18-BC85D1-2 Installer’s Guide Heat Pumps 4TWB3018–060 ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES IMPORTANT — This Document is customer property and is to remain with this unit. Please return to service information pack upon completion of work. These instructions do not cover all variations in systems or provide for every possible contingency to be met in connection with the installation. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to your installing dealer or local distributor. Note: The manufacturer recommends installing only approved matched indoor and outdoor systems. All of the manufacture’s split systems are AHRI rated only with TXV/EEV indoor systems. Some of the benefits of installing approved matched indoor and outdoor split systems are maximum efficiency, optimum performance and the best overall system reliability. Table of Contents Section 1. Safety...................................................................................... 2 Section 2. Unit Location Considerations.............................................. 3 Section 3. Unit Preparation..................................................................... 5 Section 4. Setting the Unit...................................................................... 5 Section 5. Refrigerant Line Considerations.......................................... 6 Section 6. Refrigerant Line Routing...................................................... 7 Section 7. Refrigerant Line Brazing....................................................... 8 Section 8. Refrigerant Line Leak Check.............................................. 10 Section 9. Evacuation............................................................................ 11 Section 10. Service Valves.................................................................... 11 Section 11. Electrical - Low Voltage..................................................... 13 Section 12. Electrical - High Voltage.................................................... 16 Section 13. Start Up............................................................................... 17 Section 14. System Charge Adjustment.............................................. 18 Section 15. Checkout Procedures and Troubleshooting.................... 23 Section 1. Safety ▲! WARNING This information is intended for use by individuals possessing adequate backgrounds of electrical and mechanical experience. Any attempt to repair a central air conditioning product may result in personal injury and/or property damage. The manufacture or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use. ▲! WARNING These units use R-410A refrigerant which operates at 50 to 70% higher pressures than R-22. Use only R-410A approved service equipment. Refrigerant cylinders are painted a “Rose” color to indicate the type of refrigerant and may contain a “dip” tube to allow for charging of liquid refrigerant into the system. All R-410A systems use a POE oil that readily absorbs moisture from the atmosphere. To limit this “hygroscopic” action, the system should remain sealed whenever possible. If a system has been open to the atmosphere for more than 4 hours, the compressor oil must be replaced. Never break a vacuum with air and always change the driers when opening the system for component replacement. For specific handling concerns with R-410A and POE oil reference Retrofit Bulletins SS-APG006-EN and APP-APG011-EN or APPAPG012-EN. ▲! WARNING LIVE ELECTRICAL COMPONENTS! During installation, testing, servicing, and troubleshooting of this product, it may be necessary to work with live electrical components. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury. ▲! CAUTION If using existing refrigerant lines make certain that all joints are brazed, not soldered. ! CAUTION ▲ Scroll compressor dome temperatures may be hot. Do not touch the top of compressor; it may cause minor to severe burning. ▲! WARNING UNIT CONTAINS R-410A REFRIGERANT! R-410A operating pressures exceed the limit of R-22. Proper service equipment is required. Failure to use proper service tools may result in equipment damage or personal injury. SERVICE USE ONLY R-410A REFRIGERANT AND APPROVED POE COMPRESSOR OIL. ▲! WARNING Extreme caution should be exercised when opening the Liquid Line Service Valve. Turn counterclockwise until the valve stem just touches the rolled edge. No torque is required. Failure to follow this warning will result in abrupt release of system charge and may result in personal injury and /or property damage. 218-BC85D1-2 Section 2. Unit Location Considerations 2.1 Unit Dimensions and Weight Table 2.1 Unit Dimensions and Weight Models H x D x W (in) Weight* (lb) 4TWB3018D 29 x 30 x 33 160 4TWB3024D 29 x 30 x 33 160 4TWB3030C 33 x 30 x 33 193 4TWB3036C 33 x 34 x 37 198 4TWB3042B 33 x 34 x 37 219 4TWB3048B 37 x 34 x 37 234 4TWB3060B 41 x 34 x 37 248 W H * Weight values are estimated. When mounting the outdoor unit on a roof, be sure the roof will support the unit’s weight. D Properly selected isolation is recommended to alleviate sound or vibration transmission to the building structure. 2.2 Refrigerant Piping Limits 1. The maximum length of refrigerant lines from outdoor to indoor unit should NOT exceed sixty (60) feet. 2. The maximum vertical change should not exceed sixty (60) feet. 3. Service valve connection diameters are shown in Table 5.1. Note: For line lengths greater than sixty (60) feet, Refer to Refrigerant Piping Application Guide, SS-APG006-EN or Refrigerant Piping Software Program, 32-3312-03 (or latest revision). Standard Line Set 60’ Max Line Length 60’ Max Vertical Change 60’ Max Vertical Change 18-BC85D1-2 3 2.3 Suggested Locations for Best Reliability Ensure the top discharge area is unrestricted for at least five (5) feet above the unit. Avoid Install Near Bedrooms Three (3) feet clearance must be provided in front of the control box (access panels) and any other side requiring service. It is not recommended to install in a location where noise may distract the building occupants. Some examples of these types of locations are sleeping quarters and by windows of a living area. Please discuss location with the building owner prior to installation. Min 5’ Unrestricted Min. 12” to Shrubbery Min 3’ Unrestricted Access Panel Avoid locations such as near windows where condensation and freezing defrost vapor can annoy a customer. Position the outdoor unit a minimum of 12” from any wall or surrounding shrubbery to ensure adequate airflow. Outdoor unit location must be far enough away from any structure to prevent excess roof runoff water or icicles from falling directly on the unit. Min. 12” to Shrubbery Min. 12” to Wall 2.4 Cold Climate Considerations NOTE: It is recommended that these precautions be taken for units being installed in areas where snow accumulation and prolonged below freezing temperatures occur. • Units should be elevated 3-12 inches above the pad or rooftop, depending on local weather. This additional height will allow drainage of snow and ice melted during defrost cycle prior to its refreezing. Ensure that drain holes in unit base pan are not obstructed preventing draining of defrost water. • If possible, avoid locations that are likely to accumulate snow drifts. If not possible, a snow drift barrier should be installed around the unit to prevent a build-up of snow on the sides of the unit. Min. 12” Snow Barrier Snow Legs 3-12” Elevation Pad 418-BC85D1-2 2.5 Coastal Considerations If installed within one mile of salt water, including seacoasts and inland waterways, models without factory supplied Seacoast Salt Shields require the addition of BAYSEAC001 (Seacoast Kit) at installation time. Section 3. Unit Preparation 3.1 Prepare The Unit For Installation STEP 1 - Check for damage and report promptly to the carrier any damage found to the unit. STEP 2 - To remove the unit from the pallet, remove tabs by cutting with a sharp tool. Section 4. Setting the Unit 4.1 Pad Installation When installing the unit on a support pad, such as a concrete slab, consider the following: • The pad should be at least 1” larger than the unit on all sides. • The pad must be separate from any structure. • The pad must be level. • The pad should be high enough above grade to allow for drainage. • The pad location must comply with National, State, and Local codes. 18-BC85D1-2 5 Section 5. Refrigerant Line Considerations 5.1 Refrigerant Line and Service Valve Connection Sizes Table 5.1 Line Sizes Service Valve Connection Sizes Model Vapor Line Liquid Line Vapor Line Connection Liquid Line Connection 4TWB3018D 5/8 3/8 5/8 3/8 4TWB3024D 5/8 3/8 5/8 3/8 4TWB3030C 3/4 3/8 3/4 3/8 4TWB3036C 3/4 3/8 3/4 3/8 4TWB3042B 3/4 3/8 3/4 3/8 4TWB3048B 7/8 3/8 7/8 3/8 4TWB3060B 7/8 3/8 7/8 3/8 5.2 Factory Charge Outdoor condensing units are factory charged with the system charge required for the outdoor condensing unit, fifteen (15) feet of tested connecting line, and the smallest indoor evaporative coil match. If connecting line length exceeds fifteen (15) feet and/or a larger indoor evaporative coil is installed, then final refrigerant charge adjustment is necessary. 5.3 Required Refrigerant Line Length Determine required line length and lift. You will need this later in STEP 2 of Section 14. Total Line Length = __________ Ft. Line Length Total Vertical Change (lift) = __________ Ft. 5.4 Refrigerant Line Insulation Important: The Vapor Line must always be insulated. DO NOT allow the Liquid Line and Vapor Line to come in direct (metal to metal) contact. Liquid Line Vapor Line Insulation 618-BC85D1-2 5.5 Reuse Existing Refrigerant Lines ▲! CAUTION If using existing refrigerant lines make certain that all joints are brazed, not soldered. For retrofit applications, where the existing indoor evaporator coil and/or refrigerant lines will be used, the following precautions should be taken: • Ensure that the indoor evaporator coil and refrigerant lines are the correct size. • Ensure that the refrigerant lines are free of leaks, acid, and oil. Important: For more information see publication numbers SS-APG006-EN. Section 6. Refrigerant Line Routing 6.1 Precautions Important: Take precautions to prevent noise within the building structure due to vibration transmission from the refrigerant lines. Comply with National, State, and Local Codes when isolating line sets from joists, rafters, walls, or other structural elements. For Example: • When the refrigerant lines have to be fastened to floor joists or other framing in a structure, use isolation type hangers. • Isolation hangers should also be used when refrigerant lines are run in stud spaces or enclosed ceilings. • Where the refrigerant lines run through a wall or sill, they should be insulated and isolated. • Isolate the lines from all ductwork. •Minimize the number of 90º turns. 8 Feet Maximum Joist/Rafter Isolator Side View 8 Feet Maximum Line Set Secure Vapor line from joists using isolators every 8 ft. Secure Liquid Line directly to Vapor line using tape, wire, or other appropriate method every 8 ft. Isolation From Joist/Rafter 18-BC85D1-2 7 8 Feet Maximum Wall Isolator 8 Feet Maximum Side View Line Set Secure Vapor Line using isolators every 8 ft. Secure Liquid Line directly to Vapor Line using tape, wire, or other appropriate method every 8 ft. Isolation In Wall Spaces Wall Sealant Ductwork Insulation Vapor Line Isolator Line Set Isolation Through Wall DO NOT hang line sets from ductwork Section 7. Refrigerant Line Brazing 7.1 Braze The Refrigerant Lines STEP 1 - Remove caps or plugs. Use a deburing tool to debur the pipe ends. Clean both internal and external surfaces of the tubing using an emery cloth. 818-BC85D1-2 STEP 2 - Remove the pressure tap cap and valve cores from both service valves. STEP 3 - Purge the refrigerant lines and indoor coil with dry nitrogen. STEP 4 - Wrap a wet rag around the valve body to avoid heat damage and continue the dry nitrogen purge. Braze the refrigerant lines to the service valves. Continue the dry nitrogen purge. Do not remove the wet rag until all brazing is completed. Important: Remove the wet rag before stopping the dry nitrogen purge. NOTE: Precautions should be taken to avoid heat damage to basepan during brazing. It is recommended to keep the flame directly off of the basepan. 18-BC85D1-2 9 STEP 5 - Replace the pressure tap valve cores after the service valves have cooled. Section 8. Refrigerant Line Leak Check 8.1 Check For Leaks STEP 1 - Pressurize the refrigerant lines and evaporator coil to 150 PSIG using dry nitrogen. 150 PSIG STEP 2 - Check for leaks by using a soapy solution or bubbles at each brazed location. Remove nitrogren pressure and repair any leaks before continuing. 1018-BC85D1-2 Section 9. Evacuation 9.1 Evacuate the Refrigerant Lines and Indoor Coil Important: Do not open the service valves until the refrigerant lines and indoor coil leak check and evacuation are complete. 0350 Microns STEP 1 - Evacuate until the micron gauge reads no higher than 350 microns, then close off the valve to the vacuum pump. ON OFF STEP 2 - Observe the micron gauge. Evacuation is complete if the micron gauge does not rise above 500 microns in one (1) minute. 1 MIN. Once evacuation is complete blank off the vacuum pump and micron gauge, and close the valves on the manifold gauge set. Section 10. Service Valves 10.1 Open the Gas Service Valve Important: Leak check and evacuation must be completed before opening the service valves. CAP NOTE: Do not vent refrigerant gases into the atmosphere. VALVE STEM STEP 1 - Remove valve stem cap. STEP 2 - Using an adjustable wrench, turn valve stem 1/4 turn counterclockwise to the fully open position. STEP 3 - Replace the valve stem cap to prevent leaks. Tighten finger tight plus an additional 1/6 turn. 1/4 TURN ONLY COUNTERCLOCKWISE FOR FULL OPEN POSITION UNIT SIDE OF VALVE PRESSURE TAP PORT GAS LINE CONNECTION 18-BC85D1-2 11 10.1 Open the Liquid Service Valve ▲! WARNING Extreme caution should be exercised when opening the Liquid Line Service Valve. Turn counterclockwise until the valve stem just touches the rolled edge. No torque is required. Failure to follow this warning will result in abrupt release of system charge and may result in personal injury and /or property damage. Cap Unit Side of Service Valve 3/16” Hex Wrench Rolled Edge to Captivate Stem Important: Leak check and evacuation must be completed before opening the service valves. Hex Headed Valve System STEP 1 - Remove service valve cap. STEP 2 - Fully insert 3/16” hex wrench into the stem and back out counterclockwise until valve stem just touches the rolled edge (approximately five (5) turns.) Service Port STEP 3 - Replace the valve cap to prevent leaks. Tighten finger tight plus an additional 1/6 turn. Section 11. Electrical - Low Voltage 11.1 Low Voltage Maximum Wire Length Table 11.1 defines the maximum total length of low voltage wiring from the outdoor unit, to the indoor unit, and to the thermostat. Table 11.1 24 VOLTS WIRE SIZE MAX. WIRE LENGTH 18 AWG 150 Ft. 16 AWG 225 Ft. 14 AWG 300 Ft. 1218-BC85D1-2 11.2 Low Voltage Hook-up Diagrams Communicating Indoor Unit with 24 V Control Hook-up Diagram Heat Pump Neatly bundle all low voltage wires as shown. Comm. Variable Speed Furnace or Air Handler R BK D Y1 Y2 G W1 W2 W3 B O Comfort Control R Y1 Red Yellow G W1 X2 Green White B O Blue Orange Orange Red Red Black Yellow (X2) Yellow Blue Black Blue Orange Notes: 1. See User Interface 24 V Mode setup menu for control mode and cooling CFM options. 2. W3 terminal may not be present on unit. 3. (Air Handlers only) If electric heat does not have 3rd contactor (CH), connect a jumper wire from W3 to W2. If electric heat does not have 2nd contactor (BH), connect a jumper wire from W2 to W1. 4. W1 - X2 is a field installed jumper. Variable Speed Furnace Hook-up Diagram Heat Pump Neatly bundle all low voltage wires as shown. Variable Speed Furnace Comfort Control R Y1 Red Yellow G W1 X2 B O Green White Blue Orange R YLO Y BK G W1 W2 B O Orange Red Red Yellow 18-BC85D1-2 Black (X2) Yellow Blue Black Blue Notes: 1. Comfort control must be dual fuel capable or use accessory TAYPLUS103A. 2. Ylo and BK may not be present on unit. 3. W1 - X2 is a field installed jumper. Orange 13 TAM7 Air Handler Hook-up Diagram Heat Pump Neatly bundle all low voltage wires as shown. Black Air Handler (X2) Comfort Control Blue W1 - White Yellow Red O - Orange R - Red B - Blue Y1 - Yellow Control Board OUTDOOR DH/BK on Must configure to “OFF” for HP Units. HP 1 1 R4 1 2 3 4 5 Field wiring } Capacity (Tons) AC (System) 2 (Stages) 2 (Compressor) S1 1 INDOOR R NET 1 R6 R1 on R NET 2 CFM/Ton Cool Off Delay U1 C22 D9 C10 L1 C19 Torque R14 C21 C15 C18 C12 R13 R22 1 2 3 4 5 Must configure to “OFF” for single-stage compressors. } White Green Yellow Orange Red Blue Orange } X2 W G Y1 O R B W3 W2 W1 G YI (In) O R B YO (Out) CFM S2 +12V TAM4 Air Handler Hook-up Diagram W2 Pink W3 Brown W1 White * Yello w Orange Purple YO YI Bl ue n Gree d Re Heat Pump Yellow Comfort Control Black Air Handler (X2) Orange White Green Yellow Orange Red Blue W G Y O R B Field wiring Y - Yellow Blue Red O - Orange B - Blue R - Red W1 - White •• * For multiple stages of electric heat, jumper W1, W2, and W3 together if comfort control has only one stage of heat •• YI and YO connections must be made as shown for proper operation, freeze protection, and internally mounted condensate overflow circuits to work properly •• Internally mounted condensate switch is optional and must be ordered separately •• If a 3rd party condensate overflow switch is installed, it should be wired between Y of the thermostat and YI of the EEV control. •• Some models have a terminal strip. Refer to air handler Installer’s Guide. 1418-BC85D1-2 GAM5 Air Handler Hook-up Diagram Heat Pump W2 Pink W3 Brown W1 White e d Re Yellow Blu Green Air Handler Comfort Control White Green Yellow Orange Red Blue W G Y O R B Black (X2) Orange White Green Yellow Orange Red Blue Yellow Red Blue R - Red B - Blue Y - Yellow •• * For multiple stages of electric heat, jumper W1, W2, and W3 together if comfort control has only one stage of heat •• Some models have a terminal strip. Refer to air handler Installer’s Guide. Field wiring GAM2 Air Handler Hook-up Diagram Heat Pump W2 Pink W3 Brown W1 White Green Red Blue Air Handler Comfort Control White Green Yellow Orange Red Blue W G Y O R B Field wiring Black (X2) Orange White Green Yellow Orange Red Blue Yellow Red Blue R - Red B - Blue Y - Yellow •• * For multiple stages of electric heat, jumper W1, W2, and W3 together if comfort control has only one stage of heat 18-BC85D1-2 15 GAF2 Air Handler Hook-up Diagram Heat Pump W1 White Green Red Blue Air Handler Comfort Control White Green Yellow Orange Red Blue W G Y O R B Black (X2) Yellow Orange White Green Yellow Orange Red Blue Red Blue R - Red B - Blue Y - Yellow Field wiring GAF2-36M Air Handler Hook-up Diagram White n Yello w Orange Purple YO YI Bl ue Gree d Re Heat Pump Air Handler Yellow Black (X2) Comfort Control Orange White Green Yellow Orange Red Blue W G Y O R B Field wiring Blue Red •• YI and YO connections must be made as shown •• Internally mounted condensate switch is optional and must be ordered separately •• If a 3rd party condensate overflow switch is installed, it should be wired between Y of the thermostat and YI of the EEV control. 1618-BC85D1-2 11.3 Defrost Control Defrost controls have a selectable termination temperature. As shipped, defrost will terminate at 47°F. For a higher termination temperature, cut Jumper J2 to achieve 70°F when at or below 30°F ambient. See Service Facts shipped in the outdoor unit for more information. Pin Identification (See Illustration at right) 1. TEST_COMMON (Shorting any of the other pins to this pin causes the function of the other pin to be executed. Leaving this pin open results in the normal mode of operation.) 2. TST = Test (Shorting TEST_COMMON to this pin speeds up all defrost board timings.) 3. FRC_DFT = Forced Defrost (Short TEST_COMMON to this pin for two (2) seconds to initiate a forced defrost. Remove the short after defrost initiates.) Defrost Control Checkout Normal operation requires: • LED on board flashing 1 time/second. • 24V AC between R & B. • 24V AC between Y & B with unit operating. • Defrost initiation when FRC_DFT pin is shorted to TEST_COMMON pin. If a defrost control problem is suspected, refer to the service information in control box. Defrost Termination Temperatures As Shipped All Termination Temperature >22°F 47°F Defrost Board Detail J1 J2 J3 JUMPER 2 10°F–22°F ODT + 25°F 6°F–10°F 35°F >30°F 47°F 6°F–30°F 70°F < 6°F 12 min. or 35°F every 3 hrs. 18-BC85D1-2 FRC_DFT TEST PINS TST TEST_COMMON Cut Jumper 2 Outdoor Temperature U1 17 Section 12. Electrical - High Voltage 12.1 High Voltage Power Supply ▲! WARNING LIVE ELECTRICAL COMPONENTS! During installation, testing, servicing, and troubleshooting of this product, it may be necessary to work with live electrical components. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury. The high voltage power supply must agree with the equipment nameplate. Power wiring must comply with national, state, and local codes. Follow instructions on unit wiring diagram located on the inside of the control box cover and in the Service Facts document included with the unit. 12.2 High Voltage Disconnect Switch Install a separate disconnect switch at the outdoor unit. For high voltage connections, flexible electrical conduit is recommended whenever vibration transmission may create a noise problem within the structure. 12.3 High Voltage Ground Ground the outdoor unit per national, state, and local code requirements. 1818-BC85D1-2 Section 13. Start Up 13.1 System Start Up STEP 1 - Ensure Sections 7 through 12 have been completed. STEP 2 - Set System Thermostat to OFF. OFF DONE CANCEL STEP 3 - Turn on disconnect(s) to apply power to the indoor and outdoor units. ON OFF STEP 4 - Wait one (1) hour before starting the unit if compressor crankcase heater accessory is used and the Outdoor Ambient is below 70ºF. 60 MIN. STEP 5 - Set system thermostat to ON. ON DONE 18-BC85D1-2 CANCEL 19 Section 14. System Charge Adjustment 14.1 Temperature Measurements STEP 1 - Check the outdoor temperatures. Subcooling (in cooling mode) is the only recommended method of charging above 55º F ambient outdoor temperature. See Section 14.2. 120º F See Section 14.2 for Outdoor Temperatures Above 55º F 55º F Outdoor Temp 1 For outdoor temperatures below 55º F, see Section 14.3. Note: It is important to return in the spring or summer to accurately charge the system in the cooling mode when outdoor ambient temperature is above 55º F. See Section 14.3 for Outdoor Temperatures Below 55º F 55º F Outdoor Temp 2 For best results the indoor temperature should be kept between 70º F to 80º F. 80º F 70º F Indoor Temp 14.2 Subcooling Charging in Cooling (Above 55º F Outdoor Temp.) STEP 1 - Use the refrigerant line total length and lift measurements from Section 5.3. Total Line Length = __________ Ft. Vertical Change (Lift) = __________ Ft. LIFT 2018-BC85D1-2 STEP 2 - Determine the final subcooling value using total Line Length and Lift measured in STEP 1 and the charts below. SUBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE) SUBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE) REFRIGERANT LINE LIFT (FEET) 2 Ton Heat Pump REFRIGERANT LINE LIFT (FEET) 1 1/2 Ton Heat Pump 60 Add 3° 50 Add 2° Add 1° of Subcooling 40 30 25 20 Use Design Subcool Value 15 10 0 10 20 25 30 40 60 TOTAL REFRIGERANT LINE LENGTH (FEET) Add 4° 60 Add 2° 50 Add 1° of Subcooling 40 30 25 20 15 Use Design Subcool Value 10 0 10 20 25 30 40 60 TOTAL REFRIGERANT LINE LENGTH (FEET) SUBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE) REFRIGERANT LINE LIFT (FEET) 3 Ton Heat Pump SUBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE) REFRIGERANT LINE LIFT (FEET) 2 1/2 Ton Heat Pump 60 Add 4° 50 Add 3° Add 2° of Subcooling 40 Add 1° of Subcooling 30 25 20 Use Design Subcool Value 15 10 0 10 20 25 30 40 60 TOTAL REFRIGERANT LINE LENGTH (FEET) Add 5° 60 Add 4° 50 Add 3° of Subcooling 40 30 Add 2° Add 1° of Subcooling 25 20 15 Use Design Subcool Value 10 0 10 20 25 30 40 60 TOTAL REFRIGERANT LINE LENGTH (FEET) SUBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE) SUBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE) REFRIGERANT LINE LIFT (FEET) 4 Ton Heat Pump REFRIGERANT LINE LIFT (FEET) 3 1/2 Ton Heat Pump Add 6° 60 Add 5° 50 Add 3° of Subcooling 40 Add 2° of Subcooling 30 25 Add 1° of Subcooling 20 15 Use Design Subcool Value 10 0 10 20 25 30 40 60 TOTAL REFRIGERANT LINE LENGTH (FEET) 60 Add 6° 50 Add 4° of Subcooling 40 Add 3° of Subcooling 30 25 20 15 10 0 Add 2° of Subcooling Add 1° of Subcooling Use Design Subcool Value 10 20 25 30 40 60 TOTAL REFRIGERANT LINE LENGTH (FEET) 5 Ton Heat Pump REFRIGERANT LINE LIFT (FEET) SUBCOOL CHARGING CHART CORRECTIONS TABLE (FOR LINE LENGTH AND RISE) 60 Design Subcooling Value = __________º F (from nameplate or Service Facts) Add 6° 50 40 Add 5° of Subcooling 30 Add 4° of Subcooling Subcooling Correction = __________º F 25 20 Add 2° of Subcooling 15 10 0 Design Add 3° of Subcooling Add 1° of Subcooling Final Subcooling Value = __________º F 10 20 25 30 40 60 TOTAL REFRIGERANT LINE LENGTH (FEET) STEP 3 - Stabilize the system by operating for a minimum of 20 minutes. At startup, or whenever charge is removed or added, the system must be operated for a minimum of 20 minutes to stabilize before accurate measurements can be made. 18-BC85D1-2 20 MIN. 21 STEP 4 - Measure the liquid line temperature and pressure at the outdoor unit’s service valve. Measured Liquid Line Temp = __________ º F Liquid Gage Pressure = __________ PSI Final Subcooling Value = __________ º F STEP 5 - Use the final subcooling value, refrigerant temperature and pressure from STEP 4, to determine the proper liquid gage pressure using Table 14.2. Example: Assume a 12º F Final Subcooling value and liquid temp of 90º F. 1. Locate 12º F Final Subcooling in Table 14.2. 2. Locate the Liquid Temperarature (90º F) in the left column. 3. The Liquid Gage Pressure should be approximately 327 PSIG. (This is the shown as the intersection of the Final Subcooling column and the Liquid Temperature row. 107 °F Table 14.2 R-410A REFRIGERANT CHARGING CHART FINAL SUBCOOLING (°F) LIQUID 8 9 10 11 12 13 14 TEMP (°F) LIQUID GAGE PRESSURE (PSI) 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 179 195 211 229 247 267 287 309 331 355 381 407 435 464 495 182 198 215 232 251 271 291 313 336 360 386 413 441 470 501 185 201 218 236 255 275 296 318 341 365 391 418 446 476 507 188 204 222 240 259 279 300 322 346 370 396 424 452 482 514 191 208 225 243 263 283 304 327 351 376 402 429 458 488 520 195 211 229 247 267 287 309 331 355 381 407 435 464 495 527 198 215 232 251 271 291 313 336 360 386 413 441 470 501 533 From Dwg. D154557P01 Rev. 3 2218-BC85D1-2 STEP 6 - Adjust refrigerant level to attain proper gage pressure. Add refrigerant if the Liquid Gage Pressure is lower than the chart value. 1. Connect gages to refrigerant bottle and unit as illustrated. 2. Purge all hoses. 3. Open bottle. 4. Stop adding refrigerant when liquid line temperature and Liquid Gage Pressure matches the charging chart Final Subcooling value. Recover refrigerant if the Liquid Gage Pressure is higher than the chart value. STEP 7 - Stabilize the system. 1. Wait 20 minutes for the system condition to stabilize between adjustments. 20 MIN. Note: When the Liquid Line Temperature and Gage Pressure approximately match the chart, the system is properly charged. 2. Remove gages. 3. Replace service port caps to prevent leaks. Tighten finger tight plus an additional 1/6 turn. STEP 8 - Verify typical performance. (Example only - see Service Facts) PRESSURE TABLES FOR 4TWB30** *AM4A0****** Air Handler Heating Cooling Outdoor Size & AH OD ** AH****** 18 A18S11 24 A24S21 30 A30S21 36 A36S31 42 3 B42S31 Outdoor Size & AH 48 C48S41 60 C60S51 515 485 455 425 395 370 335 320 300 280 260 225 540 510 480 450 420 390 365 345 320 300 280 260 48 C48S41 60 C60S51 155 148 140 134 151 144 137 131 148 141 134 127 146 139 132 125 143 136 129 123 141 134 127 121 154 146 137 130 150 142 134 126 146 138 131 123 144 136 128 121 141 133 126 118 138 131 123 116 OD ** AH****** Discharge Pressure (PSIG) 490 460 435 405 375 350 325 305 285 265 245 225 515 485 455 425 395 370 4 335 320 300 280 260 225 Outdoor Size & AH OD ** AH****** Outdoor Temp. Indoor Wet Bulb (Degree F) (Degree F) 110 100 90 1 80 70 60 18 A18S11 24 A24S21 30 A30S21 71 67 63 59 71 67 63 59 71 67 2 63 59 71 67 63 59 71 67 63 59 71 67 63 59 36 A36S31 42 3 B42S31 55 45 35 25 153 146 139 132 148 141 134 128 144 137 131 124 141 134 128 122 138 131 125 119 135 128 122 116 154 147 139 133 150 143 136 129 147 139 4 133 127 144 137 131 124 141 134 128 122 139 132 125 119 15 5 -5 30 A30S21 36 A36S31 42 B42S31 48 C48S41 60 C60S51 445 405 365 420 385 345 395 360 325 380 345 305 365 325 285 345 305 270 325 285 255 315 275 235 445 405 365 415 380 345 395 355 320 380 340 305 355 320 285 335 300 265 320 280 245 305 265 230 48 C48S41 60 C60S51 142 120 98 83 68 55 44 35 134 114 94 81 66 53 42 33 Discharge Pressure (PSIG) 80 70 60 80 70 60 80 70 60 80 70 60 80 70 60 80 70 60 80 70 60 80 70 60 65 Suction Pressure (PSIG) 154 146 138 131 149 141 134 127 145 137 130 123 141 134 127 120 138 131 124 117 135 128 121 114 24 A24S21 Indoor Entering (Deg.F) Outdoor Temperature (Degree F) 510 480 450 425 390 365 340 315 290 275 255 235 480 440 400 455 415 375 430 390 350 415 370 335 390 350 310 370 330 290 350 310 270 335 290 255 485 445 405 460 420 380 435 390 355 420 375 335 390 350 310 370 330 290 350 310 270 335 290 255 435 395 355 410 370 335 390 350 315 375 335 295 355 315 280 335 295 265 320 275 245 300 265 225 Outdoor Size & AH OD ** AH****** 18 A18S11 24 A24S21 30 A30S21 36 A36S31 42 B42S31 Suction Pressure (PSIG) Outdoor Temperature (Degree F) Outdoor Temperature (Degree F) Refer to System Pressure Tables in the Service Facts to verify typical performance. 115 110 105 100 95 90 1 85 80 75 70 65 60 18 A18S11 65 55 45 35 25 15 5 -5 142 120 100 83 69 56 44 35 150 127 105 89 74 60 49 40 138 116 96 82 67 53 42 32 OUTDOOR TEMPERATURE (Degree F) COOLING PERFORMANCE CAN BE CHECKED WHEN THE OUTDOOR TEMP IS ABOVE 65 DEG F. TO CHECK COOLING PERFORMANCE, SELECT THE PROPER INDOOR CFM, ALLOW PRESSURES TO STABILIZE. MEASURE INDOOR WET BULB TEMPERATURE, OUTDOOR TEMPERATURE, DISCHARGE AND SUCTION PRESSURES. ON THE PLOTS LOCATE OUTDOOR TEMPERATURE (1); LOCATE INDOOR WET BULB (2); LOCATE MODEL OUTDOOR (3); FIND INTERSECTION BETWEEN 1, 2, & 3 . (4) FIND TARGET PRESSURE. EXAMPLE: (1) OUTDOOR TEMP. 90 F. (2) INDOOR WET BULB 67 F. (3) OD 4TWB3042 (4) DISCHARGE PRESSURE IS 370 PSIG DISCHARGE PRESSURE (5) SUCTION PRESSURE IS 139 PSIG SUCTION PRESSURE ACTUAL: SHOULD BE +/ 10 PSIG OF CHART SHOULD BE +/ 3 PSIG OF CHART INTERCONNECTING LINES GAS 3/4" O.D. LIQUID 3/8" O.D. 18-BC85D1-2 23 STEP 9 - Record System Information for reference. Record system pressures and temperatures after charging is complete. Outdoor model number = _________________ Measured Suction Line Temp = __________ º F Measured Outdoor Ambient = __________ º F Liquid Gage Pressure = __________ PSIG Measured Indoor Ambient = __________ º F Suction Gage Pressure = __________ PSIG Measured Liquid Line Temp = __________ º F 14.3 Subcooling Charging Below 55º F Outdoor Temp. (In Heating Only) The Subcooling Charging method in cooling is not recommended below 55º F outdoor temperature. The only recommended method of charging at outdoor temperatures below 55º F is weighing in the charge in heating mode. Table 14.3 STEP 1 - Determine additional charge. From the nameplate label (shown in Section 12.1), record namplate charge below. Note: The nameplate charge value represents the amount of refrigerant shipped in the outdoor unit and is compatible with 15 feet of AHRI rated refrigerant lines and the smallest AHRI rated coil. Using Table 14.3, find the charge associated with the additional length of tubing above 15 ft. and record it below. TUBING INFORMATION LINE TYPE REFRIGERANT TO ADD AT SPECIFIED ADDITIONAL LENGTH Suction Line Liquid Line 20 ft 30 ft 40 ft 1.5 – 2 Ton 5/8" 3/8" 3 oz 8 oz 14 oz 20 oz 25 oz 2.5 – 3.5 Ton 3/4" 3/8" 3 oz 9 oz 15 oz 21 oz 27 oz 4 – 5 Ton 7/8" 3/8" 3 oz 9 oz 16 oz 22 oz 28 oz Tonnage 50 ft 60 ft Namplate charge = ____________ Oz. Charge adder = ______________ Oz. (from Table 14.2) 2418-BC85D1-2 STEP 2 - Stabilize the system by operating for a minimum of 20 minutes. At startup, or whenever charge is removed or added, the system must be operated for a minimum of 20 minutes to stabilize before accurate measurements can be made. 20 MIN. STEP 3 - Check the liquid line temperature and liquid gage pressure to obtain a minimum of 10º subcooling in heating mode. Measured Liquid Line Temp = __________ º F Liquid Gage Pressure = __________ PSIG STEP 4 - Add charge if a minimum of 10º subcooling is not obtained with the namplate charge plus additional charge previously added. STEP 5 - Return to site for adjustment. Important: Return in the spring or summer to accurately charge the system in the cooling mode with outdoor ambient above 55º F. 18-BC85D1-2 25 Section 15. Checkout Procedures and Troubleshooting 15.1 Operational And Checkout Procedures Final phases of this installation are the unit Operational and Checkout Procedures. To obtain proper performance, all units must be operated and charge adjustments made. Important: Perform a final unit inspection to be sure that factory tubing has not shifted during shipment. Adjust tubing if necessary so tubes do not rub against each other when the unit runs. Also be sure that wiring connections are tight and properly secured. CHECKOUT PROCEDURE After installation has been completed, it is recommended that the entire system be checked against the following list: 1. Leak check refrigerant lines. ......................................... [ ] 2. Properly insulate suction lines and fittings..................... [ ] 3. Properly secure and isolate all refrigerant lines............. [ ] 4. Seal passages through masonry. If mortar is used, prevent mortar from coming into direct contact with copper tubing............................ [ ] 5. Verify that all electrical connections are tight................. [ ] 6. Observe outdoor fan during on cycle for clearance and smooth operation.................................................... [ ] 7. Be sure that indoor coil drain line drains freely. Pour water into drain pan................................................................. [ ] 8. Be sure that supply registers and return grilles are .open and unobstructed........................................................... [ ] 9. Be sure that a return air filter is installed....................... [ ] 10. Be sure that the correct airflow setting is used. (Indoor blower motor).................................................... [ ] 11. Operate complete system in each mode to ensure safe operation.................................................... [ ] 2618-BC85D1-2 15.2 Troubleshooting . DEF OL NTR DEF. CO Y ST RELA ING RO K T D E F F RO S LEA E DE VALVE ECTIV CK DEF NG CHE COIL LEAKI S SOV SOV CTION T R I OW RES AIRFL IR. EAT .C I.D. R E F R E S. U P E R H N S PE KO TUC ION V S CULAT /EE W R TXV RECI IRFLO R . A LES D . . AI B O.D RES. O ENSA D ND L OA NCO AP. NO E EV ARGE H IV ESS ERC GE EXC EF. OV CHAR . R P R NDE T COM .U REF FICIEN SSOR E F INE OMPR USE F C CK IL AG E STU VOLT R CO CTO STAT L OW O NTA CO HERM ER M T OR NSF ING TRA WIR OL GE TS NTR LTA NTAC O V CO CO LAY E LOW TOR C TR NTA TAR TOR S CO AC I CAP ITOR C RT STA CAPA IOL RUN SSOR G RE IRIN MP CO AGE W PLY OLT SUP E H V ER H I G P OW K M O D C CHE TO AT * WH SYSTEM FAULTS REFRIGERANT CIRCUIT Head Pressure Too High Head Pressure Too Low Suction Pressure Too High Suction Pressure Too Low Liquid Refrig. Floodback (TXV/EEV) Liquid Refrig. Floodback (Cap. Tube) I.D. Coil Frosting Compressor Runs Inadequate or No Cooling/Htg ELECTRICAL Compressor & O.D. Fan Won’t Start Compressor Will Not Start But O.D. Fan Runs O.D. Fan Won’t Start Compressor Hums But Won’t Start Compressor Cycles on IOL I.D. Blower Won’t Start P P C H C H C H C H C H C H C H C H C H C H C H C H C H C H S S S S P P S S P S P P P S S P P P P S S S S S S S S P S S S S S S P P S S S S P P P P P P S S S P P P P P P P P P P P P P P P S S S S S S P P P P P P P P S S S S S S S S S S S S P P S S P P S S P P S S P P S S S S S S P P P S S P S S P P S S P S S S S S S S S P P P P S S S S S S S S P P P P S S P P S S P P S S S S S S S S S DEFROST Unit Won’t Initiate Defrost Defrost Terminates on Time Unit Icing Up C - Cooling H - Heating C H C H C H P - Primary Causes P P P S - Secondary Causes 18-BC85D1-2 P P P * S S S P P - 3 Phase Only 27 The manufacturer has a policy of continuous product and product data improvement and it reserves the right to change design and specifications without notice. Representative-only illustrations included in this document. © 2013 Trane 04/13 2818-BC85D1-2
© Copyright 2024