ICP Package Units(both Units Combined) Manual L0522838
User Manual: ICP ICP Package Units(both units combined) Manual ICP Package Units(both units combined) Owner's Manual, ICP Package Units(both units combined) installation guides
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Installation Instructions I DIRECT DRIVE BLOWER PA95/PAPC PA55/PAPA SERI ES SINGLEPACKAGE AIRCONDITIONERS ELECTRIC COOL / ELECTRIC HEAT(OPTIONAL)c TABLEOF CONTENTS 1. Safety Labeling and Signal Words .......................... 2 Danger, Warning and Caution .................................... 2 2. Safe Installation 3. Locating Requirements The Unit ....................... .................................. Clearances ............................................... Dimensions ................................................... MinimumClearancesto CombustibleConstruction..................... Installation ................................................... InstallingDuct Collars ........................................ CondensateDrain ............................................. 4. Electrical Wiring .................................... 2 2 2 2 3 3 3 4 4 6. Air Distribution System .............................. 9 Ductwork .................................................... DuctworkInsulation ............................................ 9 9 DuctwotkConnections .......................................... 9 Fi_ers .............................. 7. Start-up Procedures 9 ............................... 10 FinalElectricalCheck ................ 10 CirculaUngAir Blower .......................................... Determining 8_owerSpeed .......... 10 10 Steed Taos ............................ 10 Cooling andAuxiliary Electric Strip Heat ............................ CheckBefore Starting ...................... CirculatingAir Blower ..................... tO 10 11 Ground Connections........................................... 4 Cooling ................................................... 11 Line VoltageWiring ............................................. Unit Disconnect ............................................... 4 4 AuxiliaryHeating ......................... 11 Converting230V Unitsto 208V .................................... Low VoltageWiring ............................................ ThermostatConnections......................................... 4 4 5 Field Installed Equipment ........................................ 5. Electric Heat Installation ............................. General Information ................................ AdjustingTherrnostat Anticipator ................................. 5 6 6 6 Umit Controls .............................................. 6 Time Delay Operation ................................... 6 Staging .................................................. Install Heater ................................................. 6 6 HeaterWiring ........................................... 6 Grounding ................................................ InstallingWiring .......................................... Unit DisconnectBreaker ......................................... Rain Shield Installation ......................................... Printed in U.S.A. 6 7 8 8 TemperatureRiseCheck ..................... Sequenceof Operation ......................................... Cooling Mode:Energized(R,G,Yt_ De-energized_N/At ................ 8. Operation .......................................... 11 Scroll Acti- Cycle Timer(Where Applicable}.......................... TurningTheUnit Off ....................... ThermostatFan Switch Operation ................................. AdjustingRoom Temperatures ...... 13. Maintenance 11 tt 11 11 12 12 12 .................................. 12 MonthlyMaintenanceandInspectionChecks ........................ Air Filters ................................................ 12 12 CoolingSeason Checks (Monthly)................................. CondenserCoil ........................................... 12 12 CondensateDrain ............................................ 12 Annual Maintenance and Inspection ............................... Condense"Fan Motor ......................................... 12 12 CirculatingAir Blower ......................................... 12 426 011001 2/20/96 02 1. Safetv Labelinq and Siflnal Words Danger,Warning and Caution Thesignal wordsDANGER,WARNINGand CAUTIONare used to identifylevels of hazard seriousness.The signal word DANGERis only used on productlabels to signify an immediate hazard.The signal words WARNINGand CAUTIONwill be used on product labels and throughoutthis manualand other manualsthat may applyto the product. 2. Safe Installation Requirem CAUTION ents Do NOT operate unit in a corrosive atmosphere containing chlorine, fluorine, or any other corrosive chemicals. 3. Installation or repairs made by unqualified persons can result in hazards to you and others. Installation MUST conform with local building codes or, in the absence of local codes, with the National Electrical Code NFPA70-1990 or current edition. The information by a qualified dures and equipped ments. familiar & Installinq The Unit The unit is designedfor outdoorinstallationonly.Placethe unit on a platformat ground level. The unit may be installedon a concreteslab of 48" (1219mm)x 48" (1219mm) dimensions. Cement blocks on a 3" sand footing willalso work. The slab or blocks SHOULDNOT be in contactwith any part ofthe structure. Check localcodescovering zoning,noise, platforms,etc.. contained in this manual is intended for use service technician Locatinq with safety proce- If practicalavoid locatingnext to freshair intakes,vent or bedroomwindows. Noisemay carry into the openingsand disturbpeopleinside. with the proper tools and test instru- Avoid installationsunder roof overhangswithoutguttering. Waterdrainingfrom the roof ontotheunit could produceexcessivenoise,and may causeice to buildup on coil orfan. Failure to carefully read and follow all instructions in this manual can result in unit malfunction, property damage, per- Placementofthe unit shouldbe ina well drainedareaor the unit MUSTbe supportedhigh enoughso runoffwill notenter the unit. sonal injury and/or death. Do not locate unit whereheat, lint or exhaustfumes will be dischargedon unit (asfrom dryer vents.) Clearances • Seal supply and return air ducts. Minimum clearances,as specified in FIGURE 1, MUST be maintained from adjacent structuresto provideadequate air circulationand roomfor service personnel. • Check to see that filters are installed correctly and are the proper type and size. While minimumclearancesare acceptablefor safety reasons,they may not allow adequateaircirculationaroundthe unitfor properoperation.Wheneverpossible,it isdesirable to allow additionalclearance,especiallyaroundthe condenserinlet and dischargeopenings. NOTE:It is thepersonalresponsibilityandobligationofthecustomer tocontacta qualified installerto ensurethat the installationis adequate and conformsto governingcodes and ordinances. Do NOTinstallthe unit in a recessedor confinedarea that will permitdischargedair from the condenserto recirculateto the condenserinlet. Dimensions NOTE: DUCT COLLARS ATTACHED TO SUPPLY AND RETURN MUST BE REVERSED AT INSTALLATION. SEE INSTRUCTIONS ON PAGE 3. ALL DIMENSIONS t 26.5 IN iNCHES ROUND SHAPED ACCOMMODATE SUPPLY DUCT COIL ACCESS PANEL ROUND FLANGE WILL ACCOMMODATE 14_ DIA. RETURN DUCT FLANGE WiLL 12" DIA. DIA HOLE** _/4 DIA.* _/4 DIA.* T m 10 3/4 \ 41 CONDENSATE DRAIN CONECTION * ELECTRICAL ACCESS FOR LINE VOLTAGE POWER SUPPLY-ONE ** FOR LOW VOLTAGE WIRING FOR UNIT, ONE FOR HEATER Minimum Clearances to Combustible Construction FIGURE 2 Blower Compartment SERVICE ACCESS CLEARANCES Blower Access Panel Side .......................... Electrical Access Panel Side ........................ OPERATIONAL CLEARANCES Combustible Base 30" (762mm) 30" (762mm) (Wood or Class A, B or C roof covering material) ......................... Supply and Return Air Ducts ................................. Duct Connection Side Clearance Clearance 0" 0" between Overhang and Top of Unit ..................... 48" (1219mm) around Condenser Coil area to wall or shrubs ........ 10" I FIGURE 1 I Minimum Clearances and Access Panels I Overhang Evaporator Access Panel 48" Minimum Overhang Clearance f 10"around condenser coil area Installing Duct Collars Ductcollars are suppliedwiththe unit and are attachedto the supply and returnopenings withthe flanges to the inside and must be reversed beforeunit's installation. 1. Remove the screws from the collars and reverse them so the flange is to the outside. 6" Blower/Electrical Access Panel Cover Plate 2. Make sure when pushing the collars into place that the "V" flange of the collars seats into the supply and return holes securely. 3. Re-install screw in each collar so it goes through both of the holes in the collar end. It does not matter how the ends of the collar overlap in order to accomplish this. FIGURE 3 Installation CAUTION The unit must be installed as level as possible, with a maximau slope no greater than 1/8" per foot (10mm per meter). For side to side leveling, the condensate drain side of the u nit MUST always be lower to provide proper drainage. The unit MUST be situated in such a way as to provide safe access for servicing. The platform may be made of either concrete or pressure treated wood and MUST be level and strong enough to support the unit's weight. Position platform separate from the building's foundation. install in a well-drained area, with the top surface of the platform high enough above grade level to allow installation of a condensate drain trap. See FIGURE4 I Duct Collar Installation I Condensate Drain Thecondensatedrainoutlet isa 314 " (19.1mm)threadedfemale PVCconnectionlocated at the bottom of the unit to the leftof the evaporatoraccesspanel. The circulatingblowerandthe condenserfan createa negativepressureon the condensate drain line that will preventthe condensatefrom drainingproperly without a trap. To combatthis negativepressure,a field suppliedcondensatetrap that willallow a standing columnof waterof at least2" (50.8mm) MUSTbe installed.The outletofthe trap mustbeat least 1"below the unit drainconnection.Install the trapas nearto theunit as possible for proper drainage. FIGURE 4 Condensate Drain Information * 3/4" (19.1mm) Threaded Female PVC Fitting 1" (25.4mm) 3/4" (19.1mm) Drain Line A 3/4" (19.1mm) drainline MUST be installedif requiredby localcodesor iflocationof unit requires it. Runthe drainline to an open drainor othersuitable disposalpoint. 33/4 "" (82.5mm) 2" (50.8mm) _,_kv 4. Electrical * Condensate Wirinq Electrical shock hazard. Disconnect power at fuse box or service panel before making any electrical connections. Unit MUST be grounded to electrical service panel. Failure to follow this warning can result in property damage, personal injury, and/or death. NOTE:All electricalwork MUST conformwith the requirementsof localcodesand ordinancesand in the United States with NationalElectricalCodeANSI/NFPA70-1990 (or current edition). Provide line voltagepowersupply from a separate fused circuit witha disconnectswitch(whenrequired)locatedwithinsight ofthe unit. Supplyvoltage,amperage, fuse and disconnectswitchsizes MUST conformwithlocalcodes and ordinances. NOTE:If an ElectricHeatAccessoryisinstalled,referto theElectricHeatAccessorysection of this manual to determineline voltage connections.The ElectricHeat Accessory mounts insidethe unit in the heater box. Field suppliedline voltage wiresfor the Electric HeatAccessory(separatefrom the fieldsupplied linevoltagewirestothe unit)connectto the appropriatecircuitbreaker (if used)in the Electric HeatAccessory. Unit Disconnect A DisconnectSwitchKit isavailablethat installsinsidetheunit or a seperatecircuitbreaker may be installedto controlthe unit. Referto instructionsfollowing heaterinstallationsec* tion. Converting 230V Units to 208V To convert230V unitsto 208V: 1 .Turn electric power OFF. Wiring MUSTbe protectedfrom possiblemechanicaldamage and MUST NOT interfere with removalof access panels,filters, etc. 2. Remove the blower/electrical AllexposedlinevoltageconnectionsMUSTbemadethroughliquidtight conduitto prevent water from enteringthe unit throughthe electricalaccess.. 3. Locate the 24V control transformer. Ground Connections A groundlugis installedonthe controlplate (orelectricheatmountingplate)for the ground connection.Use a copperconductorof the appropriatesize from the unit to a grounded access panel. 4. Remove wire from the terminal labeled "240V" on the 24V control transformer and reconnect it to the 208V terminal of the 24V control transformer. connectioninthe electricalservicepanel or to a properlydrivenand electricallygrounded ground rod. 5. Replace the electrical/compressor Line Low Voltage trap MUST be installed. Wiring Do NOTcompletelinevoltageconnectionsuntilunit ispermanently grounded.All linevoltage connectionsand the groundconnection MUSTbe made withcopper wire. Connectionsfor linevoltageare madeon the unit electricalcontrolplate (seeFIGURE7). For access,removethe Blower/Electricalaccesspanel. Referto applicablewiringdiagram andFIGURE6. Completetheline serviceconnections to the contactor'L' terminalson the electricalcontrol plate.Check all screw terminalsto ensurethey are tight. Voltage access panel. Wiring For access,removethe electricalcontrol/bloweraccesspanel. Referto the connectionwiringdiagram for the applicablemodel andto the instructionsincludedwith the thermostat. Route low voltagewiresthroughthe port locatedon the rearpaneland upto the control box. NOTE:If an ElectricHeatAccessoryis installed,see the ElectricHeatAccessoryInstallation Sectionof thismanual for lowvoltage connections. ThermostatConnections Field The location ofthethermostat has animportanteffecton theoperationof the unit. Seethe thermostatinstructionsfor proper connection. See FIGURE5 for Low VoltageWireHarness Connections FIGURE 5 Harness Connection Diagram J Electronic Thermostat Low Voltage Wiring Installed Equipment Wiringto be donein thefieldbetweenthe unit andother devices,or betweenseparatedeviceswhichare fieldinstalledandlocated,MUSTNOTexceedthe temperaturelimitations for type T wireand MUSTbe installedaccordingtothe manufacturer'sinstructionsfor the devices. FIGURE 6 J Typical Connections at Unit USE CO PPER CONDUCTORS 208/Z30V Typical Thermostat "F_'I I I I I I I I I I I , = = , (when used) I I I I I II II aCT i [Blue] i [Green] Com (when used) Fan ONLY 7PH Subbase [,q [?] [R,] I 60HZ , , [Red] [Yellow] [W'h ite] 24V Elect. Heat Acces. Comp Cool I ' I I I I I I ] I I I I I I • F _ J 3 1 Unit Low Voltage Wiring Harness. '1 ' I -_ I I 'l'' K_ I BL I I_ I\ J GND I L__ R__/_R I L=BL THERMOSTAT OONNEOTION£ FIGURE 7 J Control Box Configuration Component Wire Opening Capacitor Ground lug, Blower Relay or Sequencer Transformer Anti-Cycle Time (If Used) Contactor \ Control Box Line Volt Wire Entrance Low Volt 5. Electric Heat General Information Adjusting Thermostat Installation FIGURE 8 Typical Electric Heat Accessory Anticipator Breaker- Style Heater rl e Set the heat anticipatorof the thermostatto the proper value.See instructions provided with thethermostat beforemakingthis adjustment. Limit Model Number AMMK05AHBIA AnticipatorSettin_l .18 AMM F,U/API_tA ,;Jb .._IVl IVli% I U,_,I'ID/P_ ^_AHV4c^t _ntA .,.lt_ ,_ A_A_I _OI'_AWRIA _A Controls Thelimitcontrolsare mountedonthe faceofthe heaterandare wiredintothesupply wires to each element. If there is notenoughair flowthroughthe heater,the limitwill openand breakthe powercircuit. The limitwill reset whenthe electricaccessorycoolsdown. Time Delay Operation The heaterelementsare switchedON andOFF throughoneor more controlswhichoperate throughthe lowvoltagethermostatcircuit. Thesecontrolsconsistof a numberoftime delaysdependingon thespecificheatermodel. An electricheataccessoryhas 1,2 or 3 of these controls.The first time delayis activated whenthethermostatcontactsclose.Approximately1to 20secondslaterthe indoorblower and the first heater bank are energized.Approximately70 seconds after the first heater bank is energizedthe remainingtime delays and heaterbanks are energized. FIGURE 9 Installing The Electric Heat Accessory Staging Some electric utilities require staging on electric heaters larger than 6 kilowatts. Therefore, the heater elements are turned on in 5 or 10 kW increments under control of the sequencers. If staging based on heat loss or demand is required, the use of accessory outdoor thermostats is recommended. The heat sequencer wiring is designed to be staged by breaking the 24V "Common" Leg (normally brown or gray). Outdoor thermostats available through your wholesale supplier allow the control of two or four stages of electrical heat. Some indoor electronic thermostats may provide for multiple stages of electric heat. When this type thermostat is used, it may be necessary to break the 24V "Hot" leg of the sequencer (as fed from the "W' circuit at the thermostat). This will require field modification of the control wiring and should only be done by an experienced controls technician or electrician. Install Heater 1. Shut OFF electric power at unit disconnect switch or service panel. 2. Remove the blower access panel from unit. NOTE: Installation of field wiring and conduit for heaters to the unit prior to installing the heater will simplify wiring of heaters. 3. From inside the blower compartment, remove the six screws on the heater cover plate and save the screws. Discard the heater cover plate. Heater Wiring Grounding The screws will be used later to mount the electric heat accessory and its cover. 4. Remove the cardboard wrapper from the heater's elements. 5. Insert the heater into the heater/blower prevent damage to heater elements. 6.Secure heater to heater/blower moved in Step 3. box. Exercise caution to Permanentlygroundthe electricheataccessoryin accordancewithlocalcodesandordinancesandinthe UnitedStateswithNationalElectricalCodeANSIINFPA70-1990or current edition. Use a copper conductor of the appropriate size from the electric heat accessoryto the groundlug on the circuit breakerpanel as shown in FIGURE10. Installing Wiring When an electricheataccessoryis installed,two separatefield powersupplies MUSTbe provided - one or more for the electric heat accessoryand one for the unit. box with four of the six screws re1.Shut OFF electric power at unit disconnect or service panel. 2.Install theappropriate fieldsupplied conduit fitting intotheheater knockout located in the rear panel of the unit. The knockout is sized NOTE: Check FIGURE 11 for heater/speed unacceptable. combinations that are 11/4" in diameter. 3.Connect field installed copper ground wire(s) to the ground lug(s) on the heater mounting plate. On models with more than one circuit, a separate copper ground wire MUST be connected to a separate ground lug for each circuit. 4. Route the field supplied line voltage wires for the heater to the line side of the electric heat accessory's circuit breaker(s) or high voltage wiring harness. Leave approximately 8" of excess wire so the breaker or wiring harness may be moved to service. Make line voltage connections to L3-L6 as appropriate. NOTE: If heaters without breakers are used, route field wires to inside of unit and attach to heater wires tagged L3-L6 as appropriate using supplied wire nuts. 5.Connect the black wire with terminal from the heater wire harness to the loose black wire at the unit blower or appropriate speed tap if lower speed is desired in electric heat mode. FIGURE 10 1 Typical Wiring Installation ( Breaker 6 Connect the red wire with terminal in the heater wire harness to the loose red wire from the unit sequencer. 7.Connect the white wire from the heater wire harness to the white wire from the thermostat at the field supplied low volt wire harness in the control box. 8.Connect the grey and brown wires from the heater wire harness to the blue wire from the unit 24V common. NOTE: If outdoor thermostats are used for staging electric heat, connect the grey and brown wires according to the thermostat instructions. See "Staging" in Electrical Wiring Section of this Manual. After completing installation of the heater, install the breaker rain shield on the blower access panel according to the following instructions on page 8. If using a pigtail style heater, proceed to Start-Up Procedures for Auxiliary Electric Strip Heat on page 10. Style Heater Shown-Pigtail style also available) Unit Line Voltage Wires Access hole for low voltage wires Knockout for unit field supplied line voltage wires Ground Lug Heater Ground Lug Unit blower heating speed tap leads FIGURE 11 Accessory Electric Heater Electrical Data MaximumOverourrent HEATER MODEL AMMK05AHA Used With SupplyVoltage KW Rating Nominal Heating BTUH 2-5 TON 240-1-60 4.8 t6,382 L3_ L4 20.0 25.0 30 208-1-60 3.6 t2,287 L3- L4 17.3 21.6 25 240-1-60 7.5 25,598 L3-L4 3t.2 39.1 45 208-1-60 5.6 19,113 L3-L4 26.9 33.6 40 240-1-60 9.6 32,765 L3- L4 40.0 50.0 60 208-1-60 7.2 24,574 L5- L6 34.6 43.3 50 40.0 20.0 50.0 25.0 60 30 AMMK05AHB AMMK07AHA 2-5 TON AMMK07AHB AMMK10AHA 2-5 TON AMMK10AHB AMMK15AHB AMMK20AHB 21/2-5 TON 21/2-5 TON Supply Circuit No. Heater Amps MininumCircuit Ampacity ProtectiveDevice (Amps) 240-1-60 14.4 49,t47 L3- L4 L5- L6 208-1-60 10.8 36,860 L3- L4 L5- L6 34.6 17.3 43.3 21.6 50 25 240-1-60 19.2 65,530 L3 - L4 L5 - L6 40.0 40.0 50.0 50.0 60 60 208-1-60 14.4 49,t47 L3 - L4 L5 - L6 34.6 34.6 43.3 43.3 50 50 FIGURE 12 Accessory Electric Heater Heating Data *TemperatureRise °F @ CFM Heater Model UseWith AMMK05AHA NC: 2-5 TON 1400 1600 1800 2000 12.6 10.6 9.5 8.4 7.6 2200 12,287 19.0 t4.2 11.4 9.5 8.1 7.1 6.3 5.7 --- 240-1-60 7.5 25,596 39.5 29.6 23.7 19.8 16.9 14.8 13.2 11.9 10.8 208-1-60 5.6 19,113 29.5 22.t 17.7 14.7 12.6 11.1 9.8 8.8 8.0 240-1-60 9.6 32,765 50.6 37.9 30.3 25.3 21.7 19.0 16.9 15.2 13.8 AMMK10AHB * ** 1200 15.2 3.6 NC: 2-5 TON AMMK20AHB** 1000 t9.0 208-1-60 AMMK07AHB AMMK15AHB* 800 25.3 KWHating 4.8 NC: 2-5 TON AMMK10AHA 600 16,832 SupplyVoltage 240-1-60 AMMK05AHB AMMK07AHA TotalHeating BTUH 208-1-60 7.2 24,574 37.9 28.4 22.8 19.0 16.3 14.2 12.6 11.4 10.3 21/2-5 TON 240-1-60 14.4 49,147 --- 56.9 45.5 37.9 32.5 28.4 25.3 22.8 20.7 10.6 19.2 36.860 56.9 42.7 21/2-5 TON 208-1-60 240-1-60 65,530 ...... 34.1 --- 28.4 50.6 24.4 43.3 2t.3 37.9 19.0 33.7 17.1 30.3 15.5 27.6 208-1-60 14.4 49,147 --- 56.9 45.5 37.9 32.5 28.4 25.3 22.8 20.7 15 KW HEATERNOTTO BE OPERATEDON LOWTAP FOR2 1/2 TON NC AND HP. 20 KW HEATERNOTTO BE OPERATEDON LOW ORMEDIUMLOWTAP FOR 3 AND 3 1/2 NC AND HP. Unit Disconnect Breaker FIGURE 13 l Installing Rain Circuit Breaker Shield Installation FIGURE 14 I Installing The Rain Shield 1 Spring Clip ReleaseTab RAIN SHIELD CLOSED CELL FOAM PAD 1/8" THICK 3 3/8' X 71/16" IN SIZE, ADHESIVE BACKED. INSIDE CIRCUIT BREAKER COVER. BREAKER HEATER PLUGS 1. Removeall screwsfrom thecover plate on Blower/ElectricalAccessPanel. If a seperateunit disconnectbreaker/switchisrequireditcan beinstalledinsidethe unit in 2. Installadhesive backedgasketon Blower/ElectricalAccess Panel. the heateraccessoryor asa singleinstallation byusingthe DisconnectSwitchKit.A sep erate powersupply circuit must be providedfor the unit. 3. Installlower frame of rainshield with4 screws. 1.To install the circuit breakeror switch,insertthe bottomfoot of thebreaker intolower mounting hole on the heater panel withthe breakerat a slightangle out from the panel. 4. Installrain shield hinged cover with4 screws. 5. Installcircuit breakerfiller plates(2 each per unusedbreakerslot.) 2. Pushbreakerin towardspaneland lift up slightlyso breakerfits intothe top mountinghole and snaps (locks)in position. 6. Re-install Blower/ElectricalAccess Panel. Breakers havea lockingspring clipto hold them inposition.Toremovebreakerlift upon the releasetab on top of the breakerand pullout and downslightly. FIGURE 15 --- Accessory Breaker Amps Electric NOTE: VERIFY ALLAPPROPRIATESEALSARE iN PLACE.SEE FIGURE14. Heater Heating Data Part Number Application 25 1082008 PA9524, PA5524, PAPA24, PAPC24 30 1082009 PA9530, PA5530, PAPA30, PAPC30 35 1082010 PA5536, PAPA36 40 1082011 PA9536, PAPC36 45 1082012 PA9542, PAPC42 50 1082013 PA5542, PA5548, PAPA42, PAPA48 60 1082014 PA9548, PAPC48 60 Switch 1082042 Fits AII- AMMO01 DSA Disconnect Switch Only (No Over Current Protection) DISCONNECT SWITCH KIT (includes 60A switch & rain shield) BREAKER FOR "NO HEAT" or PIGTAIL STYLE HEATER APPLICATION ONLY. FOR UNIT ONLY. 6. Air Distribution System For airflow data (blower performance data, blower speed tap settings, etc.) see theTechni- Ductwork Insulation cal Data Sheet attachedto the unit.. It is recommendedthat ductworkinstalledoutdoorshave a minimumof2" (51mm)offiberglassinsulationandbe coveredby a weatherproofvapor barrierthat is protectedagainst damage.Caulkingandflashings,or othermeansadequateto providea permanentweather seal,must be used. Ductwork NOTE:The total heatgain ofthestructureto be conditionedas expressedintotal Btuihr should be calculatedby manufacturer's methodor in accordance with"A.S.H.R.A.E Guide"or"Manual J - LoadCalculations"publishedbythe Air ConditioningContractorsof America. Thetotal heatgain calculatedshouldbe equal toor lessthan the coolingcapacity output basedon D.O.E.test procedures,steadystate efficiencytimes input. Ductwork,supply registers,and return air grilles MUST be designedand sizedto handle the unit's coolingair volume requirements,tf the unit is connectedto an existingsystem, theductworkMUSTbecheckedto makesureitis adequate.Extrarunsor largerductsizes may have to be installed. Maximumrecemmendedvelocityintrunkductsis 1000feetper minute(5.08m/s).Velocity in branchesshouldnot exceed800feet per minute(4.06m/s).Referto the TechnicaIData Label on the unit for unit air volumerequirements and system sizing recommendations. NOTE:Ductworksizing affectstemperaturerise and coolingtemperaturedifferential.Be sureto properlysizeductworkto the capacityand airflowcharacteristicsof your unit.Failure to doso can affectlimitcontrols,compressors,motors,andother componentsandwill lead to prematurefailure of components. This willalso adversely affectday to day unit performance. FlexibleDuctKitsare availablefrom yoursupplierto effectproper sizingand installationto Mobile Homesandother standardconstruction.. Referto unitratingplatefor properElectricHeat Accessorysizing andsee the TemperatureRiseChecksectionintheElectricHeatAccessorylnstallaUonSectionofthismanuaL FIGURE 16 Recommended It is recemmendedthatductworkinstalledin atticsor other areasexposedto outdoortemperatureshavea minimumof 2" (51ram)fiberglassinsulationand havean indoortypevapor barrier. Ductwork Connections The use of flexible, non-combustibleconnectorsbetweenmaintrunk ductsand supply and return air plenumsis recommendedto minimizevibrationtransmission. NOTE: Connectsupplyand returnair plenumsto unitin a mannerthatwill allowthe topof the unit to be removedwithout removingplenums.Plenums MUSTbe individuallysealed to unit casing. DuctsMUST be terminatedinside structure. Filters All return air MUSTpassthrough a fieldsuppliedfilter before enteringthe unit. If used,an electronic air cleaner MUST be installed in the return air ductwork. Minimum recommended filter areasare listed in FIGURE16 and are based on a velocityof 300 ftfmin (12m/s) for disposablefiltersand 500 ff/min (2.54m/s)for washablehigh velocityfilters. CAUTION Do NOT operate the unit without all filters in place. Filter Sizes NOTE: Some filtersare markedwithan arrowto indicatethe properdirectionof air flowthroughthe filter. The airflow directionwill betowardsthe blower motor.Make surefilter i installedcorrectly. Nominal Tons Air Conditioning 2 21/2 3 31/2 4 5 Recommended Filter Sizes Sq. In. Surface Arep/Nominal Size Nominal Air Flow Cubic Feet per Minute 700-900 900-1100 t100-1300 1300-1500 1500-1700 1900-2100 Disposable Filters 400 or 20 x 25 487 or 20 x 30 576 665 753 960 or or or or 14 16 20 20 x x x x 25 25 25 30 (2Req.) (2Req.) (2 Rea.'_ (2 Req.'l Cleanable 246 30t 356 411 466 575 Filters or 15 x 20 or 14x25 or 16 x 25 or 20 x25 or 20 x 25 or 24 x 25 7. Start-up Procedures I FIGURE 18 I Blower Motor Speed Taps I Electrical shock hazard. BIow'er Speed Tap Block Use extreme care during all of the following cedures. checks and pro- Make sure electric power is turned OFF as instructed propriate steps. in ap- Failure to follow this warning can result in property damage, personal injury, and/or death. Final Electrical Check Makeafinal wiringchecktobesuresystemiscorrectly wired.Inspectfieldinstalledwiring andtheroutingtoensurethatrubbingor chafingdue tovibrationwillnot occur. NOTE:Wiring MUSTbe installedso it is protectedfrom possiblemechanicaldamage. Circulating Air Blower Auxiliary DeterminingBlower Speed E_ectric Heat Wire (if used) connects here B 1.Turn electric power OFF. 2. From the system design, determine the total external static pressure (ESP) for the supply ducts, return ducts and registers, diffusers, grilles, dampers, heaters and filters. 3.To your system ESP determined wet coil. in Step 2, add 0.05 In. W.C. for a 4. From the system design, determine the desired cooling airflow in cubic feet per minute (CFM). 5. Locate the unit's Blower Performance Data table on the tech data label for the unit's voltage. (The tech data sheet is attached to the evaporator access panel on the unit.) From the table, determine the speed tap required to achieve the desired airflow. &See next section, Speed Taps, to set the blower motor speed terminal block (speed taps) to the cooling speed determined in the previous steps. Speed Taps AfterdeterminingtherequiredCFMandspeedtap datafromthetech datasheet, followthe steps below to change speedsif necessary. BE SURE TO CHECK BLOWER MOTOR SPEED DATA ON THE UNITS TECHNICAL DATA LABEL LOCATED ON THE UNIT. NOTE: Electric heater blower wire may be attached to any "Appropriate" speed tap See FIGURE 11 notes. The yellow lead MUST always be connected to the speed tap block at the common quick connect terminal. The terminal is identified as COM. Refer to FIGURE 18 and the appropriate unit wiring diagram included in this manual. Wire the black wire to the required speed tap terminal to achieve required airflow determined in Step 5. Cooling and Auxiliary Electric Strip Heat On Air Conditioning units with electric heat, the heat strip may be operated on a lower blower speed than cooling (Refer to Heater Chart FIG URE 11 ) See FIGURE 15 for connection location. Check Before Starting 1. Check that the blower motor speed terminal block is set to the proper cooling speed. Refer to the unit wiring diagram and the various airflow tables in this manual. 2. Check to see that clean, properly sized field supplied air filters are installed in the return air duct. FIGURE 17 [ Blower Speed Tap Settings 10 10 10 10 10 10 SEER SEER SEER SEER SEER SEER 2 TON 21/2 TON 3 TON 31/2 TON 4 TON 5 TON MED MED LOW MED HI LOW HI 12 12 12 12 12 SEER SEER SEER SEER SEER 2 TON 21/2 TON 3 TON 31/2 TON 4 TON MED MED LOW MED HI LOW 3. Inspect the inside of the unit to be sure that all wires are in place and all tools, etc. are removed. 4. Replace all service access panels. Checktheunit's operationasoutlinedinthe followinginstructions.If anyunusualsparking, odorsor noisesareencountered,shut OFFelectricpowerimmediately.Recheckfor wiring errors, or obstructionsin or near blower motors. Circulating Air Blower 1. Be sure electric power is OFF. 2. Set thermostat 10 Heat-Cool selector to OFF. 3.Setthermostat fanswitch toAUTO. Atemperature rise greater than 60°F (33.3°C) isnot recommended. (This applies toelectricheat only). 4.Turn electric power ON.Nothing should startrunning. 1.To check 5.Setthermostat fanswitch toON.Thecirculating airblower should come ONafter a30second delay. 2.Open ALL registers and duct dampers. the temperature rise through the unit, place thermometers in the supply and return air ducts as close to the unit as possible. 6. Reset thermostat fan switch to AUTO. The circulating air blower should go OFF after a 30 second delay. Nothing should be running. 3.Set thermostat Heat-Cool selector to HEAT. 4.Set the thermostat temperature setting as high as it will go. Cooling 5.Turn electric power ON. 1. Be sure that electric power is OFF. 6.Operate 2. Set thermostat Heat-Cool unit AT LEAST 5 minutes, then check temperature rise. select to COOL. NOTE: The maximum outlet air temperature for all models is 200°F (93.35C). Maximum temperature rise for electric heat is 60°F (33.35C) 3. Adjust thermostat setting to below room temperature. 7.Set thermostat 4. Turn electric power ON. During power application check the following: to normal temperature setting. 8.Turn electric power OFF. a. Contactor- Contactsclosing b. Compressor- ON c. Condenserfan motor - ON 9 Change blower speed tap if 60°F (33.3°C) TemperatureRise wasexceeded and repeat. d. Circulatingair blower- ON (afterdelay) 10.Be sure to seal all holes in ducts if any were created during this process. 5.Switch the thermostat to OFF, check the following: a. Contactorcontactsopening. b. Compressor- OFF c. Condenserfan motor - OFF Sequence of Operation d. Circulatingblower - OFF (afterdelay) CoolingMode: Energized(R,G,YI) De-energized (N/A) 6.Turn electric power OFF (a) When high and low voltage is initially applied to unit: Auxiliary Heating (f)On a call for cooling ......... : The compressor and condenser fan will energize. The evaporator blower motor will have a delay on and will energize after 30 seconds. NOTE: Repeat circulatingair blower procedureabove if AuxiliaryElectricHeat is being installedafter unit has been installedand checkedout. (2)When the cooling setpoint has been satisfied ......... : The compressor and condenser fan will de-energize immediately. The evaporator blower motor will have a delay off and will de-energize after 30 seconds. Temperature Rise Check Temperaturerise is the differencebetweenthe supply and return air temperatures.The temperaturerise shouldbe -+2°F (1.1°C) of the temperaturerise shown in FIGURE12. NOTE:The temperaturerise can be adjustedby changingthe heating speed tap at the unit's blowerterminal block.Referto the unit'sInstallationInstructionsfor airflowinformation. if temperature rise is excessive, verify proper airflow through the unit. if temperature rise is inadequate, check for proper electrical supply to the heater and verify correct airflow. 8. Operation izespressurethroughoutthe system and preventspossiblereverserotationof thescroll compressor. Electrical shock hazard. Turn OFF electric power supply at disconnect CAUTION Do NOT operate unit on cooling when the outdoor temperature is below 60°F. This is necessary to prevent possible damage to the com- switch or ser- vice panel before removing any access or service panel from unit. pressor. Failure to follow this warning can result in property damage, Turning The Unit Off personal injury, and/or death. 1.Set the thermostat selector switch to OFF and set the fan switch to AUTO. To restart, set thermostat selector switch to COOL or HEAT and set thermostat to temperature desired. Scroll Anti-Cycle Timer (Where Applicable) Single phaseunits withscrollcompressorscan be equipped withan anti-cycle device whichdelaysthe start of the compressorinthe event of a powerinterruption.This equal- 2.To shut the unit down completely, turn electric high voltage power OFF tl Thermostat Fan Switch Operation Withthe thermostatfan switchinthe ONposition,thecirculatingair blowerwillrun continuouslyat the speed usedfor cooling. Withthe thermostatfan switchinthe AUTOposition,thecirculatingair blowerwillonly run duringeach cooling or heatingcycle. Adjusting RoomTemperatures If the temperaturein individualroomsis not as desired,balancethe system byadjusting the dampets inthe branchducts.Adjusta littleata time andwaita dayafter eachchangeto judgethe effect.Oncethedampersare adjustedfor normalweatherconditions,it is bestto leavethem that way.Compensatefor temporaryweatherchanges byadjustingthe thermostatsetting. 9. Maintenance Monthly Maintenance and Inspection Checks CondenserFan Motor Air Filters CAUTION CAUTION Do NOT use 3in I oil, penetrating oil, WD40 or similar oilsto oil motor Do NOT operate unit without air filters. bearings. Inspectfiltersat leastmonthlyand replaceor clean as required.Washablefiltersmay be cleanedby soakingin mild detergentand rinsingwithcold water.Replacefilters withthe arrows on the side pointingin the directionof air flow.Dirtyfilters are the most common cause of inadequateheatingor cooling performance,and of compressorfailures. Motors used in this product are considered permanently lubricated for up to 5 years. If oil ports are provided on the motor, oilthe cendenserfanmotorand evaporatorblowermotor afterfive years of operationand every five years thereafter. Cooling Season Checks (M onthly) CondenserCoil UseSAE 10W30motoroil. To oil,removethe hole plugsfrom themotor endbellsand add severaldropsof oil witha squeezetype,flexibletube oiler.Replacehole plugsafteroiling. Do NOTover oil. Clean the surroundingareaand the condenserandevaporatorcoils.Usecautionto avoid damage to coil fins. Usea non-acid type of cleaner ONLY. Circulating Air Blower Keepthe condenserinletand outletarea cleanandfree of leaves,grassclippings or other debris.Grassshouldbe kept shortinfront of the condenserair inlet.Shrubbery MUSTbe trimmed back so it is no closer than 30 inches (762mm)to unit panels and 10 inches (254mm)to coil inlet. The condenserand evaporatorcoilsshouldbe cleanedbyusing a non-acid type cleaner to avoidremovingpaint or othertype ofcoatingon thecoi!. Alwaysturn offelectricalpower to the unit duringservice and maintenance. CondensateDrain Toaccessor removethe blowermotorusethe following steps. 1.Turn electric power OFF 2. Remove the blower access panel. 3. Unplug the wires connected to the speed tap block if necessary, ing the location of each wire for re-installation. Periodiccleaningofthe condensatedrain&trap maybe required.Inspectdrainageof condensate after at least 15 minutesof continuousoperationin cooling mode duringhumid conditions. Annual Maintenance and Inspection not- 4.Slide entire housing toward you. &Visually inspect the blower wheel for accumulations of dirt or lint. Clean the compartment and the blower wheel. If accumulation is excessive on blower wheel, or does not easily remove, it may be necessary to remove and disassemble the blower assembly for proper cleaning. Electrical shock hazard. &Oil blower motor if needed. Turn OFF electric power supply at disconnect switch or service panel before removing any access or service panel from unit. Failure to follow this warning personal injury, and/or death. CAUTION can result in property damage, Do NOT use 3in I oil, penetrating oil, WD40 or similar oilsto oil motor bearings. Oil the blowermotor byadding severaldropsof SAE 10W30 to each motor bearing.The blowermotor shouldbe oiledafter five yearsof operationand everyfive yearsthereafter. The annualinspectionMUST includelubricationand cleaningas requiredto ensureefficient operationof the unit.To simplifyaccess,removeall access panels. 7.When finished, reassemble 12 in reverse order.
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