade. - 3. -Minimum clearances: , - KEY KEYWAY carr .PFG-48"between jacket top and combustible ceiling.- 6. Remove dummy receptacle from damper plug in boiler wiring • .. - harness. Plug damper harness receptacje into damper harness DANGER DO NOT modify draft hood or plug. See Figure 1 or 2. - - - damper,or make another connection between draft hood and damper DANGER Bypassing(jumpering)damper will or boiler. This will void C.S.A. - cause flue products such as carbon ' - _ ' certification and will not be covered - monoxide to escape into house.This by Weil-McLain warranty: Any', will cause severe personal injury or changes will cause severe personal death. ' injury,,death or substantial property - - . - damage. After boiler has operated once, if CAUTION either end of harness is disconnected, ' - system shutdown will occur.Boiler - 4. PFG-Damper must be installed directly on top of draftwill not operate until harness is ' hood so that it serves only one boiler and so that damper - reconnected. blade indicator is visible to homeowner: See Figure 1 or 2 - , • and Figure 3 or 4. 7. Effikal damper-damper"Hold Open"switch must be in"Au- tomatic Operation"position for system to operate properly. 8. Apply label shown in step 5 to damper, so that it is visible •. after installation. 9. Proceed to page 7. - - - _ INSTALL PLUG INSTALL PLUG IN HOLE - IN HOLE ' rI ihF 01i11un1�� '4.. ,.�IIIIII I I� - DAMPER - ,,,,,e_., ,, _ - ' BLADE DAMPER INDICATOR 1`1����/.= BLADE—`—`1 INDICATOR t HOLD ' sass iry III OPEN , SWITCH-,INSTALL DAMPER SO THAT SWITCH 0436 IS VISIBLE AND ACCESSIBLE TO - ' HOMEOWNER Effikal Damper - Johnson Damper Figure 3 -- - Figure 4 - - ', IIIMIII 6 1 Part Number 550-110-643/0605 3 PFG SERIES 7 GAS-FIRED WATER BOILER — UNIVERSAL CONTROL SYSTEMS Fon Section C: Check-Out ' 1. See Figure 5 for operating instructions,page numbers.Raise Operating room thermostat to call for heat.Damper actuator will slowly Instructions open damper(if provided). Gas Valve on page 2. When damper (if provided) is fully open, ignition control Honeywell VR8204 8- powers spark generator and opens pilot valve. Honeywell VR8304 8 DANGER Damper must be m open position when White-Rodgers 36E 9 appliance main burners are operating. White-Rodgers 36C 10 If damper is not in open position, flue Robertshaw 7200 11 products will escape into house,causing severe personal injury or death. Robertshaw 7000 12 3. a. If pilot does not light within 15 seconds,pilot valve is closed Figure 5 and spark generator is turned off.The ignition control initi- ` ates a five minute wait period.If call for heat exists after five minutes,ignition sequence starts at Step 2. b. If pilot lights and ignition control senses flame current, main valve opens and spark generator is turned off. 4. During main burner operation: a. Ignition control monitors pilot flame current.If signal is lost,main valve is closed,spark generator activated,and sequence returns to Step 3. b. If power-is interrupted,the control system shuts off pilot and main gas valves and restarts at Step 1 when power is restored. - 5. Thermostat is satisfied:pilot and main gas valves are closed. Damper(if provided)will close. - 6. Boiler is now in the off cycle. 7. Repeat steps 1-6 several times to verify operation. 8. Return thermostat to normal setting. 9. Set thermostat heat anticipator setting indicated in notes on wiring diagram. - - - Part Number 550-110-643/0605 7 o G` I 11 moml - PFG SERIES 7 GAS-FIRED WATER BOILER — UNIVERSAL CONTROL SYSTEMS PFG-5 WITH HONEYWELL VR8204NR8304 GAS VALVE FOR-YOUR SAFETY- READ BEFORE OPERATING ' WARNING If you do not follow these instructions exactly, a fire or explosion. may result causing property damage,personal injury or loss of life. A. This appliance is equipped with an ignition device C. Use only your hand to turn the gas control knob.Never use tools.If the which automatically lights the"pilot.Do not try to knob will not turn by hand,don't try to repair it call a qualified service light the pilot by hand. - technician.Force or attempted repair may result in a fire or explosion. B. BEFORE OPERATING, smell all around the D. Do not use this appliance if any part has been under water. appliance area for gas.Be sure to smell next to the Immediately call a qualified service technician to inspectth'e appliance floor because some gas is heavier than air and will and to replace any part of the control system and any gas control, settle on the floor.See below.-S ' which has been underwater. - - - WHAT TO DO IF YOU SMELL GAS • Donottrytolight any appliance. • Immediately call your gas supplier from a neighbor's phone.Follow • Do not touch any electric switch;-do not use any " the gas supplier's instructions. , phone in your building. _ " : • ' If you cannot reach your gas suppHet call the fire department. � .. , .= OPERATING INSTRUCTIONS ` �,.. a, 1. "'STOP! Read the safety information above on this label. 9. When equipped with vent damper,verify damper blade is,in 2. Set the thermostat to lowest setting. , full open position. 3. When equipped with Effikal vent damper Model RVGP,place 10. Wait five(5)minutes to clear out any gas.Then smell for gas, service switch in "HOLD DAMPER OPEN" position. See including near the floor.If you smell gas,STOP!Follow"B"in. Control Supplement for additional information. the safety information above.If you don't smell gas,go to the 4. Turn off all elect'ricalpower tothe appliance. - next step. . S 5.. Remove front panel. - - - 11. Turn gas control knob counterclockwise ,<Th, to"ON." ' 6. When equipped with Johnson Controls vent damper Model - 12. Turn on all electric power to the appliance. M35,manually,rotate damper blade in direction of arrow to "OPEN"position indicated on damper assembly. - 13. When equipped with Effikal vent damper, place service 7. This appliance is equipped with an ignition device which switch in"AUTOMATIC OPERATION"position. automatically lightsthe pilot.Do not try to light the pilot by -14. Set thermostat to desired setting. hand. 5 8. Turn gas control knob clockwise rte, to"OFF." 15. If the appliance will not operate,follow the instructions"To Turn Off Gas To The Appliance" and call your service T.r technician or gas supplier. Position e 0 - Gas - " 16. Replace front panel indicator 6, control (shown in knob "ON"position) Alt " °" ) d 1�111I OFF' � . - S 69331 1'10 td.ttai7.:(alti TO TURN OFF GAS TO THE APPLIANCE R 1. Set the thermostat to lowest setting. ' 3. Remove front panel. , 2. Turn off all electric power to the,appliance if service is to be 4. Turn gas control knob clockwise,(-4. to"OFF."Do not force. " performed. 5. Replace frontpanel. S " 550-223-041(1101)- 8 1=IMMEIMMI Part Number 550-1.10-643/0605 1".; • J PFG SERIES 7 GAS-FIRED WATER BOILER— UNIVERSAL CONTROL SYSTEMS PFG-5 WITH WHITE-RODGERS 36C GAS VALVE FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly, a fire or explosion • may result causing property damage,personal injury or loss of life. A. This appliance is equipped with an ignition device C. Use only your hand to depress or turn the gas control knob.Never use which automatically lights the pilot.Do not try to tools.If the knob will not depress or turn by hand,don't try to repair it, " light the pilot by hand. - call a qualified service technician: Force or attempted repair may B. BEFORE OPERATING, smell all around the result in a fire or explosion. - - appliance area for gas.Be sure to smell next to the D. Do not use this appliance if any part has been under water. - floor because some gas is heavier than air and will Immediately call a qualified service technician to inspect the appliance • settle on the floor.See below. - -and to replace any part of the control system and any gas control, which has been underwater. WHAT TO DO IF YOU SMELL GAS • Donottrytolightanyappliance. • Immediately call your gas supplier from a neighbor's phone.Follow • Do not touch any electric switch;do not use any the gas supplier's instructions. - - - phone in your building. • If you cannot reach your gas supplier,call the fire department. OPERATING INSTRUCTIONS 1.. STOP! Read the safety information above on this label. 9. When equipped with vent damper,verify damper blade is in ' 2. Set the thermostat to lowest setting. full"OPEN"position. 3.. When equipped with Effikal vent damper Model RVGP,place 10. Wait five(5)minutes to clear out any gas.Then smell for gas, service"switch in "HOLD DAMPER OPEN" position. See including near the floor.If you smell gas,STOP!Follow"B"in Control Supplement for additional information° the safety information above.If you don't smell gas,go to the 4. Turn off all electrical power to the appliance. next step. 5. Remove front panel. 11. Turn gas control knob counterclockwise T to"ON." 6. When equipped with Johnson Controls vent damper Model 12. Turn on all electric power to the appliance. M35,manually rotate damper blade in direction of arrow to "OPEN"position indicated on damper assembly. - 13. When equipped with Effikal vent damper, place service 7. This appliance is equipped with an ignition device which switch in"AUTOMATIC OPERATION"position. automatically lights the pilot.Do not try to light the pilot by 14. Set thermostat to desired setting. - hand. 8.' Depress gas control knob slightly and turn clockwise, to 15. If the appliance will not operate,follow the instructions"To "OFF."Note:Knob cannot be turned to"OFF"unless knob Turn Off Gas To The Appliance" and call your service is depressed slightly.Do not force.. technician or gas supplier. - - 16. Replace front panel. - Position o •T---\11, Gas - - indicator o 5, 0 control -- --1J 'knob po sitmo 54130 % / _ - • -TO TURN OFF GAS TO THE-APPLIANCE 1. Set the thermostat to lowest setting. . - 3. Remove front panel. 2. Turn off all electric power to the appliance if service is to be 4. Depress gas control knob slightly and turn clockwise r to performed. - "OFF."Do not force. 5. Replace front panel. 550-223-043(1101) Part Number 550-110-643/0605 - 9 mrnPFG SERIES 7 GAS-FIRED WATER BOILER — UNIVERSAL CONTROL SYSTEMS PFG 6-8 WITH ROBERTSHAW 7000 DERHC GAS VALVE • FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage,personal injury or loss of life. A. This appliance is equipped with an ignition device C. Use only your hand to depress or turn the gas control knob.Never use which automatically lights the pilot.Do not try to tools.If the knob will not depress or turn by hand,don't try to repair it, light the pilot by hand. call a qualified service technician. Force or attempted repair may. B. BEFORE OPERATING, smell all around the result in afire or explosion. appliance area for gas.Be sure to smell next to the D. Do not use this appliance if any part has been under water. floor because some gas is heavier than air and will Immediately call a qualified service technician to inspect the appliance settle on the floor.See below. and to replace any part of the control system and any gas control, which has been underwater. - WHAT TO DO IF YOU SMELL GAS • Do not try to light any appliance. • Immediately call your gas supplier from a neighbor's phone.Follow • Do not touch any electric switch; do not use any the gas supplier's instructions. - phoneinyourbuilding. • If you cannot reach your gas supplier,call the fire department. OPERATING INSTRUCTIONS 1. STOP! Read the safety information above on this label. 2. Set the thermostat to lowest setting. , -- - 3. When equipped with Effikal vent damper Model RVGP, place service switch in "HOLD DAMPER OPEN"position.See'Control Supplement for additional information. 4. Turn off all electrical power to the appliance. - Gas,control knob 5. Remove front panel. (Shown in"ON"position) 6. This appliance is equipped with an ignition device which automatically lights the pilot.Do Position not try tolightthepilot byhand. - �.� indicator 7. When equipped with Johnson Controls vent damper Model M35,manually rotate damper ;` ^, 1 blade in direction ofarrow to OPEN position indicated on damper assembly. :,`= 8. Turn gas control knob clockwise r-4.. to"OFF." E<<<_-J t 9. When equipped with vent damper,verify damper blade is in full open position. 10. Wait five(5)minutes to clear out any gas.Then smell for gas,including near the floor.If you - �-�?p Py' smell gas,STOP!Follow"B"in the safety information above.If you don't smell gas,go to 59205b the nextstep. - 11.'Turn gas control knob counterclockwise to"ON." - 12. Turn on all electric power to the appliance. 13. When equipped with Effikal vent damper, place service switch in "AUTOMATIC OPERATION"position. 14. Set thermostat to desired setting. 15. If the appliance will not operate,follow the instructions"To Turn Off Gas To The Appliance" and call your service technician or gas supplier. 16. Replace front panel. TO TURN OFF GAS TO THE APPLIANCE 1. Set the thermostat to lowest setting. 3. Remove front panel. • • - 2. Turn off all electric power to the appliance if service is to be 4. Turn gas control knob clockwise r to "OFF." Do not performed. force. 5. Replace front panel. 550-223-045(1101) 10 imoimi Part Number 550-110-643/0605 PFG SERIES 7 GAS-FIRED WATER BOILER— UNIVERSAL CONTROL SYSTEMS gin Section D: Troubleshooting VERIFY PROPER OPERATION AFTER SERVICING WARNING Never jumper(bypass)any device except /SHAFT for momentary testing as outlined in IFIBlU Y � Troubleshooting Charts.-Substantial it property damage and/or severe personal / injury could occur. hIII tir—.iN0I'I WARNING Label all wires prior to disconnection - Q_�, when servicing controls. Wiring errors I \438 can cause improper and dangerous - operation. DAMPER POSITION INDICATOR WRENCH OR PLIERS Figure 6 1. Before troubleshooting. a. Have a voltmeter that can check 120VAC, 24VAC, a microammeter with minimum scale range of 0-25,and a continuity tester. JOHNSON DAMPER b.Check for 120VAC(min.102-max.132)to boiler. If troubleshooting chart recommends replacing actuator, and c.Check for 24VAC at secondary side of transformer. actuator is not immediately available,damper blade can be fixed d. Make sure thermostat is calling for heat and contacts in open position to allow boiler operation.Follow these instruc- (including appropriate zone controls)are closed.Check for tions only in case of no heat or damper actuator malfunction. 24VAC between thermostat wire nuts and ground. See Figure 7. IN EVENT OF ACTUATOR FAILURE 1)Turn off power to boiler. —EFFIKAL DAMPER WARNING Failure to turn off power to boiler can result If troubleshooting chart recommends replacing actuator, and in severe personal injury,death or substantial actuator is not immediately available,damper blade can be property damage. fixed in an open position to allow boiler operation. 2)Remove damper actuator cover. Manually turning blade can cause actuator damage.Follow these 3)On PC board,move wire from A to B. instructions only in case of no heat or damper actuator malfunc- 4)Turn on power to boiler. tion.See Figure 6. 5)Using wrench or pliers on flat shaft section,manually rotate 1. Move damper service switch to"HOLD DAMPER OPEN" damper blade until green light turns on.Boiler will fire. - position.Apply"call for heat"to boiler.Damper blade should 6) Do not leave damper permanently in this position. Replace then rotate to open position and boiler will fire. - actuator immediately.If damper is left in open position,boiler 2. If Step 1 above does not open damper, manually rotate will not operate at pubhshed efficiencies. damper blade to open position using wrench or pliers on fiat shaft_between damper and actuator. Boiler will fire.Verify See damper manufacturer's instructions packed with that damper service switch is in"HOLD DAMPER OPEN" damper for additional information. position. 3. Do not leave damper permanently in this position.Replace FLAT actuator immediately.If damper is left in open position,boiler 51 SHAFT will not operate at published efficiencies. See damper manufacturer's instructions packed with damper for additional information. 4 0� Qno \39 PC BOARD / WRENCH OR PLIERS Figure 7 Part Number 550-110-643/0605 11 e L' • Ernmom PFG SERIES 7 GAS-FIRED WATER BOILER — UNIVERSAL CONTROL SYSTEMS TABLE I:No Spark,System Does Not Work Without Vent Damper VISUALLY CHECK-is ground wire connected from "GND(Burner)"to ignition control mounting screw; and ground wire connected from transformer , Terminal"C"to case ground? . Correct by making connections. No I Yes is 24VAC present across Terminals 24V&24V(GND)9 No I Yes Check for open thermostat or circ.relay - (where used)or check for loose wire - connections,defective spill switch or rollout thermal fuse element,or open , LWCO or limit contacts. DANGER If LWCO,spill switch or rollout thermal fuse element contacts are open,determine cause - - and correct condition.Failure to do so will cause severe personal injury,death, - - ' or substantial property damage. Open thermostat contacts for 15 seconds.Close thermostat contacts-is 24 VAC across terminals PV&MV/PV? Replace ignition control. '/ No Yes Turn OFF supply voltage. -- Check spark wire.Is it securely connected to spark transformer? Securely connect,then turn ON supply voltage and re test, No YYes Is condition of spark wire good(not cut, brittle,burned,or cracked)? Replace pilot assembly. / No Yes ♦- Is spark electrode ceramic cracked? Is spark gap 0.125"and Isolated in pilot gas steam? 4 No Yes No Yes - • Replace pilot assembly,turn ON supply voltage,operate system several Replace pilot assembly,turn ON supply - - complete heat cycles. voltage,operate system several complete - heat cycles. Replace Ignition control. - 12 Part Number 550-110-643/0605 `i SJ f . PFG SERIES 7 GAS-FIRED WATER BOILER- UNIVERSAL CONTROL SYSTEMS • ,TABLE II:No Spark,System Does Not Work With Vent Damper _ - Is damper harness securely plugged In at both , Secure connections. - ends? 4 No I Yes - i Is 24VAC present across terminals C and Y on - transformer? ' Check for loose wire connections 4 No I Yes - ' or bad relay on transformer. - is 24VAC present across terminal C and yellow wire ' between damper connector and rollout thermal fuse Check for open thermostat or circ,relay(where used)or check for element? loose wire connections,defective spill switch or rollout thermal fuse . I Yes element,or open LWCO or hlght limit contacts. DANGER If LWCO,spill switch or rollout thermal fuse element , contacts are open,determine cause and correct • condition.Failure to do so will cause severe personal injury,death, ' or substantial property damage. - - Is damper rotated open? Check for out of round stack section. / _ No I -Yes Does motor rotate open? Replace actuator. 14 No Yes - I " Is 24VAC present at Terminals ► PV and MV/PV? Open thermostat contacts for 30 No I Yes Is 24VAC present across terminals PV seconds.Damper will rotate to closed and MV/PV? . - position.Close thermostat contacts. No I Yes Damper will rotate to open position.. - Is spark present now? 4 111 Yes I , No ► Turn OFF continuity of each wire in wiring . . - _ harness to damper.Does continuity exist • for each wire? I Re test. No I Yes _ t_ - Check spark wire.Is It securely Ilrconnected to ignition control? . ___iSecurely connect and No I Yes Replace damper Remove damper harness from boiler turn ON supply voltage. wiring harness, wiring harness.TEMPORARILY Install Re-test. jumper between terminal 2 and - , terminal 5 on damper plug in boiler Is condition of spark wiring harness.See Figure 10.Does wire good(not brittle, boiler fire? burned or cracked)? No Yes Replace pilot assembly. No Yes Replace ignition control. Is spark electrode ceramic Is spark gap 0.125'and cracked? located in pilot gas stream? 41No Yes V No I Yes Replace actuator. - Ilr Replace pilot assembly. Replace ignition - Replace allot assembly. � — control, + 10 2• 30 -" 4 0 5• 6 0 Turn ON supply voltage ' -- and operate system ' FIGURE 10 several complete cycles. Part Number 550-110-643/0605 13 y ,d ; :In I_ PFG SERIES 7 GAS-FIRED WATER BOILER — UNIVERSAL CONTROL SYSTEMS TABLE III:Pilot Lights,Main Valve Will Not Come On With or Without Vent Damper 'Does spark stay on for snore than a few seconds after pilot is established? No . - I Yes - Is 24VAC between Terminals " Make sure sense wire is not wrapped MV and MV/PV on,ignition control? around any pipe or accessories. Replace ignition 4 . No -Yes - control, Is sense wire securely attached to sense terminal and pilot assembly? Is inlet gas pressure at least 5.0'WC.and not over No Yes 14"W.C.? Contact gas supplier to No Yes correct. Correct. Is sensing probe ceramic • cracked? No Yes main valve wiring secure at terminals? Correct wiring. 4 No I Yes Is sense wire or sensing Replace pilot probe shorted out to assembly, metal surface? Replace No I Yes valve. Check for continuity of sense wire Correct, and condition of insulation. Replace pilot, 4- Not OK I OK assembly. V Does system have proper flame signal? Set up microammeter to measure d. Energize the system.Spark should output current in flame sensor circuit ignite the pilot.As soon as pilot is as follows: burning,microammeter should read at least 1.0 rnlcroamp for a. Detach sense lead from ignition Honeywell S8620C,0.1 microamp control.Attach negative lead for U.T.1003-510. -. - from microammeter to sense - terminal on ignition control. e. Is flame current signal less than the minimum specified in"d"above? b. Attach positive lead to sense wire from pilot assembly. c. Disconnect main valve lead from Terminal"MV"on ignition control. No Yes Replace ignition control. Check for proper gas pressure,clean pilot assembly tight mechanical and electrical connections. Also check for proper system grounding. See additional information on page 15. 14- Part Number 550-110-643/0605 PFG SERIES 7 GAS-FIRED WATER BOILER— UNIVERSAL CONTROL SYSTEMS 1 1 • TO CHECK IGNITION SYSTEM GROUNDING FOR TABLE III, PAGE 14. - Pilot assembly and ignition control must share common ground with main burner. Nuisance shutdowns are often caused by poor or erratic ground. • Check for good metal-to-metal contact between pilot burner bracket and main burner,and between main burner and burner rest • Check ground lead from GND(BURNER)terminal on ignition control to ignition control mounting screw,and from"C"on transformer to transformer case ground. Make sure connections are clean and tight.If wire is damaged or deteriorated, replace with No. 18 ga.moisture-resistant,thermosplastic insulated wire with 105°C minimum rating. TABLE IV:Spark is Present,Pilot Will Not Light With or Without Vent Damper - Are pilot valve connections CORRECT and securely fastened? Connect securely to Terminals PV - - and MV/PV on Ignition control. / No Yes - Is Inlet gas pressure at least 5,0"W,C,and not over 14,0"WC.? Is manual hand valve open? No Yes Open manual hand-valve, No Yes Is gas present at pilot burner assembly?CAUTION- Remove MV wire from ignition control,use a match Contact gas supplier to taped to a long screwdriver or pilot lighter rod and correct gas pressure. manually light pilot. - Make sure gas cock Is in"ON"position and pilot line is 4 No Yes not kinked or obstructed.Check for clean pilot orifice. If OK,replace gas valve. Is spark gap 0.125"and located in pilot gas stream? [Replace pilot assembly. No Yes - 1 Block any draft around boiler.Check for clean pilot orifice. Part Number 550-110-643/0605 - 15 PFG SERIES 7 GAS-FIRED WATER BOILER — UNIVERSAL CONTROL SYSTEMS Section 'E: Parts Part Description Vendor Part Number W-M Part No. , • Damper Assembly ' • PFG-5) Effikal RVGP-KS-7BKF 381-800-477 Johnson Q35GH-2 consisting of M35BC actuator and Y15 vent pipe 8"(PFG-6) - - Effikal RVGP-KS-8BFK 381-800-478 Johnson Q35GK-2 consisting of M35BC actuator and Y15 vent - pipe 9"(PFG 7-8) - Effikal RVGP-KS-9BF** 381-800-445 Johnson Q35GM-2 consisting of M35BC actuator and Y15 vent pipe** - Damper Actuator Effikal RVGP(Effikal Only) 510-512-337 Johnson M35BE-1C(Johnson Only) 510-312-255 Damper Harness Weil-McLain 591-391-795 UCS Ignition Control Honeywell S8620C1003 511-330-097 United Technologies 1003-511 Pilot Burner Assembly - Johnson Controls Q9OGE-1 consisting of J981 LYW pilot and 511-330-218 - , Y75AA-3 flame sensor - Boiler Wiring Harness,PFG-5 Weil-McLain 591-391-878 Boiler Wiring Harness,PFG 6-8 Weil-McLain 591-391-880 Gas Valve 3/4"X3/4" _ Honeywell VR8304P4348 511-044-382 PFG 5 White-Rodgers 36C74-474 • Gas Valve 3/4"X1" Robertshaw 7000 DERHC-S7C 511-044-286 PFG 6-7 Robertshaw 7000 DERHC-S7C Gas Valve 1"Xl" 511-044-287 PFG-8 • **Not for use on Canadian PFG-8 boilers. NOTICE - Only dampers listed above are approved for use on and PFG Series 6&7 boilers. - Any other damper installed can cause severe personal injury or death. Weil-McLain 500 Street 011 WEILrnc LAIN Michigan City,N 416360-2388 http://wii w Weil-inclam.com inum 16 Part Number 550-110-643/0605 Häiér Central Air,Conditioning SERVICE MANUAL , Models HCI8D1VAR HC24D1VAR Ltllllulllh1llllhIIIIIIIIIIIIIIIIIIIIIIIlIIIIIIHC30D1VAR HC36D1VAR 11111HC42D1VAR HC48D1VAR 110111111111111Ha�er11111111111IIUIII HC60D1VAR 111110111111111111111111111111111111111111111 ' 111111111111111111111111111111111111111111111111 :111111111111111111111111111111111111111111111111=:IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII' II IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII •Features • High efficiency design • Benchmark hermetic compressor design • Haler Hi-Efficiency aluminium fin and copper tube design • Compact design of outdoor unit • Manufactured for convenient installation and maintenance • Cooling only ,13SEER • Powder coated full metal jacket Manual code: SYJS----AM 004-05---Rev.6 Edition: 2006-11-20 Downloaded from www Manualshb corn manuals search engine I-la ` Central Air Conditioner Model: Cooling Only, 13SEER.units CONTENTS 1. DESCRIPTION OF PRODUCTS & FEATURES 3 - - 2. PHYSICAL AND ELECTRICAL SPECIFICATIONS 5 3. SAFETY PRECAUTION 8 54. SYSTEM COMPONENTS AND FUNCTIONS • S °8 "5. ELECTRICAL CONTROL DEVICES 10 . - , 6. APPLICATION ....11 7. INSTALLATION INSTRUCTIONS-- 13 8. MAINTENANCE INSTRUCTIONS 21 9. SERVICE-AND TROUBLESHOOTING • - 22 10: WIRING DIAGRAMS ` 32 Warning . I -` The equipment detailed in this manual should be installed and , serviced only,by qualified technicians who are familiar with the safety procedures required for this work and who have the proper tools, - testing equipment and replacement parts. " During testing,it may be necessary to work with circuits with live electrical components:Only individuals with proper-training that can' , , - 'follow all electrical safety precautions should perform this work. Failure to follow all safety precautions could result in property • damage, serious injury, or death. • 2 - , , Downloaded from www Manualslib corn manuals search engine - ' Ha i e r Central Air Conditioner Model: Cooling Only, 13SEER units 1. DESCRIPTION OF PRODUCTS & FEATURES 1.1 Air conditioner This manual discusses 'split' central air conditioning and indoor coils. "Split" central air condition system refers to the physical location of major air conditioning components. The split system air conditioning are manufactured to standards of quality and performance.They are 13 SEER(Seasonal Engery Efficiency Ratio) which meet or exceed the standards imposed by efficiency legislated and therefore represent both good value today and for years to come. The current'air conditioning system use scroll and reciprocating compressors. This gives the air condition a durable compressor which needs less external protection,while increasing the unit efficiency in cooling mode. 1.2 NOMENCLATURE FOR MODEL NUMBER Model number explanation---indoor unit H B 24 00 V A 1 ,M 20 P Nominal Electric Electric Efficiency Design Airflow Unit Haler Blower unit capacity in Continuation heater Designation code series configuration Width(in.) (1000)Btu/h Y:575V-3Ph-60Hz, 00 No; V 208/230V-1 Ph- A.10 SEER B•Blower unit 24: 05 5KW; 60Hz; NC coil 1:1st M:Multi- 17:17"[432] P.Powder Brand C:Evaporator 24000BTU/h 10.10KW; C•208/230V-3Ph- B:11 SEER Generation; direction 20.20"[497] paint symbol WWall moun 60 15:15KW; 60Hz; NC coil 2.2nd V.Vertical 22.22"[559] E.DC motor -ted unit 60000BTU/h 20:20KW D.460V-3Ph- C 12 SEER Generation, H.Horizontal 25:25"[625] 60Hz; NC coil A:115V,1 Ph,60Hz Table 1-1 • Model number explanation---outdoor unit H C 24 D 1 V A R Nominal System SEER Design Compressor Haler capacity in Electric Designation Body style type designation series type (1000)Btuh A:10SEER; B:IISEER; A: 115V,1Ph,60Hz; C:Air 1: 1st C:12SEER; C:208/230V,3Ph, Brand Conditioner 24: Generation ; D:13SEER 60Hz; A: symbol: 24000BTU/h; S=Scroll, E:14SEER; D: 460V, 3Ph, 60Hz; standard H:. 60: 2: 2nd R=Recipr F:15SEER; V:208/230V,1 Ph, style Haier R: Heat 60000BTU/h Generation ocating G:16SEER; 60Hz; Pump H:17SEER Y:575V,3Ph,60Hz • I:18SEER Table 1-2 1.3 ENGINEERING FEATURES: COPPER TUBE/ALUMINUM FIN COILS:Both indoor and outdoor coils are designed and matched to optimize heat transfer while minimizing size and cost,with increased durability and reliability. 3 Downloaded from www Manualslib corn manuals search engine I-I a ler - Central Air Conditioner Model: Cooling Only, 13SEER units CABINETS: Constructed of powder painted galvanized steel to provide a durable finish (///�//�per�O%--' and protection for the outdoor coil. Fig.1-1 FAN GUARD AND MOTOR BRACKET: Welded powder coated guard with independent rod and band motor 6`',�" bracket, unit top has a deep draw fan venturi for efficient air flow. \......_____ Fig.1-2 . 7. SERVICE VALVES: Facilitates unit servicing and provides a reliable and safe access to measure unit pressures . ,,,, , 0. Fig.1-3 BASE PAN: This deep-drawn base keeps the bottom of the coil off the ground, has weep holes to allow for complete drainage. rt Fig.1-4 FLOWCHECK DISTRIBUTORS: Outdoor units use the Flowcheck Distributor to act as an open check valve in the cooling mode. ACCESSORIES: - LOW AMBIENT CONTROL: This factory installed option allows for low temperature operation in the cooling cycle ambient temperatures down to 0 T. This control should be installed in units that operate in cooling when outdoor ambient temperatures below 65T, and is recommended for all commercial applications. _ START COMPONENTS : This option provides additional starting for covering a wide range of voltages and system pressure combinations.This option maybe required on reciprocating compressors with flowcheck piston metering. SERVICE VALVES AND PRESSURE PORTS: Mounted external to the cabinet for easy access at installation and during service. 4 Downloaded from www Manualslib corn manuals search engine v 0 0 0 ' 0. n 0. 5 i Hailer Central Air Conditioner Model: Cooling Only, 13SEER units g. 2. PHYSICAL AND' ELECTRICAL SPECIFICATIONS . 8 Specifications Subject to Change without Prior Notice a Model Number HC18D1VAR HC24D1VAR HC30D1VAR HC36D1VAR HC42D1VAR - HC48D1VAR HC60D1VAR c UPC Code. _ - - P Comments 1.5-Ton Outdoor AC 2-Ton Outdoor AC 2 5-Ton Outdoor AC 3-Ton Outdoor AC 3 5-Ton Outdoor AC 4-Ton Outdoor AC 5-Ton Outdoor AC 0 Model Status - ` .'New Model New Model New Model New Model New Model New Model New Model s Performance 3 HB2400VD*M20 HB2400VD*M20 .HB3600VD*M22 HB3600VD*M22 HB4800VD*M22 HB4800VD*M22 HB6000VD*M22 aq 5 with Matching Indoor Unit HB2400VD*V20 , HB2400VD*V20 HB3600VD*V22 HB3600VD*V22 HB4800VD"V22 HB4800VD*V22 HB6000VD*V22 , CD HW18**VD1V22(-P) HW24**VD1V22(-P) HW30**VD1V22(-P) Cooling Capacity(Btu/h) 18000 24000 28000 .35000 40000 47000 56000 Net Sensible Capacity(Btu/h) 13800 17300 20,300 _ 25500 28800 33970 41580 Net Latent Capacity(Btu/h) 4,200 6,700 7,700 9,500 11,200 13,030 14,420 SEER ' - 13 13 _ . 13 13 13 13 13 Total Input Watts 1,720 2,150 _ _ 2,420 3,100 3,350 4,200 5,100 Airflow Rate(CFM) 1350 1800 . 2100 2700 3200 3600 .4300 Noise level(Semi-Anechoic) . 58 58. 63_ _ 65 68 - 68 68 Electrical - - Voltage-Phase-Frequency(Hz) 208/230-1-60 208/230-1:60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 208/230-1-60 Minimum Circuit Amps 8.6 . ' 11.6 12.4 - 15.9 17 7 21.8 33.7 ' Maximum Overload Amps . 15 . ' 2020 25 30 35 • 55 Compressor Type/Maker . _ Reciprocating Reciprocating Reciprocating Reciprocating Reciprocating Reciprocating Scroll Model Number _ . H2OJ153ABCA H2OJ213ABCA H2OJ223ABCA H2OJ293ABCA H2OJ323ABCA H2OJ403ABCA H23R543ABCA ' RLA(Rated Load Amps) . . . 6 2 8.6 . 9.2 _- 11 7 - 13 0 15.8 25.0 LRA(Locked Rotor Amps) 41 0 60 0 60.0 73 85.0 90.0 150.0 Input Watts _ . _ Internal Overload Protection _ Yes. _ Yes . ` Yes Yes Yes Yes' Yes - Crankcase Heater NA . NA . NA - NA NA- - NA NA Fan Motor - RLA(Rated Load Amps). . . 0.86 1.1 ' 1.1 1.3 - 1.43 _ 2.0 2.5 Rated House Power(hp) , 1/8 . 1/6 1/6 1/4 1/3 1/3 1/2 Nominal RPM 1000 - 840 . 840 850 1070 960 1000 Input Watts 180.0.._ _200.0 _ 200.0 280 0 - 310.0 340.0 510 Fan , . Diameter(In) 18"- . _ .23" 23" . 24" ' 23" 24" , 24" No.of Blade 3 3 3 - _ 3 3 3 3 Fan Material Zinc-Coated Steel aluminium - aluminium aluminium aluminium aluminium Plastic-Coated Steel 5 . 0 0 0 POQ. Cl.CD 0 3 i Hale 1 Central Air Conditioner Model: Cooling Only, 13SEER units 4 g w y Condenser coil 9- Number or Rows 1 1 1 1 1 2 2 o Tube spacings(V x H)(In) 1 x 0.85 1x085 1 x 0.85 1x085 1x085 1 x 0.85 1 x 0.85 3 Fins per Inch-FPI 21 21 21 21 21 16 21 2, Fin Type Enhanced fins Enhanced fins Enhanced fins Enhanced fins Enhanced fins Enhanced fins Enhanced fins m Tube OD and Type 3/8"Grooved 3/8"Grooved 3/8"Grooved 3/8"Grooved 3/8"Grooved 3/8"Grooved 3/8"Grooved F3 Gross Finned Face Area(Sq Ft) 10 8 16.0 18 4 18 4 20 85 18 4 23.3 Number of Circuits(In/Out) 2/2 4/4 3/3 3/3 7/7 6/6 9/9 Min inlet or outlet airflow opening size 0 n Exterior-Appearance - . as . FD Cabinet color White White White White White White White Top cover Stamped sheet metal Stamped sheet metal Stamped sheet metal Stamped sheet metal Stamped sheet metal Stamped sheet metal Stamped sheet metal Basepan Deep Drawn,Elevated Deep Drawn,Elevated Deep Drawn,Elevated Deep Drawn,Elevated Deep Drawn,Elevated Deep Drawn,Elevated Deep Drawn,Elevated Service panel . Easy Access Easy Access Easy Access Easy Access Easy Access Easy Access Easy Access Body style/Coil guard Full metal jacket Yes Yes Yes Yes Yes Yes Yes Wire grill Optional ` Optional Optional Optional Optional Optional Optional Plastic mesh Optional Optional Optional Optional Optional Optional Optional Features Galvanized Steel Cabinet Yes Yes Yes Yes Yes Yes Yes Coil Design Haler Enhanced Coil Haler Enhanced Coil Haler Enhanced Coil Haler Enhanced Coil Haler Enhanced Coil Haler Enhanced Coil Haler Enhanced Coil Fully Enclosed Motor Yes Yes Yes Yes Yes Yes Yes Removable Top Grill Assembly Yes Yes ,Yes Yes Yes Yes Yes Elevated Base Pan Yes Yes Yes Yes - Yes Yes Yes High and Low Pressure Switches Optional Optional Optional Optional Optional Optional Optional Filter Dryer Yes . Yes . Yes Yes, Yes Yes Yes Full,Reusable Service Valves Yes Yes Yes Yes Yes Yes Yes Easy Service Access Yes Yes -Yes Yes Yes Yes Yes Corrosion Resistant Outside Screws Yes Yes Yes Yes Yes Yes Yes Accessories ' Room Thermostat No No No No No No No Start Assist Kit No No No • No No No No- Low Ambient Kit No No No No No ' No No Compressor Time Delay No No No No No No No Compressor Blanket Kit No No No No No No No Fan Delay Kit(Note 1) No No No No No No No Piston YES YES YES YES YES YES YES Dimensions and Installation • . Unit Dimensions(inches) Height ' 321/5 281/4 32 3/16 32 3/16 361/8 32 3/16 40 Width 23 3/8 30 5/8 30 5/8 30 5/8 30 5/8 - 30 5/8 30 5/8 Depth 23 3/8 30 5/8 30 5/8 30 5/8 30 5/8 30 5/8 30 5/8 Cubic Volume(Cu.Ft) 10.18 15.33 17 46 17 46 19.60 17 46 21 70 6 - P• o • aa o - a I-'Iaie( - . . . Central Air Conditioner Model: Cooling Only, 13SEER units • Refrigerant Line - "' - • 9 Liquid Line Dimension(In) 3/8" 3/8" 3/8" - 3/8" - 3/8" 3/8" - 3/8" . Vapor Line Dimension(In) 3/4" 3/4" 3/4" 7/8" 7/8" 7/8" 7/8" 7 Max Refrigerant Line Length(Ft) 115 - 115 - 115 115 _115 115 - - 115 w Max Vertical Distance(Ft) - - - . • Outdoor above Indoor Unit 70 - 70 70 - 70 70 • 70 70 -0 Indoor above Outdoor Unit - 50 50 . ' 50 50 • 50 50 . 50 Service Valves - _ Re-usable - - • Re-usable . Re-usable. Re-usable Re-usable Re-usable • • Re-usable CD Qa - Refrigerant Connection Type • Sweat Sweat -- Sweat Sweat Sweat Sweat Sweat Metering device(Piston size) Piston(073) - - Piston(073) Orifice,(078) Onfice(091) Orifice(087) Onfice(097) Orifice(096) Refrigerant Type/Charge(Oz)(Note 2) R22/86.57 R22/102.47 R22/121.91 R22/134.28 R22/148 41 R22/178:45 R22/259.72 • Min Clearances ' 10"sides/18"service 10"sides/15"service 10"sides/18"service 10"sides/18"service 10"sides/18"service 10"sides/18"service 10",sides/18"service Weight(lbs) Net 156.0 • -194.0 -198 0 203.0 • • 231.0 244 0- - - 271 0 Ship 167.0 209.0 216.0 • 220 0 249 0 262.0 291:0 Agency Approvals • . - Performance Certification • ARI ARI ARI - ARI ARI ARI ARI Safety Approvals • • - , UUcUL UUcUL' UUcUL - UUcUL • • UUcUL UUcUL - UUcUL , • - Packaging - • Carton Type - Cardboard pallet Cardboard pallet Cardboard pallet' Cardboard pallet Cardboard pallet Cardboard pallet Cardboard pallet , Shipping _ • ' • Carton Dimensions , ' Height - - 331/8 291/2 331/2 - 331/2 371/2 331/2 413/8 " Width - 25 _ 32 321/2 321/2 ' 321/2 321/2 321/2 ; 321/2 Depth -25 ' 32 1/2 32 1/2 32 1/2 32 1/2 -32 1/2 32 1/2 Cubic Volume(Cu.Ft) 11.98 18 03 - 20.48 20.48 22.92 20.48 - . 25.29 ' - Container Loading(40'High) - Warranty(Haier Brand Only) • " Parts 5 _ 5 5 5 5 5 5 Compressor - - , . 10 10 10- - 10 10 10 _ 10 ' ' Carry in/In Home In Home - -.In Home - In Home In Home" In Home• In Home _ In Home Noise level dB(A) • 61.7 - 61.1 60.5 62 2 67.1 66.6 64.2 Notes: . • - - 1- 120-second fan delay for air handler , -- - - 2- R-22 Charge for the outdoor unit with matching indoor unit and 25'line set.- - , ' . ' 6 - - , . . , . I-lae Central Air Conditioner Model: Cooling Only, 13SEER units ,` 3 SAFETY PRECAUTIONS ; CAUTION: please read all,instructions prior to installing, operating, maintaining or repairing the product. - _ ' WARNING: THE MANUFACTURER'S WARRANTY DOES NOT COVER DAMAGE TO CAUSED BY THE USE OF ANSUTHORIZED COMPONENTS OR ACCESSORIES, THE USE OF SUCH UNAUTHORIZED COMPONENTS OR ACCESSORIES MAY 'ENDANGER LIFE,AND PROPERTY. THE MANUFACTURER DISCLAIMS ANY RESPONSIBILITY FOR SUCH LOSS OR INJURY RESULTING FROM THE USE OF SUCH UNAUTHORIZED COMPONENTS OR , ACCESSORIES _ - •- Always use industry-recognized service practices in the maintenance,adjustment and repair of the " products covered in this manual. - • Always wear safety glasses when handling refrigerant-and'Reforming brazing operations. • Follow the manufacturer's instruction's when making repairs, installing replacement parts and performing system maintenance. - • • Use only authorized factory parts. - 4. SYSTEM COMPONENTS AND FUNCTIONS • This section describes the various air conditioning components,,their purpose and operation. This section is only a guide and does not consider all components that.could be found on anair conditioner in . .the field.' - . COMPRESSORS(Fig.4-1) . - -The heart of any refrigerant system is the,compressor. It is a pump that causes refrigerant to flow.There . are several different types of compressors, but all use electricity to turn an electric motor to drive a pump. Central air conditioners use two types of compressors. The first is the enhanced reciprocating compres- -sor. it operates,with an offset crankshaft and pistons, and resembles an internal combustion engine. the driving force is supplied by an electric motor turning the crankshaft and forcing pistons up"and down in cylinders where valves control the flow of refrigerant.The'valves provide a seal between high . and low pressure sides of'the system. If the valves are damaged, the compressor's:function and efficiency is reduced. . , � . _ L Reciprocating type compressor , , - Scroll type compressor - - - : - Fig.4-1- - ' " _ Generally,-liquid refrigerant is suspected if valve damage occurs.•Some compressors can tolerate the " _ presence of small amounts of liquid refrigerant in the return gas;but this condition must be avoided , through,proper refrigrant control. Returning refrigerant cools the compressor motor and surrounding the motor with=low pressure,gas gives it the name of"low-side"shell•compressor . The scroll compressor used a,helix (similar in shape to a snail shell)to move refrigerant. When paired - - _within a similar stationary helix, the moving helix rotates so that the space,between the two constantly decreases as the gas moves toward the center of the Scrolls.The returning refrigerant gas first cools the motor, then flows into the suction intake of the compressor scroll: Thedischarge,gas leaves'from'the • : , center of the helix and exits the,compressor.The lower part of the shell should be cool to the touch.• , Current single phase units use two types of compressors. The design.of the two compressors types is, quite different. But they function the same way. Scroll units do not need start components or crank -case heaters. The reciprocating compressor may need both. Both,types benefit from using a time-delay. - time delays prevent thermostat short cycling and momentary power interruptions from damaging the- , compressor. - - - 8 - - , • - Downloaded from www Manualshb corn manuals search engine _ _ , I-I a i e r Central Air Conditioner Model: Cooling Only, 13SEER units Both compressor types are protected internally against over-current and over-temperature conditions. Some scroll compressors have an additional thermostat mounted externally in series electrically with the contactor coil. FAN AND BLOWER MOTORS(Fig.4-2 and Fig.4-3) The outdoor component of split system contains an fan motor.These PSC(permanent split capacitor) motors are single speed and drive a propeller fan.The motor mounts to the unit top with the shaft up, This fan pulls outdoor air through the outdoor coil. ., Fan Fig.4-2 To access the condenser fan or motor, carefully remove the unit top, a service loop is provided on the motor wiring for easier access. . (0---,,„ ,.,,, , ,, ,,,„ .4,„-..„---,,,,..._., ,, -, .: ,..,f ',\'''< .:1*.d' 'S :,t'.i '''' Fan and motor assembly Fig4-3 METERING DEVICES(Fig.4-4) Flow-Check Pistons One type of refrigerant metering device is the flow-check piston. It has two functions. First it acts as a refrigerant metering device controlling refrigerant flow into the evaporator. Second, it acts as an open check valve when refrigerant flows in the opposite direction. When refrigerant enters the device from the square end,the piston seats and forces all refrigerant throug the carefully sized hole in the center of the piston.This orifice functions as a metering device controlling h the amount of refrigerant flow,with flow in the opposite direction, pressure moves the piston off the seat and liquid refrigerant flows around the piston. Using too small a piston starves the coils of refrigerant.A piston that is too large floods coils. Mismatching indoor and outdoor units of split systems affects performance, efficiency, charging and reliability. PROPER MATCH OF UNIT AND PISTON SIZES Split air conditioning indoor and outdoor units must be carefully matched to balance the heat transfer indoors with the heat resected or claimed by the outdoor unit. Manufacturer's specification sheets and installation manuals should be followed to insure proper match. Matched systems are listed on the internet at ARI. ORG. Combinations for indoor and outdoor units using a distributor and flowcheck are shown in the application table 6-2. Distributor assy Fig.4-4 9 Downloaded from www Manualslib corn manuals search engine • . . Ha i e( Central Air Conditioner Model: Cooling Only, 13SEER units REFRIGERANT CIRCUIT (Fig. 4-5) ' All 13SEER units outdoor coils are multi-circuit. Refrigerent gas or liquid is uniformly distributed to from 4 to 10 circuits to improve heat transfer and reduce capacity losses due to pressure drops. - - - , Fig.4-5 , .. - 5.ELECTRICAL CONTROL DEVICES THERMOSTATS - ' - Thermostats are the most obvious control in the air conditioning system because these controls are accessible by the consumer. Contact your local distributor for information on part numbers of . various manual changeover, auto changeover and set-back thermostats or see the thermostat and subbase selection information found in the wiring diagram booklet. _ , In the cooling mode, the thermostat calls for cooling by,energizing the compressor contactor and the indoor blower control.The indoor blower can operate continuously by setting the thermostat subbase fan ' switch to the"ON"position. _ , PROTECTION DEVICES ' . Protection for the unit begins with the installation of appropriate fuses or circuit breakers by the installing contractor. Breaker or fuse size is governed by the National Electrical Code and local code. AMP draw requirements for each unit are found in the Specifications. OVERLOADS AND LIMITS Overloads protect against over-current or over-temperature conditions.Those located in the outdoor unit include the automatic reset internal overload in the fan motor and the compressor automatic reset internal overload.. Such controls are not serviceable but their operation may influence service _ troubleshooting .For example, the compressor,internal overload may stay open for several hours .A technician may incorrectly diagnose this as an open compressor winding._ - • RELAYS Relays provide a method for control switching. Relays may switch either low(24VAC)online voltage. . Generally relays used in airconditioning use 24VAC coils.Contact voltage maybe either low or line voltage. COMPREESSOR CONTACTOR The coil uses 24 volts but the contacts carry line voltage .The heater contactor is a large'relay, which controls the compressor and the outdoor fan operation.'Some contactor use single pole contacts ,while others use 2-pole or 3-pole contacts. Single-pole contactors break only one-side ofthe powerfeed to the compressor and outdoorfan.The otherside remains connected to the power source.The 2-pole or 3-pole contactor breaks power to all sides of the 'compressor and outdoor fan. _ _ ` - CAUTION: WHEN THERE IS A SINGLE POLE CONTACTOR, ONE SIDE OF A-240 V.A.C.CIRCUIT REMAINS HOT. THIS MEANS THAT THE WIRING IN THE HIGH VOLTAGE CIRCUIT MAY HAVE A POTENTIAL OF 120V.A.C.TO GROUD. BEFORE SERVICING THE UNIT, ALWAYS TURN OFF - . 'POWDER AT THE UNIT DISCONNECT SWITCH. - - - OPTIONAL DELAYS AND KITS ' A Time-Delay in the compressor contactor lowcontrol circuit allows time for system pressure to equalize before re-starting the compressor. - - - - . - , ' This delay uses solid state circuitry to measure the time since the power was interrupted and is set for approximately 3 minutes.,It is not field adjustable.-This is a delay on break timer. _ - - lo - - - -. Downloaded from www Manualshb corn manuals search engine ' Ha i e( - - Central Air Conditioner Model: Cooling Only, 13SEER units Tw Y� rte_+..+ Compressor delay PCB 'Fig.5-1 START KITS(OPTIONAL) This special relay uses the EMF generated by the compressor start windings to take a start capacitor out of the circuit. The relay and its companion capacitor can start the compressor at low voltages and against higher pressure, such as those caused by non-bleed port expansion valves. Start kit components should match the recommended ratings and functions of those provided by the reciprocating compressor manufactorer. See Specifications start components. Start kits are not normally required with scroll compressors. The operating characteristics of the scroll compressor make a start kit unnecessary. 6. APPLICATION - - Before specifying any air conditioning equipment, a survey of the structure and a heat gain calculation 'must be made.A heat gain calculation involves identifying all surfaces and openings that gain heat from the surrounding air and quantifying that heat gain. The heat calculation also calculates the extra heaty load caused by sunlight and by humidity removal.These factors must be considered before selection 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 cooling load: The cooling-load calculation determines the unit size: There are two -capacities that enable the equipment to provide comfort. The first is sensible capacity. Sensible heat is the heat energy measured on the dry bulb thermometer. • The second form of heat is called latent heat. This is heat held'by the moisture in the air. Removing this moisture does not affect a thermometer. However, removing the latent heat in the'air greatly increase comfort. A properly sized-unit, removes both forms of heat, producing a comfortable conditions, An oversized system cycles on and off quickly and does not properly remove-humidify, producing uncomfortable. The indoor and outdoor equipment combination,should be matched by the manufacturer .and based on engineering-data. After the proper equipment combination has been selected, satisfying both sensible and latent conditioning requirements, the system must be properly installed. Proper installation with cerefully distributed air through adequate duct work_will provided a comfortable living space. There are several factors thatinstallers must consider. ' •' Outdoor unit location • Proper equipment evacuation, If Outdoor unit refrigerant charge - • Indoor unit air flow - - - • Indoor unit blower speed _ • Supply and.return air duct design and sizing - , , • System air balancing • Diffuser and return air grille location and sizing , 11 Downloaded from www Manualshb corn manuals search engine I-Ia 1 e r Central Air Conditioner Model: Cooling Only, 13SEER units Unit Dimensions r IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIOil Nonni IIIII Haiec IIIIIIIIIIIIIIIIII1 � lIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII1 IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII 1IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII1111 I IIIII III I III IIIIIIIIIIII IIIIIIIIII IIII Model: HC18-60D1VAR ---D1VAR HC18 HC24 HC30 HC36 HC42 HC48 HC60 D 23-3/8" 30 5/8" 30 5/8" 30 5/8" 30 5/8" 30 5/8" 30 5/8" W 23-3/8" 30 5/8" 30 5/8" 30 5/8" . 30 5/8" 30 5/8" 30 5/8" H 32 1/5" 28 1/4" 32 3/16" 32 3/16" 32 3/16" 36 1/8" 40" Table 6-1 Piston sizes and indoor fan speed: - Note:the piston is placed in the outdoor unit package box Outdoor unit Indoor coil model Piston Indoor fan Size motor speed HC18D1VAR HB2400VD1M20 HB2400VD1V20 0.073 M HC24D1VAR HB2400VD2M20 HB2400VD2V20 0.073 H HC30D1VAR HB3600VD1M22 HB3600VD1V22 0.078 M HC36D1VAR HB3600VD2M22 -HB3600VD2V22 0.091 H HC42D1VAR HB4800VD1M22 HB4800VD1V22 0.087 M HC48D1VAR HB4800VD2M22 HB4800VD2V22 0.097 H HC60D1VAR HB6000VD1M22 HB6000VD1V22 0.096 H HB6000VD2M22 HB6000VD2V22 I Table 6-2 Piston size The air distribution system has the greatest effect. On the quality of the installation and the owner satisfaction, the duct system is totally in the responsibility of the contractor.These are numerous thchnical associations and reference that recommend correct procedures. The correct air quantity is critical for correct air conditioning system.Proper operation,efficiency,compressor life and humidity control depend on the correct balance between indoor load and outdoor unit capacity. High indoor air flow reduces system dehumidification capacity, and can leave the space humid and uncomfoltable. Low indoor air flow reduces total capacity, and can causes coil icing. Improper air balance will affect system performance and customer's satisfaction and can cause premature component failure. Air conditioning requires a specified air flow. Each ton of air conditioning requires 400 cubic feet of air per minute(400CFM/TON). Duct design and construction should be done with care. System performance' can be lowered dramatically through bad planning or workmanship. In cooling, a hot attic can cause a temperature gain of 3° in the return duct and 4° in the supply duct. This can reduce the cooling capacity of an air conditioning system by as much as 30%.This means a loss of almost one ton of cooling capacity from a three ton system. 12 Downloaded from www.Manualshb corn manuals search engine Hailer Central Air Conditioner Model: Cooling Only, 13SEER units ,Air leakage of only 3% in a return duct can cause a 5% loss in system capacity. 3% leakage on a three ton system is only 30 CFM.Two or three unsealed joints can cause a leak of this size. Sealing the return and supply ducts result in full system capacity and lower operating costs. Effective duct insulation is essential to prevent loss of capacity and sweating ducts in the cooling mode. -Duct systems installed in the'conditioned space can be leftuninsulated , but a dense 1/2"fiberglass duct liner reduces blower and air noises,and prevents sweating ducts when humidity levels are high. Supply and return duct systems in attics and crawl spaces require a minimum 1'of dense duct liner or 2" • fiberglass wrap with a sealed vapor barrier. A leaky vapor barrier results in duct sweating, causing wet insulation does not insulated. - - Heat transfer through poorly insulated systems can result in over 50%loss in operating capacity. Sweating ducts also results in rusting that leads to premature duct failure. Carefully follow the industry practices to insure a well designed duct system. - 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 air flow, they can be noisy. If they are not located,properly,they can cause drafts in the rooms. 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 air flow to all rooms in the home. This ensures a comfortable living space. 7. INSTALLATION INSTRUCTIONS = . !WARNING - These instructions are intended as an aid to qualified,service and instalolation personnel for proper installation - adjustment and operation of this unit. Read these instructions thoroughly before attempting installation or service this equipment. Failure to follow these instructions may result in improper installation, service or maintenance and could possibly result in fire, electrical shock, property damage. This product is designed and manufactured to permit installation in accordance with National Codes. It is the installer's responsibility to install the product in accordance with National Codes and/or prevailing local codes and regulations. The manufacturer assumes no responsibility for equipment installed in violation of any codes or regulations. The United States Environmental Protection Agency (EPA) has issued various regulations regarding the introduction and disposal of refrigerants from this unit.Failure to follow these regulations may harm the environment and can lead to the imposition of substantial fines. Because these regulations are subject to revision any repair on this unit should be_done by a certified technician. The manufacturer's warranty does not cover any damage failure caused by the air conditioning system. You should be'aware that the use of unauthorized components, accessories or devices may adversely affect the operation•of the air conditioner and may also endanger life and property. The manufacturer disclaims-any responsibility for loss or injury due to the use of such unauthorized components, accessories or devices.Attach the service panel to the outdoor unit after to prevent. If the service panel is not attached securely, it could result in a fire or an electric shock-due to dust, water, etc. - • , 7.1 OUTDOOR UNIT INSPECTION ' This product has been inspected at the factory and released for shipment without known damage. Inspect exterior of carton for evidence of rough handling in shipment. Unpack carefully. If damage is found, report immediately to you distributor or the transportation,agency. • 7.2 EQUIPMENT PROTECTION FROM ENVIRONMENT - The metal parts of the unit may be subject to rust or corrosion in adverse environmental.conditions.,This oxidation could shorten the unit life. Salt spray 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 are especially corrosive. ' Downloaded from www Manualslib corn manuals search engine _ , _ .. . _ ., , . , . , , _ . .. . -Ha ie( Central Air Conditioner Model: Cooling Only, 13SEER units 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 fence or shrubs may give some protection. - -, • Regular maintenance will reduce the buildup of contaminants and help.to protect the unit's finish. . !-WARNING- Disconhect-all electrical power to the unit before servicing.-Disconnect power to both the indoor and outdoor units. , . . NOTE There may be more than one electrical disconnect switch. Failure to shut off power can cause - - ,electrical shock resulting in personal injury or death. - • (1) Frequent washing of the,cabinet,"fan blade and coil with fresh water. (2) Regular cleaning and waxing of the cabinet with automobile wax. - - (3) An'appropriate coil cleaner may be used once per year to-remove matter that will not wash off ' with water. - .. , ._ - - - .' . The best protection is frequent cleaning and avoiding exposure to debris that blocks airflow., - -7.3'INSTALLATION ' • These units are designed for-outdoor installation., They can be mounted on a slab or rooftop. It is - ' - the installer's responsibility to insure that the unit is installed`in accordance-with all local codes. - -, . Check the following points before begining any installation:, Structural strength of supporting members. :" Clearances and provision for servicing. - , , _ - Power supply and wiring. . - _ Consideration be given so that operating soundswill not disturb owner or•neighbors. , Location with no risk of,combustible gas leakage. - - . , . .Location where natural water drainage,does not collect aroundtheunit. , , .Location where roof runoff does not pour directly on the unit. , • Provide gutters or other shielding at roof level. - , Avdid locating the unit in an area where excessive snow can accomulate or drifting occur. - Locate unit on a level concrete slab or prefabricate pad.To prevent transmission of noise or vibration, • . ' . "slab should not be connected-to building structure. Some sort'of_sound-absorbing material such as " rubber and cork pad should be placed between the condenser and-the slab. ' , For rooftop application,-make sure the,building construction can support the weight and,that-proper' _consideration is given to the weather-tight integrity of the roof. The condensing unit contains moving ' parts and can vibrate, so, sound,transmission is also,a consideration in rooftop applications. " !.WARNING - Install the unit securely in a place that can bear the weight of the unit.When installed in an insufficiently strong place,the unit could fall causing injury. - , 14 , Downloaded from www Manualshb coni manuals search engme . - Hailer .Central Air Conditioner ,Model: Cooling Only, 13SEER units 7.4.UNIT CLEARANCES °e e,0„;„AQ 10°Mln. o ' 4.4 vo e 4 a a eo y 1 v v Service Access— 10°Minim 18°Min. Service Access—�.j .1 O I�11k 10411--- 18" Min- f�e� V® °I I 1I 11 Jil VIII 6 0 O 10° A o -P° o a C °^ Q ° b0 — dQ ° D0 o° Fig. 7-1 The minimum clearances for the unit are shown in Fig.8--1.Condenser air enters from all(4)sides.Air discharges upward from the top of the unit. Refrigerant line and'electrical connections are made from the service access area.A typical application will find the unit located about 10"from wall with connection side facing this wall.This application minimizes exposed tubing and wiring and minimizes the traffic around the unit-reducing subsequent damage to the installation. When necessary for confined applications,,provide a minimum of 10"clearance oh all air inlet sides. For service access-to the compressor and control box, allow 18" minimum clearance. Ensure top discharged free from unobstructions. If units must be located under an overhang,there should be a minimum of 36"clearance and provision made to deflect the warm discharge air out from the overhang. In order to maintain design air flow,owners should,be advised to avoid lawn clippings from depositing on the fin coil surface and reducing the system performance.- - - 7.5 REFRIGERANT PIPING • Properly sized and installed refrigerant piping is very important for the efficient operation of the air conditioning system. Note the following guidelines: 1. The total run, both vertical and horizontal,should be less than 50 feet or line size correction may be necessary. 2. If the vertical separation exceeds 10 feet use the next larger liquid line size . OUTDOOR UNIT - �����;' WHEN INDOOR UNIT IS 4 FEET OR ■n, 30 MORE BELOW OUTDOOR UNIT,A 14■46141 SUCTION LINE OIL TRAP IS REQUIRED taePITCH SUCTION UNE TOWARD OUTDOOR ii i i PROVDE ADDITIONAL TRAPS FOR UNIT 117 FOR EVERY 10'OF LINE u<i EMZSa .a G:A A■ EVE'Y 20 FEET OF LIFT ■iia W1 INDOOR UNIT ABOVE OR 70' 1•1•s�17 0!■gl■ LEVEL TO OUTDOOR UNIT G ,o►iu MAX LIQUID LINE rip•rpa aad INDOOR UNrr OUTDOOR UNIT LIQUID UNE INDOOR UNIT _ INDOOR UNIT BELOW OUTDOOR UNIT Figure A Figure B 15 Downloaded from www.Manualslib.com manuals search engine ' ,.. . • ■ , _ , . . I-Ia re r - Central Air Conditioner " Model: Cooling'drily; 13SEER units • 6' . , INVERTED LOOP 4 I , LIQUID LINE - , " - INDOOR UNIT OUTDOOR UNIT - LU - ■■r�airz MAX - cgr�r�� rffliEMPreM , GtOaoai SUCTION LINE ` X44 , ' Figure C Fig. 7-2 ' Only refrigeration-grade copper piping (dehydrated and sealed)should be used.Take extreme care to keep the refrigerant tubing clean and dry priorto and during installation. If there is any doubt on the cleaness of the piping, blow out the line with dry nitrogen to remove any chips or debris before connection . are made.Always keep tubing sealed until the connections are to be made. , Refrigerant piping should be as short as possible,with a minimum'of elbows'or behds,to avoid capacity loss and increased operating costs., - " " Refrigerant lines must be adequately supported. If metal strapping is used to secure the tubing, do not = allow the strapping to directly,contact the tubing. Use a closed'oell insulation to separate the strapping from the tubing. Do not kink or twist the tubing. , Refrigerant piping should not be installed in a cement slab,as this limits access to the refrigerant should _ , a leak be suspected. - Note:To ensure good oil return to the compressor, it is important topitch the horizontal suction , - line toward the compressor,approximately 1/2"for every 10'of line. - - 7.6 LINE INSULATION - Suction line must be insulated in order to prevent condensation from forming on the piping and to reduce heat gain from the surrounding air. Generally 3/8"wall thickness of Armaflex or equivalent is satisfactory. In severe applications(hot, high humidity areas)greater thickness may be required.Apply the suction-line insulation by sliding it on the sealed tubing before cutting and making connections. Liquid lines do not necessarily need insulation, however, if they are run in high ambient spaces such as kitchens, boiler rooms, hot attics or on the roof, then, they should be insulated as well. Make sure to use proper size copper tubing for the liquid line to prevent liquid refrigerant flashing. . Keep the vapor line and liquid line seperated. To.prevent an undesirable heat transfer and capacity loss. , Refrigerant Line Sizing - • - ' Check the following table (Table 7-1)for correct suction and liquid line sizes for any combination of the . unit size and the maximum refrigerant line length. , 16 • Downloaded from www Manualshb corn manuals search engine - ' - Fla i e r Central.Air Conditioner, Model: Cooling Only, 13SEER units Refrigerant Line Sizing .Refrigerant Line Length (Ft) Unit Size 0—24 25—.49 50-74_ (Ton) Line Outside Diameter(In) Suction Liquid Suction Liquid Suction Liquid 1.5 , 3/4 3/8 3/4 3/8 7/8 1/2 2.0 . 3/4 3/8 3/4 .- 3/8 7/8 - 1/2 2.5 3/4 3/8 3/4 3/8 7/8 1/2 3.0 3/4 3/8 '3/4 ,3/8 . _ 7/8 ,1/2 3.5 7/8 3/8 11/8 - 3/8 11/8. 1/2 4.0 7/8 3/8 11/8 3/8 11/8 1/2 5.0 7/8 3/8 11/8 3/8 11/8 1/2 Table 7-1 - The factory charge-is sufficient for 25 feet of standard liquid line: For longer or shorter liquid line - lengths,adjust the charge as follows: 1/4" Line +/-0.3 oz. Per foot 5/16" Line +/-,0.4 oz. Per foot 3/8" Line +/-0.6 oz. Per foot 1/2" Line +/- 1.2 oz. Per foot. Vertical Separation between Indoor and Outdoor Units- Maximum allowable'vertical separations between indoor and outdoor units are illustrated in Fig, 7-2-C and Fig.7-2-B. It's 70'when the indoor unit is`below the,outdoor unit(Fig.7-3-B),and 50' when the indoor unit is above the outdoor unit(Fig. 7-2-B) .0 - To ensure good oil return to the compressor when,the in_door unit is below the outdoor unit, suction line oil trap should be used as illustrated in Fig. 7-2-B. Interconnecting piping - ! CAUTION -Use caution when removing the service valves caps from the suction and liquid line fittings,as there is pressure present.A fitting is on the liquid line to remove pressure. ! CAUTION - Condensing units ship from the factory with an operating refrigerant charge. Heat pump unit liquid and suction valves are closed to contain the charge within the unit. Do not force the valve stem against the retaining ring. If the valve stem is backed out past the retaining ring, system pressure could force the valve stem out of the valve body and possibly cause personal injury. Instructions on the interconnecting piping and valve opening procedure are listed below: 1.Tubing should be cut square. Make sure it is round and free of burrs at the connecting ends. Clean the tubing to prevent contamination from entering the system. 2.Make sure that both refrigerant shutoff valves at the outdoor unit are closed. 3.Push the tubing into the fitting until it stops.This prevents flux from getting into the system. 4.Remove the cap and Schrader valve core from the service port to protect the valve seals. 5.Wrap a wet rag around the valve stub before brazing. 6. Braze the joints of interconnecting piping. purge piping with dry nitrogen through the shutoff valve port while brazing. - 7.After brazing quench with a wet rag to cool the joint. Reinstall the Schrader core in the valve, if removed for brazing. 17 Downloaded from www Manualslib corn manuals search engine . , . . , . . . . Fia iet Central Air�Conditioner- Model: Cooling Only,73SEER units 8.Pressurize the lines to 150 psi maximum with dry nitrogen. Check for leaks at all joints with liquid detergent. If a leak is found, repair it after removing the nitrogen. Repeat the process and re-check. 9.Do not purge the lines with refrigerant. Evacuation - All refrigerant systems must be evacuated to a deep vacuum to remove all noncondensible gases and moisture priorto charging the system. Air in a system increases condensing pressure, which increases power consumption and reduces performance.The presence of moisture in a system leads to premature failure. Proper evacuation assures a dry; uncontaminated system. ' Recommended Evacuation Procedure: - - . - 1.Connect vacuumpumpto both liquid and suction valve service ports. - 2.Evacuate the interconnecting tubing and indoor coil to a level of 500 microns or less orfor a minimum of 30 minutes.Close the valve to the vacuum pump and wait 15 minutes.The vacuum should not rise above 800 microns. If unable to obtain-500 microns, or vacuum rises above 800 microns after a 15'minutes period, discontinue evacuation, pressurize and check for leaks. Repair any leaks found and repeat the step 2. . 3.Close valve to the vacuum pump and stop pump. - 4.When sure of a tight,well evacuated system, charge with refrigerant. - - " 7.7 Charging the System . - _ -, _ (For systems with capillary tube or fixed orifice metering device) - Before checking the system charge, make sure that the outdoor unit and indoor coil are an approved match system. For,best result,the indoor conditions should be within 2 F of the desired comfort conditions. ! WARNING - Do not vent refrigerant to-the atmosphere! It is a violation of federal law to do so. If the refrigerant needs to be removed from a system to correct the system charge, always usea recovery . - - or recycling device. - ! WARNING ._ Service refrigerant carefully, high pressure are present. - • - 1.Fully open both shutoff valves. . - 2.Connect service gage manifold to the valve service ports, being sure to evacuate lines. - 3.Startup the system. Run system at,least 10 minutes to allow pressure to stabilize. - - 4.Temporarily install a thermometer on the vapor line near outdoor unit. Be sure of good contact between thermometer and line.Wrap thermometer with insulating material to assure accurate reading. 5.Refer to Table 7-2 for proper system superheat.Add charge to lower superheat. Remove charge to raise superheat. Carefully remove guage. , - >s - - " . Downloaded from www Manualshb corn manuals search engine ' _ Haile( Central Air Conditioner Model: Cooling Only, 13SEER units . • System Superheat Ambient Return Air Temperature (`F) - Temperature At , Condenser Inlet 65 70 75 80 ' _ 85 (T) 60 :17 25 30 33 37 65 13 19 • 26 '32- 35- 70 5 14- 20 , 28 " 32 75• . . 5 10 , " .17 25 „ 29 .. - 80 - - 5: , ' 12 21 26 85 - 5 10 17 20 90 ' - 7 12 18 , 95 - , • 5 5 - • 5 100 - 5 , 5- Table 7-2:Svstem charging table by superheat , 7.8 ELECTRICAL WIRING , ! WARNING , A means of strain relief must be installed to this appliance at the electricaservice entrance. The interconnecting wires between indoor and outdoor units must be in accordance with the national electric code and all code regulations. Failure to follow these codes or the use of unsupported practices 'or procedures, could result in damage or personal injury or death. - ' - Do not use temporary power cords and do not connect multiple devices to the same electric circuit. Such could cause a fire or an electric shock due to circuit overloads. All electrical work should be performed by knowledgeable personals according to national codes,and in accordance with this installationmanual., ” Ground the unit.According to the national electric code. " Electrical installation consists of power supply wiring to the condensing unit and control wiring between thermostat, indoor unit and the condensing unit. All wiring must be in accordance with`National Electrical Code and/or local ordinances that may apply. ' (See unit wiring diagram furnished with this instruction). The condensing unit rating plate andthetables of"Physical and Electrical Specifications/Outdoor Units" (Table 2-1 and 2-2)provide pertinent data necessary for the selection of proper`size electrical service and over-current protection devices. " ' - Table 7-3 provides data on'the minimum copper wire size as a function of supply wire length and circuit ampacity. • 19 ' Downloaded from www Manualshb corn manuals search engine , . „ .. , . . . , _ ' -, .-.. ' ' " I-Ia ief Central Air Conditioner ' Model: Cooling Only, 13SEER units Copper Wire,Size-.AWG - _' ' (1%-Voltage Drop) - ,• Supply Circuit _ . _ • Supply'Wire Length-Ft - • _- Ampacity 50 •• - 100 . 150 200_ 15 - ` - 14 ,� 10 ' ' . 8 6 . - • - 20 12 - 8- " 6 - 4 25 10 •• 8 6 4 30 10 • 6 4 - 4 . 35 - - - 8 6 4 • - 3 . . ,40 8 6- 4- ' 2 - 45 _ 6 4 - • 3 2 _50 . - 6 - - - .4 - , 3 1 , Table7-3: Minimum Wire Size Based on N.E.C.for 60 C Type Copper Conductors Below - • 100-Ampacity. = - • • - The installer must be familiar with the location of the over-current protection, properly size for this' -this application and the proper procedure for disconnecting power service to the unit. - The location of the disconnect device must be.in accordance with local codes. _ . _ The outdoor.unit control.wiring requires a 24 Volt minimum, 25 VA service from the indoor - transformer as shown on the wiring diagram. , ' 7.9 SYSTEM STARTUP - , • - --t . : ' -- -. . , . -1.Turh thermostat to"OFF",turn on power'supply at disconnect"switch: ' 2.Turri temperature setting above the room temperature:- - - - - - - , , - - , - ; 3.Tum fan switch to"ON". Indoor blower should run.Be sure it is running in the right direction. _' 4.Turn fan switch to-"AUTO".'Turn system switch,to "COOL" and-turn temperature setting below - '- room temperature. Unit should run in cooling made. - ' - _ 5.Check to see if compressor and outdoor fan ale running correctly. ` - • 6.Check the refrigerant charge(see Instructions under"Charginq'the System."). ' I ' . 7.Replace service port caps. Service port cores are for system access only and will leak if not tightly capped. , - , - - , , 8.Check unit for tubing and sheet metal rattles. • - 9.Inst'uct the owner on operation and maintenance. - , Leave this"Installation and Operating Manual"andrthe"Use and Care Manual"with owner. - - ' 7.10 OPERATION:,, ' , , - _', :. - . - - SEQUENCE OF OPERATION . In order to service and troubleshoot a air conditioning system, ,The service technician must - , - understand the system's sequence of operation.This is the,order of events the system undergoes in ' response to.Understanding the sequence of operation aid in determining where to start troubleshooting when the unit doesn't operate properly. Deviation from the normal operation sequence will provide clues to system problems. ' . , - - - COOLING CYCLE , ' - ' Mechanical. The operation sequence is as follows: - - - - • 1. The compressor provides high pressure, superheated refrigerant vapor. , , ' -2. The vapor leaves the compressor and passes through the reversing valve. . - - 3. The vapor flows through the outdoor vapor line to the finned outdoor coil. Air from the outdoor fan removes heat from the. refrigerant vapor. When enough heat is removed, the vapor _ - , ,condenses into a high pressure Iiquid.The liquid temperature leaving the outdoor coil is slightly • warmer than ambient air temperature.- ' emperature.- 4. This warm, high pressure liquid leaves the outdoor coil, and flows through the small copper 20 _ ' , - - - -. Downloaded from-www Manualshb corn manuals search engine - • - , I-I a i e r Central Air Conditioner Model: Cooling Only, 13SEER units refrigerant liquid line. 5. At the end of the liquid line, the refrigerant passes through a fixed metering device, reducing pressure and temperature. 6. The liquid, under reduced pressure, then enters the indoor coil surface it expands and absorbs heat from the indoor air passing over the finned surface. Heat from the indoor air, causes the low pressure liquid to evaporate and cool the indoor air.The refrigerant has now been converted to cool vapor 7. The cool refrigerant vapor travels through the larger, insulated vapor line to the accumulator. 8. The accumulator separates any liquid refrigerant and holds it. Only vapor refrigerant and refrigerant oil leave the accumulator. The oil is drawn out through a special port inside the accumulator. - 9. Refrigerant vapor flows through the suction line to the intake of the compressor. The cycle then repeats. - Electrical .The operation cycle as follows: - 1. The thermostat calls for-cooling when the space temperature is•above the set point. 2. This sends a 24 voltage signal through the"Y"terminal to the outdoor unit PCB,"after 3 minutes the compressor contact in the outdoor unit are closed.The compressor and outdoor fan start. 3. At the same time, a 24 Voltage signal flows through the"G"Terminal to the air handler PCB and indoor blower starts. 4. The cooling system is now in operation. - 5. The thermostat satisfies and ends the call for cooling. 6. This ends the 24 Voltage signal to the compressor start kit and the outdoor unit stops. 7. This ends the 24 voltage signal to the indoor blower relay and this indoor blower strips 8. The system is now off. 8. MAINTENANCE INSTRUCTIONS FILTERS WARNING: DISCONNECT MAIN ELECTRICAL POWER TO THE:UNIT BEFORE ATTEMPTING ANY SERVICE OR MAINTENANCE. • - 1. The air conditioning system operates must efficiently with clean air filters, check filters monthly to determine how frequently your filters need be'cleaned. A new home require more frequent filter attention until dust and fibers from the construction,is removed. - 2. Replace glass fiber filters when dirty. • 3. Clean semi-permanent plastic impregnated fiber filters : A. Vacuum clean; or B:Wash with detergent and water, air dry thoroughly and re-install. Caution: Do not operate any system without filters Note: if an electronic air cleaner is installed, remove any mechanical filter from the air handler. Follow the installation and maintenance instructions furnished with the electronic cleaner. - OUTDOOR COIL CLEANING Keep the outdoor coil clean for'full air flow and proper operation .Do not allow leaves, grass clippings or other material to obstruct the coil. Do not allow anything to block the coil. Keep fences, shrubs, or other obstructions at least 24"away from the coil,air inlets. If the coil becomes obstructed or dirty, it may be necessary to clean the coil. - • • A. Before cleaning coil,TURN OFF ELECTRICAL POWER to the outdoor unit. B. Remove the top with the outdoor fan attached. C. Flush water through the coil from the inside out. • - NOTE: Avoid getting water on any controls or other electrical-devices. If electrical components get wet,dry it thoroughly before energizing. There are many commercial-coil cleaning materials developed to clean,outddor coils. Follow the manufacturer's instructions when using these marterials. Normally thesolvent is sprayed onto the coil. Allow several minutes for the solvent to dissolve any organic matter.Wash away the solvent and any dissolved matter with water from a garden hose., - 21 Downloaded from www Manualshb com manuals search engine F-Ia i e Central Air Conditioner. Model: Cooling Only, 13SEER units NEVER USE A WEATHER COVER OVER THE OUTDOOR UNIT.-The unit is designed to operate- outdoors. A perate"outdoors.•A cover traps moisture in the unit causing rust and corrosion .Thereis-the added danger of starting the system with the'cover on. This prevent air flow through the outdoor coil causing dangerous system pressure .Compressor damage may result. - - ,9. SERVICE AND TROUBLESHOOTING WARNING: THE ABILITY TO PROPERLY PERFORM SERVICE,ON THIS EQUIPMENT REQUIRES EXPERIENCE, MECHANICAL SKILLS,TOOLS AND TEST EQUIPMENT.IF YOU ARE NOT QUALIFIED, DO NOT ATTEMPT TO PERFORM ANY SERVICE ON-THIS EQUIPMENT, CONSULT THE USER'S MANUAL FOR ROOTING MAINTENANCE THAT CAN BE DONE BY THE HOME OWNER. FAILURE TO FOLLOW THIS WARNING COULD RESULT IN POSSIBLE DAMAGE TO THE EQUIPMENT, SERIOUS PERSONAL INJURY,OR DEATH. , The HVAC industry, had'improved the efficiency of the products offered to consumers. New and more sophisticated mechanical and electronic features for achieving higher-efficiencies have been designed.The use of test equipment is now more critical than ever. 'In the servicing and troubleshooting section is information on compressors and other components and their test procedures. There are troubleshooting charts, charging charts, wiring diagrams and service guide charts. Included is list of suggested testequipment. This information can be uesed by the service technician to understand the installation and troubleshooting and operation ofthe currentfamilie of air conditioning.The procedures in this section are generic in content. Each product family incorporates some of these components. Be aware of this is a guide compiled from numerous sources. It can not take into consideration all conditions found in all installations. Note: Upon arrival at the job site, a sound first step is a review of the system installation to identify any obvioss problems,this Installation Manual should be used as a guide. REFRIGERANT RECOVERY - - , Refrigerant systems using chlorofluorocarbon (CFC) and Hydrochlorofluorocarbon (HCFC) refrigerants system are subject regulation by the clean air Act of 1990. This act prohibits the unrestricted release of refrigerant into the air. Proper charging of refrigerant system may`require removing some refrigerant when the system is overcharged.and is to be used by personnel with appropriate industry experience recover the excess refrigerant. Recovery means to collect the refrigerant in a special holding container. Recycling means to run the refrigerant through a filtering system to remove most particles and moisture. Reclaiming means to chemically reprocess the refrigerant to return it to its original purity. Recovering and recycling refrigerant is possible with the aid of mechanical devices made for the purpose .The recovery system is a compressor/pump assembly,which removes refrigerant from a system and safely stores it in a Department of Transportation (DOT) approved container until it is re-used or returned for reclaim. - The authors of the EPA regulations enforcing the Clean Air Act realized that an accidental release of the refrigerant may happen in the course of normal service. - _ - Always use procedures so asnot to release any refrigeran.When performing service on a refrigerant system, charging should. be done using the best service practices, ensuing that the least amount of refrigerant needed is used. " - Lines must be evacuated before charging with refrigerant.. ' , WARNING : IN ORDER TO COMPLAY WITH FEDERAL LAW, ALWAYS USE A RECOVERY/ - RECYCLINE DEVICE WHEN DOING REFRIGERANT SERVICE. TEST EQUIPMENT The following test equipment is recommended to properly service air conditioning equipment: - 1.A good quality volt/ohm meter; - - - 2.A two-channel temperature electronic thermometer; • ' . - - ' ' _ 3.A Magnetic Gauge(capable of reading to 3"W.C.) - - - • 4.A refrigerant pressure Gauge manifold set; - 5.A clamp-on ammeter. 22 . Downloaded from www.Manualshb.com manuals search engine , _ - - _ • Hailer Central Air Conditioner - Model: Cooling Only, 13SEER units • 6.An electronic leak detector or bottle of soap suds. 7.A micron meter(not shown) 8.A vacuum pump capable of pulling to"1000 microns; 9. Refrigerant recovery/recycling equipment '. 111 I 1,4 -., ......,•',..:•,---.. --....+..- \,- ,11-1. to ._ vacuum pump - Fig.9-1 Before beginning any troubleshooting procedure, complete the, following installation checklist. An equipment problem is sometimes caused by an improper installation. By completing this checklist the problem may be found and corrected. Make copies of the checklist and complete one for every air conditioning system call for your records. - 9.1 INSTALLATION AND SERVICE CHECKLIST (Refer to the unit installation instructions for the specifics) ELECTRICAL Correct the thermostat and subbase - Correct line voltage supplied to indoor and outdoor units Proper equipment ground to the electrical panel , Correct control voltage at outdoor unit and transformer adequate for all control voltage loads Proper disconnect switches and breakers for indoor and outdoor units Correct wire size for both indoor and outdoor units. . OUTDOOR UNIT INSTALLATION Unit level with proper clearances for air flow and service Proper elevation of outdoor unit ' Solid pad - Coil free from dirt and debris Unit charged according to manufacturer's instructions No evidence of refrigerant leaks REFRIGERANT LINES V v Proper length according to manufacturer's instructions Proper size according to manufacturer's instructions Large vapor line insulated' V V - V V ' No inadvertent oil traps and proper sloping No kinks or restrictions No evidence of refrigerant leaks INDOOR UNIT INSTALLATION V V . Adequate clearances for air flow and service . Proper supply and return air duct size and design V Air ducts sealed to prevent leakage Correct filter(s) .External static pressure inches W.C. Proper air flow(about 400 CFM per ton) Correct indoor coil and accessories 23 Downloaded from www Manualshb corn,manuals search engine . . , , . , . . I-Ia ie( " . Central Air Conditioner ' Model: Cooling Only, 13SEER units No evidence of refrigerant leaks - : - Condensate line piped with trap and vent - - • • - Horizontal drain pan installed in horizontal applications - - Auxiliary drain pan installed in horizontal applications =- - Auxiliary condensate line installed in horizontal application- _ CAPACITOR ELECTRICAL CHECK - - ; WARNING: ANY CAPACITOR SHOWING SIGNS OF LEAKAGE OR BULDGING MUST BE REPLACED IMMEDIATEDLY DO NOT OPERATE THE AIR_CONDITIONING SYSTEM WITH A CAPACITOR SHOWING THESE SIGNS. - Single-phase compressors require a run capacitor connected to the run-and start Windings.This puts the ' - two windings out of phase from one another and allows-the compressor motor to start..Use a capacitor tester to determine if the capacitor dielectric has broken down, or if the MFD value has changed: If a capacitor analyzer is not available, use a quality ohmmeter to check the resistance between the capacitor plates.- 1. Set the ohmmeter to the highest scale available 2. Discharge the capacitor by shorting the terminals with the blade of a screwdriver having an insulated handle. 3. Place the Ohmmeter probes on the capacitor terminals and observe: A. If the meter pointer moves towards zero, then gradually moves to higher ohm values, the ' capacitor is GOOD - B. If the meter pointer does not move,the Open capacitor is open and should be REPLACED. C. If the meter pointer goes toward ZERO ohms and stays at or near zero,the capacitor is shorted and should be replaced. - • ,.. 4. Replace any failed capacitor with a capacitor having the same MFD and voltage rating. ' COMPRESSOR START KITS - - '».j� M r, " Run capacitor Fig. 9-2 , Some compressors require the assistance of a hard start kit to start, it is urgest to consult the compressor manufactores recommendations for start kits. follow the manufactores installation information. ' ' WARNING:DISCONNECT ALL POWER' TO THE OUTDOOR UNIT BEFORE BEGINNING THIS TEST. - - - -• - - • MOTORS: - " . ELECTRICAL ' - . - The motors in both the outdoor unit and indoor unit are similar .Outdoor motors have one speed while indoor motors usually are multi-speed.All fan motors require a capacitor for the best-torque and efficiency • the motor is replaced, replace the capacitor at the same time. - - ' The fan motor has both "Run" and "Start"windings .Extended run windings furnish a choice of speeds with indoor products. Use an Ohmmeter to troubleshooting motors. - - _ 24 - - - - Downloaded from www Manualshb corn manuals search engine - - I-Ia i et - Central Air Conditioner Model: Cooling Only, 13SEER units r/Vi41*".` 4F ')ljit.t L S �r }J s t Indicator • Fig. 9-3 , ELECTRICAL CHECK TO TEST FAN MOTOR: • - ' 1. Be sure power is off to the motor. - 2. Disconnect the motor wires: - - - 3. Place one ohmmeter lead on common and the other-on start.The meter should show continuity. 4. Place one ohmmeter lead on common and the other on run.The meter should show continuity with less resistance. . 5. Leave one meter lead on common'and touch each remaining lead. Each should indicate continuity. 6. If a winding does not show continuity,the motor has failed and must be replaced. - 7. If the motor needs replacing, replace-the'capacitor as well. MECHANICAL - Fan motors can fail for a number of reasons, including failure bearing loss due to a lack of lubrication.This may be caused by excessive water. Lubrication can be washed out of permanently lubricate bearing. If amotor fails, replace it with cimilar motor having the same rotation horse power, RPM and electrical characteristics. CONDENSER FAN BLADE LOCATION - Dimension "A" will be from 2" to 4" depending on the unit model number. Be sure to check this dimension BEFORE removing the fan blade. Note: When parts combination-results in motor /blade interference ,the fan blade should be located to provide 1/8"motor/blade clearance. ; RELAYS ELECTRICAL OPERATION - - Contactor coils are made with copper wires wrapped around a steel core. When energized, the coil generates a magnetic field that moves the steel core to open or close the circuit contacts. Electrical continuity indicates a good coil. Relay coils use specific voltage. Using a contactor with the-wrong voltage coil will prevent the system from operating properly.This problem is avoided when using the proper replacement part for a failed component. _ • 1' Fig. 9-4 - Relay contacts are switches and can become pitted or corroded, creating resistance. Resistance can generate enough heat to weld the contacts together. Physical examination of the contacts 25 r ' Downloaded from www Manualshb com manuals search engine . . . • Central Air Conditioner ' _,,Model: Cooling Only, 13SEER units . .. • . . I'-Iaje( will reveal this problem.With sealed relays, use"an ohmmeter to test for open or closed,contacts. t 'Fig. 9-5, : ' ELECTRICAL CHECKS 1. BE SURE ALL THE ELECTRICAL POWER, IS OFF TO THE COMPONENT BEING , CHECKED. - 2. Remove at least one wire from the component being checked. _ V .3. Measure the resistance of the holding coil with an ohmmeter - V V A. A specific resistance indicates a-good holding coil. - - B. Infinite (co) resistance indicates a relay Vwith,an.open holding coil. REPLACE the defective relay with an appropriate service part. " . " 4. Measure the resistance across the normally closed (NC) relay contacts. - ` _ - .A. The resistance should be zero(0)ohms. , - .. - , - , B. If the resistance is more than 0.2 ohms the contacts are pitted. REPLACE this relay with - ' ' an appropriate service part. V V - 5. -Measure the resistance across the normally open (NO)relay contacts. , - A. The resistance should be Infinite(co) -V -B. 'If the resistance isn't Infinite(),.REPLACE this relay with an appropriate service part. MECHANICAL CHECKS . " . In relays ,mechanical faults are few. But check relay body for signs of physical,damage .,' AIR FLOW - - - , Indoor coil air flow in any air conditioning system is critical.Too much air and the system will not be able _ to suffers lack of dehumidify in cooling.insufficienta_it flow while"cooling may result in coil freeze up, excessive dehumifification and lost capacity. V Checking air flow is.the most important diagonistics a service technican can perform. Instructions are ' rrovided to show how to measure pressure drop across the coil. If pressure drop tables are available, they,indicate the cubic feet of air per minute(CFM)moving through the coil.An inclined manometer or magnehilic guage can be used for measurement. Vv _ A velometer measures the velocity of the air in feet per minute(FPM). If the area-of duct is known, the velometer reading times the area of duct(in square feet)calculates the air flow. - ' If the indoor unit has an electrical heater, air flow can be estimated by measuring the air temperature entering and leaving the heater and calculating the CFM. ' ' _ ' , vV - . _ _ CFM (Electrical Heater)=VOLTS X AMPS X 3.414' . _ • 1.08 XTEMP RISE COMPRESSOR AND SYSTEM FAULT DIAGNOSIS Compressor manufacturers state that maul of the compressors returned as defective have been misdiagnosed.To ensure that does no t-happeri,the technician must determine if the compressor has - failed or if another control has either failed,or stopped the-compressor from operating'after detecting a problem. The following procedures should help determine if the compressor has failed. - , ' ' _ Prior to'replacing a suspected failed compresso , a thorough check must be made of all existing electrical electrical components .If not done ,a replacement compressor might also failed or not operate at all " " WARNING:THE FOLLOWING PROCEDURES SHOULD ONLY BE ATTEMPTED BY QUALIFIED SERVICE TECHICIANS ' ' ' ' EQUIPPED WITH PROPER TOOLS,SAFTY PROCEDURES AND EQUIPMENT AND INSTRUMENTS TO PERFORM - THE DESCRIBED REPAIRS. V - • 26 , , - - ' . V Downloaded from www Manualshb corn manuals search engine- - -- - IIHaler Central Air Conditioner Model: Cooling Only, 13SEER units COMPRESSOR ELECTRICAL CHECKS Single-phase compressors use permanent split capacitor motors.There are two windings that connect at a common point at the"common"wiring terminal.The two windings are called"start"and"run".The start winding has the higher resistance and is connected in series with the capacitor. The run winding has the lower resistance and connects directly to the power supply from the compressor contactor. The design uses a protective device called an "internal overload". If compressor draws high amperages, for an anusually long time or temperatures in the compressor motor, it opens an internal circuit to stop the motor. - ELECTRICAL CHECK COMPRESSORS 1. Consult the unit'wiring'diagr`am. Confirm that all electrical wiring for the units is correct and that all wiring connections are right. - - 2. Measure the available line voltage .On the single phase 208/230Volt units ,this should be from 197 to 253 Volts. _ 3. Check for proper control voltage at the unit contractor coil . If this voltage is inadequate or is not present, refer to the wiring diagram or the compressor troubleshooting flow chart at the end of this section for possible causes. 4. Disconnect all power from the unit and visually inspect the compressor contactor for pitted or burned contacts. - A.This could indicate high or low voltage problems or improper start components. ,- B.check the contactor coil with an ohmmeter for a short or open circuit. - C. Replace the contactor if any fault is noted. 5.WITH THE ELECTRICAL POWER OFF, remove all power wires from the'compressor terminals, MARK THE ORIGINAL LOCATION OF EACH WIRE. A. Use an ohmmeter set for the highest scale to check for grounding between compressor motor terminals and a good clean ground such as the compressor shell or copper line. B.The resistance from any terminal to ground should exceed 1,000,000 ohms. 6.Use an ohmmeter set for the lowest scale and check the continuity of the motor windings.These ohm values are less than ten ohms and in some cases less than one ohm. A.The ohm reading from the RUN terminal to common terminal is the lowest reading measured between. compressor terminals, approxiamtely 1 ohm. - B. The ohm reading from the Start TERMINAL TO COMMON TERMINAL will be the middle ohm value • measured between the terminals and be approximately 2.0 to 3.0 ohms ' C. The ohm reading from the Start TERMINAL TO Run terminal will be the highest ohm value of the three measurements and will be approximately the sum of the first two measurements: EXAMPLE: A. Run to Common -1.0 Ohms , Start to Run -3.0 Ohms Start to Common -4.0 Ohms Conclusion compressor motor does not have open or shorted wincings: - B. Run to Common -00 Ohms - - Start to Run -3.0 Ohms - Start to Common -C° Ohms CONSLUSION COMPRESSOR COULD HAVE AN OPEN INTERNAL OVERLOAD-ALLOW THE COMPRESSOR MOTOR TO COOL AND THE INTERNAL OVERLOAD TO RESET,THEN RETEST. C. Run to Common -1.0 ohms - Start to Run -00 Ohms - Start to Common -03 Ohms - 27 Downloaded from www Manualslib corn manuals search engine - I-Ia ie( Central Air Conditioner Model: Cooling Only, 13SEER units OPEN COMPRESSOR START WINDING---REPLACE THE COMPRESSOR. 7.The resistance from'one winding terminal to any other terminal should be the same with three phase compressors. NOTE: on larger 208/230 volt compressors the ohm values could be as low as 0.10 ohms, THIS IS NOT A SHORTED WINDING .A winding is open if resistance measured is infinite().- , , -COMPRESSOR MECHANICAL CHECKS Compressors fail mechanically due to bearing failure,valve failure ,or damage to the internal suspension system. Bearing and valve failure is almost always caused by liquid refrigerant. COMPRESSORS ARE DESIGNED TO ONLY PUMP REFRIGERANT VAPOR. Liquid refrigerant damages the valves by deforming or breaking them. Liquid refrigerant also damages bearings by diluting or foaming the lubricating oil. SYSTEM PUMP DOWN This procedure tests the compressor valves. It can indicate internal refrigerant leaks such as through the liquid line service valve. The procedure uses'the compressor-to trap all the refrigerant inside the • condensing coil (outdoor cooling). The technician's gauges indicate if the, condensing coil holds the refrigerant as intended or if it leaks out. - Procedure 1. Connect the compound refrigerant gauge to a service port that reads suction pressure such as ' on the compressor shell, or in the line between accumulator.and compressor. Connect'the high pressure gauge to a service port that reads high pressure. - 2. With the unit operating, front seat (close) the liquid line service valve.-Observe the gauges .The suction pressure should fall. The high pressure should also fall slightly. If the discharge pressure rises above 400 psi, Shut off about outdoor unit. 3. SHUT OFF THE•COMPRESSOR WHEN THE SUCTION PRESSURE DROPS TO. 3-5 PSI. POSITIVE PRESSURE..DO NOT OPERATE THE COMPRESSOR WITH A NEGATIVE SUCTION PRESSURE OR IN A VACUUM. - 4. After pump down and compressor stops,observe the suction pressure on the compound gauge. A. The suction pressure holds as steady pressure.this is a normal condition.B. Suction pressure rises above the stopping point, but then stops and holds steady. Some refrigerant finally evaporating in the coil, and registering on the gauge.This is the normal condition.- C. Suction pressure conditions rise and eventually equalizes with the observed pressure on the high pressure guage. Abnormal condition. - - . Refrigerant is leaking'from the condenser coil . - - Causes :Leaking liquid line valve, leaking discharge- check valve (scroll compressors only ); leaking compressor valves. ACTION: Determine the causes and correct it. D. Unable to reach the 3-5 PSI level for suction pressure. This is an abnormal condition. Refrigerant is leaking from the condenser coil ., , . Causes.:Leaking liquid line valve, leaking discharge check valve (scroll compressors only ), leaking compressor valves. . ACTION: Determine the causes and correct it.. SYSTEM REFRIGERANT NONCONDENSIBILES CHECK . This procedure checks the quality of the refrigerant bycomparing the refrigerant pressure to its temperature. The test tells if there are contaminating non-condensable gases in the refrigerant, usually, air or moisture. 1. Pump the system down as the explained in the previous procedure. Open the unit disconnect to SHUT Down the system when the suction pressure drops to 3-5 psi positive pressure. 2. Front SEAT THE LARGE VAPOR LINE VALVE'. 3: Disconnect the compressor by REMOVING EACH WIRE FROM THE COMPRESSOR TERMINALS. MARK AND IDENTIFY THE WIRE TERMINALS WITH THE COPRESPONDING WIRE COLOR CODE WARNING :WRAP A LAYER OF INSULATION ELECTRICAL TAPE OVER THE WIRE TERMINALS,- (NOT THE-COMPRESSOR-TERMINALS) .THESE WIRE ENDS WILL BE AND GNERGISED HOT DURING THE REMINDER OF THE TEST. " 4. Close the disconnect switch to the system and run the condensing fan .Measure the condensing coil - • 28 - - ' - - - • Downloaded from www Manualshb corn manuals search engine - - - 1-Ia j e r Central Air Conditioner • Model: Cooling Only, 13SEER units entering and leaving air temperature with accurate thermometers. 5. Run'the condensing fan until the leaving air temperature equals to the entering air temperature.This is now the refrigerant temperature. ' 6. Compare the observed'refrigerant pressure shown on the high pressure gauge to its associated pressure on a temperature—pressure conversion chart. 7. The refrigerant pressure should equal the chart pressure for the observed temperature. A. The system pressure is above the chart pressure. Capital letters: Non-condensales are present - -air and/or moisture. ACTION: Remove and recover the refrigerant. Evacuate the system and charge with new and correct refrigerant. B. The system pressure is below the chart pressure. Capital letters: A mixed refrigerant is present: ACTION: Remove and recover the refrigerant. Evacuate the system and charge with new and correct refrigerant. - COMPRESSOR REMOVAL PROCEDURES USE THESE PROCEDURES ONLY WHEN YOU HAVE POSITIVELY DETERMINED THAT THE COMPRSSOR HAS EXPERIENCED A MECHANICAL AND/OR ELECTRICAL FAILURE. CAUTION:After a seveer,motor burn-out the products of the burn-out may be acidic.The technician should wear rubber gloves and eye protection to prevent injury when testing refrigerant oil. Use the following procedure for compressor removal ONLY after determining that the compressor has failed. - 1. DISCONNECT THE MAIN POWER SOURCE TO THE UNIT AND LOCK THE DISCONNECT SWITCH IN THE OPEN POSITION. - 2. Disconnect the electrical wiring at the compressor identifying each wire and its location. 3. Remove the refrigerant charge from the entire system using proper recovery procedures. 4. Remove the failed compressor.- A. Unsolder the suction and discharge lines at.the compressor stubs. B. Remove the compressor hold down bolts. - , C. Place the failed compressor on a•smooth surface to remove the mounting grommets and sleeves for use with the new compressor D. Prevent any contamination from entering the refrigerant.lines. 5. Conduct an acid,test on the oil from the failed compressor., A, Secure a generous sample of oil from the failed compressor. B. Follow the oil test kit instructions to determine the degree of compressor bum,out: . • As a general rule,oil with,a test number less than 0.05 indicates a mild bum put. • Oil with a test number greater than 0.05 indicates a severe burn-out. •Some oil test kits indicate severity by color change . •As a guide ,burn out classifications are as follows: oil clear, no color;the compressor may have.had a mechinial failure and not a burn-out. oil clear,slight color,the compressor may have had a mild burn-out. oil very dirty, strong odor test>0.05,the compressor may have,had,severe bum-out. Note: Dispose of any contaminated refrigerant oil in accordance with all environmental regulations and procedures. 6. - Use the following procedures with units suspected of having mild to severe burn outs. A. After compressor removal, insert a clean, lint free swab into the system's suction and discharge lines to'determine the extent of contamination. - B: If contamination is noted for a considerable depth, consider replacing the lines with new tubing. C. Confirm that the new compressor has no shipping damage. The line connections must come sealed from the factory.Verify that the replacement compressor is the same model number and electrical characteristics as the original. ' • , D. Place the new compressor in the unit and install the mounting bolts. E. Remove the caps fromthe compressor stubs, clean the lines and stubs, and braze joint together. F. If any burn detected replace the liquid line filter drier with an oversized core filter drier, if the burn was severe,-and a suction line filter drier. 29 Downloaded from www Manualshb corn manuals search engine, , , . . . . I-Ia• - Central Air Conditioner -' Model: Cooling Only, 13SEER units �e� . ,. Warnings: - - - - 1. TACK APPROPRIATE STEPS TO KEEP•CONTAMINATIONS OUT OF THE LINES,WHILE THESE LINE ARE OPEN TO ATMOSPHERE. - • 2. ' USE•A OFMINIMUM 5%SILVER FOR COPPER TO COPPERCONNECTIONS. , • USE A OF MINIMUM 35%SILVER FOR COPPER TO STEEL CONNECTIONS. . 3. WHEN BRAZING, PURGE DRY NITROGEN THROUGH THE LINES TO-PREVENT THE FORMATION OF OXIDES. - - - - G. Inspect all other components such as check valve and electrical components for proper ' operation. Replace any if necessary.- - - ' H. After all connections are made, open the service valves and pressurize to 150 psi with dry nitrogen, Leak test with liquid detergent. If a leak-is found, repair it after removing th'e nitrogen,and recheck. I. After leak testing ,recover any test refrigerant. - , - J. Keep with (A)subpoints. , Evacuate through both high and low side connections to the system. Evacuate to a level of 1500 microns twice and 500 microns-the last time. - , Break each vacuum with dry nitrogen to 3.0 psi. - Use the largest connections and hoses possible to'expedite the process: - K. Charge with clean, new or reclaimed R-22 refrigerant. Charge in accordance with proper charging procedures: . -, L. Re-check the system 24 hours of run-time to verify the unit is free of acid. • . 7. Other-Check Points - ' - - A. Verify the'operating voltage is within the specified range. , B. Check that all wiring connections are tight - - - C. Verify that all fuses or circuit breakers are of the proper type and operational. - D. Verify the air conditioning"operates properly in cooling. ' - - " - E. Inspect all the other electrical components.for proper operation. - - - - , F. Verify the thermostat and,subbase are correct;and operate properly. - - . G. Verify all ducts and air moving device are sized and_operate properly. ,' H. Verify-the refrigerant piping is sized-correctly and not pinched. , - I. Verify all-the system are in correct position. . 9.2-Troubleshooting Guide - - !-WARNING — Disconnect all electrical power to the unit before servicing. Disconnect power-to both the indoor and outdoor units. NOTE: There may be more than one electrical disconnect - - switch. Failure to shut off power can cause electrical shock resulting in personal injury or death. Symptom - Possible-Cause- - Remedy Power off or loose electrical Make sure main switch is ON. Check and - connection - tighten all connections. - - No coolmg/heating ' `Incorrect thermostat setting • Set thermostat correctly - - Defective 4-way valve - - check the valve coil or replace it Compressor without pump function replace it Dirty filters , -• - . . Clean&replace • - - . - Indoor air blockage - Check supply registers and return grills for blockage. - - - - ' _ - - Blocked outdoor coil . "- Clear away leaves and other debris Improperly sized unit - - Recalculate load - - - - - Insufficient Cooling ' Improper airflow• - . - 'Check—should be 400CFM/Ton Incorrect refrigerant charge ` Charge correctly per instruction., - Air,'non-condensable ar moisture in Recover refrigerant, evacuate & recharge, system - - add filter drier - -- Incorrect voltage - At compressor terminals, voltage must be , _ • within 10% of rating plate volts when unit is - - - running. - Water on floor or in Blocked condensate -drain and "P" Remove blockage and clean drain-lines,verify , furnace trap operation of- condensate pump. 30 - - _ Downloaded from www Manualshb com•manuals search engine - I-Ia i e( Central Air Conditioner Model: Cooling Only, 13SEER units furnace trap operation of condensate pump. Condenser fan and AC Contact not connected to the Re-connect the power supply wire, and , , compressor don't run power supply wire or not tightly fasten tightly fasten. The outdoor power supply main circuit Reset the power supply switch to" ON" switch in "OFF" position or fuse • position or change the fuse and confirm the blown on main circuit main power lead to the Contactor has voltage present. Check if the relay P2 of 3-minute-timer board have current output,if not,check if P1, P3 have 24 V AC input , if have 24V AC , please check if it keep for 3 minutes, if so The control coil of AC Contactor no 24 and P2 no output , change the 3-minute VAC power timer board; if keep time<3 minutes , P2 no output ; if P1 P3 no24V AC, first • check the thermostat C Y terminal have 24 V AC, if no 24 V AC, then check the thermostat or reset the setting temp.;if have 24 V AC ,check if the C Y and P1, P3 connection wire cut off or fasten loosely, if cut off , then change the parts. _Run or start capacitor defective Replace Loose connection Check and tighten all connections. Compressor stuck, grounded or open Wait for 2 hours for overload to reset. Condenser fan runs, -motor winding,open internal overload Replace compressor if still open. compressor doesn't Low voltage condition - At compressor terminals, voltage must be within 10% of rating plate volts when unit is running. Low voltage condition Add start kit components Compressor runs, Run capacitor defective Replace • Condenser fan Loose connection Check and tighten all connections. doesn't Fan stuck, grounded or open motor Wait for 2 hours for overload to reset. winding,open internal overload Replace Fan if still open. - Low voltage condition At compressor terminals, voltage must be within 10% of rating plate volts when unit is running. Defective overload protector Replace—check for correct voltage Refrigerant undercharge Add refrigerant Register sweat Low evaporator airflow . Increase blower speed or reduce restriction —replace air filter Restriction in liquid line, metering Replace defective components High head — Low device or filter drier - _ vapor pressures Flowrator piston size too small Change to correct size piston- Incorrect capillary tubes Change coil assembly - - Blocked outdoor coil ' Clear away leaves and other debris High head — High or Refrigerant overcharge Correct system charge normal vapor Condenser fan not running Repair or replace pressures - Air, non-condensibles or moisture in' Recover refrigerant, evacuate & recharge,. system • - • • • add filter drier Low head — High Flowcheck piston size too large Change to correct size piston - vapor pressures Defective compressor valves Replace compressor Incorrect capillary tubes Replace coil assembly Low evaporator airflow Increase blower speed or reduce restriction Low vapor — cool —replace air filter compressor — iced -Operating below 65°F outdoors Add low ambient kit evaporator coil Moisture in the system Recover refngerant, evacuate & recharge, add filter drier High vapor pressure Excessive load Recheck load calculation Defective compressor Replace Fluctuating head and Air or non-condensibles in system Recover refrigerant,evacuate&recharge. vapor pressures Pulsing noise at Air or non-condensibles in system Recover refrigerant,evacuate&recharge metering device or liquid line 31 Downloaded from www Manualshb corn manuals search engine • I-Ia ie f - , .Central Air Conditioner-. Model: Cooling;Only,13SEER units - ' 10.-WIRING DIAGRAM - - - , . Air-Conditioner.. iring.Diagram 0010526552 I -_ . - I i INDOOR_ r-- - - - •-I I FACTORY ATANDARD GE OUTDOOR UNIT - :� I I UNIT erf1OMu. I FIELD INSTALLED - I - I I © I I !■■ LI -..i mum=Kum ocri 1 LPW VO T - - CMPR 4 I 'I r-,�'y OFM '© I I I eK- 1 LOW VOLTAGE - FACTORY STANDARD ' I L I �I a I"-'1 - r-•(--�D,�1 ••• I FIELD DI9TALLED - I -RCMt;1 ; , tv•�@ 'I I I (y_"'7 rl !OPTIONAL _ _ , 1 •al I I 11 0.< .1 USE COPPER CONDUCTORS ONLY 0 O� 1 1 I i I I I c 1 WARNING CABINET Muer BE PERMANENTLY GROUNDED I® O _ j ;® 1 • •-'_- I 1 - II ea - IAND ALL WIRING TO CONFORM TO LEC.,ILEC.,CEC. 1 _ 1•C'J 1• I I I I I CAC.AND LOCAL CODES AS APPLICABLE `' LYEAP_(J 1 I II ^' 1 REPLACEMENT WIRE MUST BE THE SAME GAGE AND ' - - 1 2081230V 11 f 7)07 6 - INSULATION TYPE AS ORIGIiALwmE I`- CC ! 60H21PH - :L - J i COMPONENT CODES - I I LI aK - I I SCR•BLOWER CONTROL RELAY - I _L7 SK _ .G I I yr---- Qr I BCAP•RUN CAPACITOR BLOWER MOTOR L2 ren _ ,m - I, -RH M CC•COMPRESSOR CONTACTOR - GNP ,O.ODO©:O I CCH-CRANKCASE HEATER(OPf10NAL) GND - ' I !CHS•CRANKCASE HEATER SWITCH(OP710NAL) I BCR ICMPR•COMPRF-CO -. '208/230V I I Ij NC n �2 1 HPS-HIGH PRESSURE SWITCH _ !6OH2'IPH s` I I d No �, ACPs-Low PRESSURE SNfITCH . 1 . I kril IBM-I DOOR BLOWER MOTOR1 Campreeew , I_ .c" al CON n..1 �OFM•OUTDOOR FAN MOTOR' I I I I 1.'17: 3Mie.. I F op RCAF.-RUN CAPACITOR COMPRESSORRene Wtay I i WS-REVERSING VALVE SOLENOID I - _ ! I eIl` u.'� I STCAP•START CAPACITOR(OPTIONAL) I— ��■ ('STRLY-START RELAY(OPTIONAL) I _ '" - ' I 1 ■ i BIRTH•START THERMISTOR(OPTIONAL) - ' I - - 1 I® �� • j TITAN•TRANSFORMER I - i I I � �� 1230rlOa SELECTABLE - -1 y _ I �iii:. ill;I III iBK-BLCOLOR Cooq - BK•BLACK EL-BLUE '03Y-GRAY BR-BROWN GR•GREEN OR-ORANGE - ' I - l.aw ife>h _ I I I I WN-WHITE YL-YE110W RPLE zo-RED „•�� r i m� :'!THERMOSTAT •HEAT . 0© - . . - -I L___.___.___.__ 0 0 0 OOJ. -I EI COOL A O I - L •- - - - ..1 1 ON O. 'HEAT I -1, M1 1--e�r--- qy w�r+mm - - 1 mato ml_-_W OFF x I I - MODEM SWIM xavAe POMPON _ _ -- _ L 1 0 LED C I t)Confirm tryst=selection.Optional components may be field or factory Installed. . '- - -- . 2)if LPS nndfor HPS not Installed or removed,a Jumper win must be present across circuit for system to operate., 3)'For proper system operation,consult indoor unit and outdoor unit Installation Instructions to confirm system match up and blower speed selection. - - 4)Alternate double pole contactor used on some systems. ' S)Only one start assist method to be used ata time,consult outdoor unit Installation Instructions for applcetion Information.Use only factory approved accessories. 6)Optional OFM components may connect capacitor common and motor common,for reciprocating compressor there may have crankcase heater consult outdoor rmit Installation Instructions for detalls.Seloct the running capacltor(one or duagand connect!?IFM or OFM only have one capacitor,wfn,conneet Com wire to capacitor. - - ' 7)Indoor unit shipped without optional electric he kit.To Install optional heater kl,remove power pIg tail up to 9 pin plug.Install heater kit and Connect with meting 9 pin plug.Run system power connections directly to electric heater kit power tomdnais.Consult hooter kit Installation Instructions for complete details. Note:-The diagram wiring of the fan motor may be have some difference from the real parts due to • - - ' different types of fan motor,the detailed information can refer to the fan motor nameplate. - -Wiring diagram-Outdoor Unit (HC18D1VAR—HC60D1VAR). . 32 - - . Downloaded from www Manualshb corn manuals search engine - } • • • • • • • • . • 1 55, . . 5 38 9 1 0E • 316. 10 •I ----------.--------------"T• • ift cr) . • • . . Mi : . . . , • I •• •• • a)• .. . . • 1 ,,. •. • :....:...:.:. • • .. /iv i • • . . , Pk.. . 1 • . . o I vl 1 . . . . co . • • VIIp .Z .• r 1 . , i� ,... . cr, 04 ...,:, I , .. ( ._� c_;. (., 1- 1. I I iil 01) "1 . .......... \ . • • / 20.08' I ' ( • , , 4o85ccIZ , • N631159150v 3 23 . • - .. F�'r` ... ..i? f,C�l.'Fr., '. -.'_ - ..,..ten.. a .... .. • • STATESTREET — ,�,f,,� Y_. ,:su _� • • . .. . . . . . . , , . • . • . • "• • ,'LCC%�' ,. {,,jl` ?J i �,-E{ (�J. � ct 4 • - . , . . • ' • • . - - - - . . • , . . . . . • .I • • . • . . - • . . .. . • 1 . .. . . 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