ICP Package Units(both Units Combined) Manual L0523263
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 I • • • • • Safety Labeling and Rules Installation Requirements Location/Clearances Air Distribution Economizer Accessory I RESIDENTIAL Printed in U.S.A. • Ductwork Connections • • • • Wiring Start Up Procedures Maintenance Hoisting/Rigging SINGLE PHASE WITH DIRECT DRIVE BLOWER 518 01 1001 00 7/97 Table Of Contents 1. Safety Labeling and Signal Words Danger, Warning and Caution 1 7. Economizer Accessory ............. 13 1 Theory of Operation ........................ 13 1 Sequence of Operation 14 1 Cooling Mode ............................. 14 ........................... 1 Heating Mode ............................. 14 Danger Label .......................... 1 Warning Label ......................... 1 Caution Label ......................... 1 Signal Words ............... ... .............................. Signal Words in Manuals ................ Product Labeling 2. Unit Dimensions .................... 3. Safe Installation Requirements 4. Locating 2 ...... The Unit ................... 4 4 Access Panels ............................. 4 Clearances 4 ................................ Minimum Clearances to Combustible Construction .......................... Installation ................................. 5 8. Start-up ..................... Procedures Circulating Air Blower ............... 15 ...................... 15 Determining Blower Speed ............. 15 Speed Taps ............................... 15 Cooling, Heating and Auxiliary Electric Strip Heat (Heat Pump) ......... 15 Check Before Starting ...................... 15 Circulating Air Blower .................. Sequence of Operation 9. Operation ............ 15 16-17 ......................... 18 5 Features ............................. 18 Ground Level Installation ................ 5 Scroll Anti-Cycle Timer ..................... 18 Rooftop Installation ..................... 6 Thermal Expansion Valves .................. 18 Hoisting ................................... 6 Loss of Charge Pressure Switch ............. 18 Downflow Conversion 7 Defrost Control Time Interval Adjustment ...... 18 ....................... Condensate Drain .......................... 5. Electrical Wiring Low Voltage Wiring 18 9 Turning The Unit Off ....................... 18 ......................... 9 Thermostat Fan Switch Operation ............ 19 Adjusting Room Temperatures ............... 19 ................................ Unit Without Economizer Unit With Economizer Ground Connections Cooling .............................. .................... Low Voltage Wiring With Economizer Option ..................... Thermostat 8 9 9 ............... ................. 10 10 ....................... 10 Line Voltage Wiring ........................ 10 Converting 230V Units to 208V .............. 10 Field Installed Equipment .............. Final Electrical Check .................. 10 10. Maintenance ..................... Air Filters, Condenser Coil and Condensate Drain Maintenance .............. 19 19 Refrigeration Access Ports .................. 19 Annual Maintenance and Inspection .......... 20 Condenser Fan Motor ................. Blower Motor Access ....................... Method 1 and Method 2 ................ 20 20 20 10-11 Blower Motor Removal Using Method 1 .. 21 6. Air Distribution System ............. 12 Ductwork ................................. 12 Blower Motor and Blower Housing Removal Using Method 2 .............. 21 Ductwork Insulation 12 Blower Wire Color Identification .............. 21 ................... Ductwork Connections ................. Filters .................................... 12 12 Circulating Air Blower .................. 11. Rigging Instructions .............. 21 22 I Single Package Heat Pumps Installation Instructions I 1. SafetyLabeling andSignalWords Danger, Warning and Caution The signal words DANGER, WARNING and CAUTION are used to identify levels of hazard seriousness. The signal word DANGER is only used on product labels to signify an immediate hazard. The signal words WARNING and CAUTION will be used on product labels and throughout this manual and other manuals that may apply to the product. Danger Label White lettering on a black background except the word DANGER which is white with a red background. Signal Words DANGER - Immediate hazards which WILL result in severe personal injury or death. Warning Label WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death. White lettering on a black background except the word WARNING which is black with an orange background. CAUTION - Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. Signal Words in Manuals The signal word WARNING is used throughout this manual in the following manner: Caution Label White lettering on a black background except the word CAUTION which is black with a yellow background. The signal word CAUTION is used throughout this manual in the following manner: CAUTION Product Labeling Signal words are used in combination with colors and/or pictures on product labels. Following are examples of product labels with explanations of the colors used. 12J _ Installation Instructions Single Package Heat Pumps 2. Unit Dimensions MODELS: 2- 3 TON DIM INCHES MILLMETERS A 32 1/2" 826 B 47 3/8" / 203 C 47 38" / 203 D 3 1'8" 79 E /1 //8" 283 F 12" 306 G /4 1_4" 363 H /4 I/4" 363 I /2" 306 J 4" 102 K N/A N/A L 4 /'4" /08 M 43/8" /// N /4 //2" 368 P /2 /'4" 3/1 Q /2 1'8" 308 R E4 /4" 363 S /2 /'4" 3E8 LOW VOLTAGE 1/2" CONDUIT ELECTRIC HEAT POWER 1 ", 1-1/2", 2" CONDUIT UNIT ELECTRICAL POWER 3/4", 1 ", 1-1/4" CONDUIT UNIT BASE SHOWN SEPARATELY TO ILLUSTRATE BOTTOM DUCT OPENINGS Note: The above dimensions are in inches. ROOF CURB MODELS: 2- 3 TON DIM INOHES MILLIMETERS A 42 34" /086 B 39 34" /0/0 C /8'r 457 D /8" 457 E 3 3_a" 95 F 42 34" / 086 G 39 3_a" /OE0 H E8" 457 K _ 14" 356 "F'" 8_/_/3 * Roof curbs are also available in 8" (203mm) and 24" (610mm) heights (K dimension). I I Single Package Heat Pumps Installation Instructions UNIT DIMENSIONS MODELS: 31/2 - 5 TON DIM INCHES MI L METERS A 36" B 47 38" / 203 C 73" /854 D 4 58" //7 E 15" 38I F 12" 307 G /8 3/4" 476 H /8 3_4" 476 E2" 305 J J 9/4 /02 K N/A L 4 I '4" / 08 M 5 F4" E33 N 12 F4" 311 P E9" 483 Q 15" 381 R 19" 483 S /2 //4" 3/1 • /6 78" 429 I I I LOW VOLTAGE 1/2" CONDUIT UNIT BASE SHOWN TO ILLUSTRATE DUCT ELECTRIC HEAT POWER 1", 1-1/2", 2" CONDUIT SEPARATELY BOTTOM OPENINGS UNIT ELECTRICAL POWER 3/4", 1", 1-1/4" CONDUIT Note: Above dimensions are in inches ROOF CURB MODELS: 31/2 - 5 TON DIM INCHES A 67 3;4 rr f_'ILLIMETERS /721 B 64 3;4 rr 1645 C 23" 584 D 23" 584 E 2 //2" F 42 3;4" 1086 64 G 39 3t_4rr /010 H 23" 584 I /2" 305 J 12" 305 K _ /4" 356 ,,÷j p/ 80 /0 /4 * Roof curbs are also available in 8" (203mm) and 24" (610mm) heights (K dimension). _ Installation Instructions Single Package Heat Pumps I 3. SafeInstallationRequirements • Seal supply and return air ducts. 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 or in Canada CSA C22.1 - Canadian Electrical Code Part 1 or current edition. The information contained • Check to see that filters are installed correctly and are the proper type and size. NOTE: It is the personal responsibility and obligation of the customer to contact a qualified installer to ensure that the installation is adequate and conforms to governing codes and ordinances. in this manual is in- tended for use by a qualified service technician familiar with safety procedures and equipped with the proper tools and test instruments. Failure to carefully read and follow all instructions in this manual can result in unit malfunction, property damage, personal injury and/or death. 4. Locating The Unit The unit is designed for outdoor installation only. The unit may be installed on a concrete slab (or other adequate plat- Access Panels CAUTION form) at ground level, oron a rooftop with an adequate platform or a roof curb. Typical installations are shown in FIGURE 3 through FIGURE 5. Avoid installations under roof overhangs without guttering. Unit will NOT operate properly without all access panels in place. Unit MUST NOT be moved unless all access panels are in place. See FIGURE 1 on page 5 for a general view of unit and location of access panels. Water draining from the roof onto the unit could produce excessive noise, and may cause ice to build up on coil or fan. Clearances The location MUST allow for minimum clearances and should not be adjacent to a patio or other area where the unit's operating sound level might be objectionable. Local codes MUST be observed. Roof top installations are acceptable providing the roof will support the unit and provisions are made for water drainage and for the noise or vibration through the structure. IJJ Minimum clearances, as specified below and in FIGURE 2, MUST be maintained from adjacent structures to provide adequate air circulation and room for service personnel. I Single Package Heat Pumps Installation Instructions While minimum clearances are acceptable for safety reasons, they may not allow adequate air circulation around the unit for proper operation. Whenever possible, it is desirable to allow additional clearance, especially around the condenser inlet and discharge openings. Minimum Clearances FIGURE 2 1 (Typical 2 to 3 ton unit shown) 0" (2" (50mm) on 4 & 5 ton units 48" (1220mm) on all units with economizer / 30" (762mm) FIGURE 1 Access Panels (914mm) 0" Blower Access Panel J 30" (762mm) 30" (762mm) 80-00-01 I Electrical Access Panel Installation Do NOT install the unit in a location that will permit discharged air from the condenser to recirculate to the condenser inlet. CAUTION Do NOT operate unit in a corrosive atmosphere containing chlorine, fluorine, or any other corrosive chemicals. CAUTION Unit will NOT operate properly unless it is installed level front to rear and side to side. The slope MUST NOT be greater than 1/8" per foot (lOmm per meter). For side to side leveling, the control box side MUST always be lower. Ground Level Installation Minimum Clearances to Combustible Construction Ground level platform requirements: The unit MUST be situated to provide safe access for servicing. Supply and Return Air Ducts ...................... 0" Duct Connection Side (no economizer) ...... 0" (2" (50mm) on 4 & 5 ton models) Duct Connection Side (with economizer) . 48" (1220mm) Compressor Access Panel Side ......... 30" (762mm) Blower Access Panel Side .............. 30" (762mm) Electrical Access Panel Side ............ 30" (762mm) Clearance between 3 Ft. Overhang and Top of Unit ............ 30" (762mm) Combustible Base (Wood or Class A, B or C roof covering material) ................. 0" Platform may be made of either concrete or pressure treated wood and MUST be level and strong enough to support unit weight. Position platform separate from building foundation. Install in well-drained area, with top surface of platform above grade level and above the average winter snow levels to prevent coil blockage. Platform MUST be high enough to allow for proper condensate trap installation and drainage. See Figure 8 and associated text for more information about condensate drainage. _ Installation Instructions See FIGURE 3 for illustration installation. Single Package Heat Pumps of a typical ground level Rooftop Installation I Support for the unit MUST be level and strong enough to carry unit weight. The support may consist of a platform or a combination of platform and roof beams or curb. The platform may be constructed of pressure treated wood and may be covered with Class A, B or C roof covering. Rooftop platform requirements: The unit MUST be situated to provide safe access for servicing. The existing roof structure MUST be adequate to support the weight of the unit orthe roof MUST be reinforced. Check the weight of the unit in relation to the roof structure and local building codes or ordinances and reinforce roof structure if necessary. See NO TAG on the back cover of this manual for unit weights and corner weights. The unit MUST be installed above average snowfall levels to prevent coil blockage and to provide adequate drainage for water created in the defrost mode. Platform MUST allow for proper condensate trap installation and drainage. See FIGURE8 and associated text for more information about condensate drainage. See Hoisting section below for hoisting instructions. See FIGURE 4 and FIGURE 5 for illustrations of typical rooftop installations. Hoisting FIGURE 3 I NOTE: All access panels MUST be secured in place before hoisting. The unit should be hoisted with two lifting slings. Attach the slings to rigging shackles that have been hooked through holes in the base rail. Two spreader bars MUST be placed on top of the unit to protect the unit from damage from the pressure exerted by the slings. Make sure that all equipment is adequate to handle the weight of the unit and that the slings will not allow the unit to shift. Refer to FIGURE 19 on the back cover of this manual for illustrated rigging instructions and weight chart. Typical Installation (Ground Level) 2-3 ton unit shown I Single Package Heat Pumps FIGURE 4 Installation Instructions Typical Installation (Roof Curb) 2-3 ton unit shown Downflow Conversion These units are shipped ready for horizontal operation but are adaptable to downflow use. To convert to downflow use, follow these steps: 1. Remove the blockoff plates found in the return air compartment and the supply air compartment. See FIGURE 6 and FIGURE 7. NOTE: Blockoff plate in the supply air compartment only contains one screw. If reinstalling plate, back part of plate MUST fit into mating dimples of downflow flange. To reinstall, slant plate into dimples, then put plate into position and fasten with screw. 2. 80-10-16 Install the removed plates on the horizontal return and supply air openings. NOTE: It is the installer's personal responsibility to follow all local codes and ordinances and instructions contained herein, as well as instructions included with accessory items when installing unit. It is the installer's personal responsibility to locate directions for installation of this unit and any or all accessories. Manufacturer is NOT responsible for improper installation practices. / FIGURE 5 | Typical Installation (Pitched Roof) 31/2-5 ton unit shown I . 4. Position and install appropriate roof curb. (See Page 2 or Page 3 for appropriate curb to use with your model.) Install unit on roof curb. FIGURE 6 80-30-03 Blockoff Plate (Return Air Compartment) Single Package Heat Pumps _ Installation Instructions FIGURE 7 Blockoff Plate Removed (Return Air Compartment) FIGURE 8 J Condensate Drain Information* Electrical Access Panel 3/4" (19.1mm) Threaded Female PVC Fitting 1" (25.4mm} 2" (50.8mm) Condensate Drain 3/4" (19.1mm) Drain Line The condensate drain outlet is a 3/4" (19.1mm) threaded female PVC connection located at the bottom of the unit to the left of the electrical access panel (see FIGURE 8). Condensate drain outlet MUST be held with wrench when installing trap and drain line. The circulating blower and the condenser fan create a negative pressure on the condensate drain line that will prevent the condensate from draining properly without a trap. To combat this negative pressure, a field supplied condensate trap that will allow a standing column of water of at least 2" (50.8mm) MUST be installed. Top of outlet from trap MUST be at least 1" (25.4mm) below top of outlet from unit. Install the trap as near to the unit as possible for proper drainage. A3/4" (19.1mm) drain line MUST be installed if required by local codes or if location of unit requires it. Run the drain line to an open drain or other suitable disposal point. 80-30-27 * Condensate trap MUST be installed. I I Single Package Heat Pumps Installation Instructions 5. ElectricalWiring connections. If an economizer is installed, see the following section, Low Voltage Wiring With Economizer Option. Electrical shock hazard. LowVoltage Wiring With Economizer Option 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 electrical work MUST conform with the requirements of local codes and ordinances and in the United States with National Electrical Code ANSI/NFPA 70-1990 (or current edition) and in Canada with CSA C22.1 - Canadian Electrical Code Part 1 (or current edition). Provide line voltage power supply from a separate fused circuit with a disconnect switch (when required) located within sight of the unit. Supply voltage, amperage, wire, fuse and disconnect switch sizes MUST conform with specifications in the Parts List and on the unit rating plate. Wiring MUST be protected from possible mechanical damage and MUST NOT interfere with removal of access panels, filters, etc. Same as the above Low Voltage Wiring section except refer to the connection wiring diagram supplied with the economizer. NOTE: The jumper wire on the heat/cool relay must be disconnected from terminal number 3 and reconnected to the economizer wire terminated with an insulated male quick connect. See installation/operation manual accompanying economizer for more information. the the Thermostat The location of the thermostat has an important effect on the operation of the unit. FIGURE 9 and FIGURE t 0 show typical wiring connections for both manual and electronic thermostats. FOLLOW THE INSTRUCTIONS INCLUDED WITH THE THERMOSTAT FOR CORRECT LOCATION, MOUNTING AND WIRING FIGURE 9 All exposed wiring and connections MUST be made with weatherproof cable or wire unless installed in conduit. Mechnical Thermostat Low Voltage Connection Diagram Mechanical Thermostat Subbase LowVoltage Wiring (White Rodgers: 1F58-34) (2) ' I I Low voltage connections are made on the low voltage terminal board inside the electrical control compartment (see FIGURE 11). For access, remove the electrical control access panel (see FIGURE 1). Refer to the Parts List for the connection wiring diagram for the applicable model and to the instructions included with the thermostat. [C] [G] NOTE: If an Electric Heat Accessory is installed, see the Electric Heat Accessory Installation Manual for low voltage [O1 [Y] I (1) [W21 [El Jumper Wire [C] [G] [R] [O] [Y1] [Y2] [VVl] [vv2] Com Fan 24V Rev, Valve Ener Cool Pump Heat Cool Route low voltage wires through the port located at the bottom left corner of the blower access panel side of the unit. Route low voltage wires behind unit cornerpost, through the wire clip provided, and up to the low voltage terminal board. [R] Econo. Aux. Emer. Heat Low Voltage Terminal Board at the Unit. Thermostat Subbase Notes: (1) Common [q may be shown as [B] or [X] on other types of thermostats. (2) Terminals [W2] and [E] already jumpered at subbase. _ Installation Instructions Single Package Heat Pumps FIGURE 10 J Connection ElectronicThermostat Diagram Low Voltage Electronic Thermostat Subbase "- (White Rodgers: [C] [G] [R] [O1 f " " 1F92-71 _ 6"'''1 and 1F94-71) !2) 'I [YI] .... [Wl] (3) , '! [W21 [Ell (t1 I Connections for line voltage are made on the unit electrical control plate (see FIGURE tt). For access, remove the electrical access panel (see FIGURE 1). Refer to applicable wiring diagram in the Parts List. Complete the line service connections to the contactor 'L' terminals on the electrical control plate. Check all screw terminals to ensure they are tight. i I I ! ,' Jumper Wire i I I I I [C] [G] [R] [O1 Corn Fan 24V Rev. Valve Energ Cool I I I [YI] [Y21 [Wl] Pump Heat Coo! Econo. Aux. Emer. Heat ['v_/21 NOTE: If an Electric Heat Accessory is installed, refer to the Electric Heat Accessory Installation Manual to determine line voltage connections. The Electric Heat Accessory mounts inside the unit. Field supplied line voltage wires for the Electric Heat Accessory (separate from the field supplied line voltage wires to the unit) connect to the circuit breaker(s) in the Electric Heat Accessory. Low Voltage Terminal Board at the Unit. Thermostat Subbase Notes: (1) Common [C] may be shown as [B] or IX] on other types of thermostats. (2) Jumper subbase terminals [Y1] and [Wt]. (3) Jumper subbase terminals [W2] and [Et]. Unit Without Economizer A field supplied two stage heating-single heat pump thermostat is required. stage cooling Converting 230V Units to 208V To convert 230V units to 208V: 1. Turn electric power OFF. 2. Remove the electrical access panel. 3. Locate the 24V control transformer. 4. Remove wires from the terminal labeled "240V" on the 24V control transformer and reconnect them to the 208V terminal of the 24V control transformer. 5. Replace the electrical access panel. Unit With Economizer A field supplied two stage cooling-two stage heating thermostat is recommended for use with an economizer. If a single stage cooling thermostat is used, the compressor will not start if the economizer can not satisfy the demand for cooling. GroundConnections A ground lug is installed on the control plate for the ground connection (see FIGURE tt). Use a copper conductor of the appropriate size from the unit to a grounded connection in the electrical service panel or to a properly driven and electrically grounded ground rod. See warning above. Field Installed Equipment Wiring to be done in the field between the unit and other devices, or between separate devices which are field installed and located, MUST NOT exceed the temperature limitations for type T wire and MUST be installed according to the manufacturer's instructions for the devices. Final Electrical Check Une Voltage Wiring Make a final wiring check to be sure system is correctly wired. Inspect field installed wiring and the routing to ensure that rubbing or chafing due to vibration will not occur. Do NOT complete line voltage connections until unit is permanently grounded. All line voltage connections and the ground connection MUST be made with copper wire. NOTE: Wiring MUST be installed so it is protected from possible mechanical damage. I Single Package Heat Pumps Installation Instructions FIGURE 11 I Typical Wiring Installation Low Voltage Terminal Board Electrical Control Plate Contactor 'L' Terminals Ground lug Carefully route low voltage wires behind unit cornerpost through wire clip Field supplied line voltage wires Knockout for Electric Heat Accessory field supplied line voltage wires _ Installation Instructions Single Package Heat Pumps I 6. Air DistributionSystem For airflow data (blower performance data, blower speed tap settings, filter sizes, etc.) see the Parts List. Ductwork Connections Ductwork The use of flexible, non-combustible connectors between main trunk ducts and supply and return air plenums is recommended to minimize vibration transmission. NOTE: The total heat gain/heat loss from the structure as expressed in total Btu/hr MUST be calculated by manufacturer's method or in accordance with "A.S.H.R.A.E. Guide" or "Manual J - Load Calculations" published by the Air Conditioning Contractors of America or in Canada "H.R.A.I. Residential Heating and Cooling Load Calculation Manual." The total heat gain calculated should be equal to or less than the cooling capacity output based on D.O.E. test procedures, steady state efficiency times input. Ductwork, supply registers, and return air grilles MUST be designed and sized to handle the unit's cooling air volume requirements. If the unit is connected to an existing system, the ductwork MUST be checked to make sure it is adequate. Extra runs or larger duct sizes may have to be installed. NOTE: Connect supply and return air plenums to unit in a manner that will allowthe top of the unit to be removed without removing plenums. Plenums MUST be individually sealed to unit casing. Ducts MUST be terminated inside structure. Filters All return air MUST pass through a filter before entering the unit. An electronic air cleaner, optional filter racks or other accessible filter arrangements MUST be installed in the return air ductwork. Minimum recommended filter areas are listed in the Parts List and are based on a velocity of 300 ft/min Maximum recommended velocity in trunk ducts is 1000 feet per minute (5.08m/s). Velocity in branches should not exceed 800 feet per minute (4.06m/s). Refer to the Parts List for unit air volume requirements and system sizing recommendations. NOTE: Ductwork sizing affects temperature rise and cooling temperature differential. Be sure to properly size ductwork to the capacity and airflow characteristics of your unit. Failure to do so can affect limit controls, compressors, motors, and other components and will lead to premature failure of components. This will also adversely affect day to day unit performance. Refer to unit rating plate for proper Electric Heat Accessory sizing and see the Temperature Rise Check section in the Electric Heat Accessory Installation Instructions. Ductwork Insulation It is recommended that ductwork installed outdoors have a minimum of 2" (51 mm) of fiberglass insulation and be covered by a weatherproof vapor barrier that is protected against damage. Caulking and flashings, or other means adequate to provide a permanent weather seal, must be used. It is recommended that ductwork installed in attics or other areas exposed to outdoor temperatures have a minimum of 2" (51 mm) fiberglass insulation and have an indoor type vapor barrier. (1.2m/s) for disposable filters and 500 ft/min (2.54m/s) for washable high velocity filters. CAUTION Do NOT operate the unit without all filters in place. I Single Package Heat Pumps Installation Instructions 7. EconomizerAccessory NOTE: see"Low For installation Voltage Wiring and wiring of economizer of Economizer Option" logic module also controls the compressor staging based on the thermostat input. (pg.10). The purpose of an economizer is to: • Provide cool outdoor air to the conditioned space during the cooling cycle to minimize the use of compressors. • Bring outdoor air into the conditioned space to meet minimum ventilation air requirements whenever the circulation blower is running. Theory of Operation The economizer has two sets of dampers that are mechanically linked together. The outdoor air dampers regulate the intake of outdoor air and the return air dampers regulate the flow of return air (see FIGURE 12). When the outdoor air dampers modulate open, the linkage causes the return air dampers to modulate closed. A barometric relief damper is installed in the return air side of the system. It relieves any positive pressure in the unit created by the economizer. The economizer is controlled by a logic module which field connects to the unit controls through a harness plug. The FIGURE 12 ] The minimum opening position of the outdoor air dampers is field adjustable. It is set on the logic module of modulating economizers or on the actuator motor of three-position economizers. The outdoor air enthalpy sensor is factory installed on the outdoor air dampers. The enthalpy change-over point is adjustable on the logic module. A mixed air sensor is field installed in the blower inlet. The mixed air sensor keeps the mixed air above 56°F (13.3°C). See the economizer installation instructions for the location of the mixed air sensor. A positive pressure is created in the building when the outdoor air dampers open and the return dampers close. This pressure must be vented or the air will not circulate properly. This is the function of the barometric relief dampers. A positive pressure forces the passive exhaust dampers to swing open. The outdoor air dampers open to the mininum position for outside air whenever the circulation blower is ON in the cooling or heating mode. Typical Downflow Economizer Outdoor Air Dampers Mixed Air Sensor Actuator Motor and Logic Module 80-50-28b Return Air Dampers Single Package Heat Pumps I _ Installation Instructions Sequence of Operation a. The economizer dampers will close to the minimum position for outdoor air and remain there. NOTE: For correct wiring to the low voltage terminal board, see the connection wiring diagram in the economizer's documentation and page 10 of this manual. b. Contactor Cl will remain energized and the compressor will continue to run. Heating Mode Cooling Mode When a field supplied two stage thermostat is in the FAN ON position: 1. The outdoor air dampers will open to the minimum position with R & G energized. 2. On the thermostat's call for cooling, the thermostat completes Circuit 1 between thermostat terminals R, G, O and Y1 for first stage cooling. 1. The outdoor air dampers will open to the minimum position with R & G energized. 2. The damper operates at minimum position with R, G & Y1 energized; in heating operation O is de-energized. The dampers will not modulate based on the enthalpy changeover setpoint. Turn to the "D" setpoint and dampers will remain at the minimum position setting at high enthalpy conditions for outdoor air. Turn to the "A" setpoint and the dampers will remain at the minimum setting at low enthalpy conditions for outdoor air. This can be checked by putting a 1.2K ohm resistor across terminals O & + and then by adjusting the setpoint on the enthalpy setpoint changeover potentiometer. The compressor will run atthe "D" setting: as the setting is moved to "A" the compressor will continue to run and the dampers will remain at minimum position. As the setting is changed from "A" to "D" the dampers will remain at minimum position and the compressor will continue to run. . The minimum damper position setting can be set by adjusting the setting damper position potentiometer. This can be set so that the dampers will fully close for a minimum setting if required. If the economizer's outdoor air enthalpy sensor determines that the outdoor air conditions are belowthe setting for economizer operation, the outdoor air dampers will modulate open and the return air dampers will modulate closed. . The mixed air sensor at the blower inlet modulates the economizer dampers to prevent the mixed air from falling below 56°F (13.3°C). (Mixed air refers to return air after it combines with outdoor air from the economizer.) The mixed air sensor modulates the outdoor air dampers between the full open and minimum outdoor air positions. If the mixed air is not cold enough to maintain the conditioned space at the selected temperature, the thermostat will make ¥2 and call for second stage cooling by energizing the economizer logic module. This energizes the Y1 anti-cycle delay timer and contactor Cl which starts the condenser fan and the 4. The economizer can be set at a minimum damper position in heating. The economizer will not modulate in the heating mode. compressor. 4. If the thermostat is still calling for cooling and the economizer's outdoor air enthalpy sensor determines that the outdoor air conditions have risen above the setting for economizer operation: NOTE: For residential applications, it is recommended that the minimum damper position be set to fully closed position unless fresh air requirements in the heating mode are necessary. I Single Package Heat Pumps Installation Instructions 8. Start-upProcedures cess panel and is also published in the Parts List for the desired speed tap to achieve the required CFM for the applicable model. Electrical shock hazard. Use extreme care during checks and procedures. all of the following Make sure electric power is turned instructed in appropriate steps. OFF as Failure to follow this warning can result in property damage, personal injury, and/or death. Circulating Air Blower Determining Blower Speed 1. Turn electric power OFF. 2. From the system design, determine the external static pressure (ESP) for the supply ducts, return ducts and registers, diffusers, grilles, dampers, heaters and filters. 3. To your system ESP determined in Step 2, add 0.05 In. W.C. for a wet coil. 4. From the system design, determine the desired cooling airflow in cubic feet per minute (CFM). . 6. Locate the unit's Blower Performance Data table in the tech data sheet for the unit's voltage. (The tech data sheet is attached to the inside of the electrical access panel and is also published in the Parts List.) From the table, determine the speed tap the desired airflow requires. See next section, Speed Taps, to set the blower motor speed terminal block (speed taps) determined in the following steps. SpeedTaps After determining the required CFM and speed tap data from the tech data sheet, follow the steps below to change speeds if necessary. NOTE: The yellow lead MUST always be connected to the speed tap block at the common quick connect terminal. The terminal is identified as COM. Also, this is the only lead which is 3/16" wide. All other quick connects are 1/4" wide. Refer to FIGURE 13 on Page 18 and the unit's wiring diagram, which is attached to the inside of the electrical ac- Cooling,Heating(Heat Pump)and Auxiliary Electric StripHeat NOTE: The cooling, heat pump and strip heat airflows are all on the same speed tap. The refrigerant system requires the same specific CFM for proper operation in the cooling and the heat pump mode. For this reason, cooling and heating airflow must be the same. DO NOT SPLITOUT INTO A COOLING SPEED AND HEATING SPEED. Check Before Starting 1. 2. Check that the blower motor speed terminal block is set to the proper speed. Refer to the unit wiring diagram and the Technical Labels in the Parts List. Check to see that clean, properly sized field supplied air filters are installed in the return air duct. 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. Check the unit's operation as outlined in the following instructions. If any unusual sparking, odors or noises are encountered, shut OFF electric power immediately. Recheck for wiring errors, or obstructions in or near blower motors. Circulating Air Blower 1. Be sure electric power is OFF. 2. Set thermostat Heat-Cool selector to OFF. 3. Set thermostat fan switch to AUTO. 4. Turn electric power ON. Nothing should start running. 5. Set thermostat fan switch to ON. The circulating air blower should come ON after a 30 second delay. 6. Reset thermostat fan switch to AUTO. The circulating air blower should go OFF after a 30 second delay. Nothing should be running. 7. Turn electric power OFF. _ Installation Instructions Sequence of Operation Cooling Mode: Energized(R,G,O,Y1) De-energized(N/A) (a) When high and low voltage is initially applied to unit: (1) On a call for cooling ......... : The compressor and condenser fan will have a delay on and will energize after 3 minutes. The evaporator blower motor will have a delay on and will energize after 30 seconds. The delay on for the compressor and the condenser fan can be by-passed by jumpering the test pins on the defrost board control. (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. (b)Whenhighand low voltage hasbeen applied to unitfor morethan 3 minutes: (1) On a call for cooling ......... : The compressor and condenser fan will energize immediately. The evaporator blower motor will have a delay on and will energize after 30 seconds. (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. HeatingMode:Energized(R,G,Y1) De-energized(13) (a) When high and low voltage is initially applied to unit: (1) On a call for heating ......... : The compressor and condenser fan will have a delay on and will energize after 3 minutes. The evaporator blower motor will have a delay on and will energize after 30 seconds. The delay on for the compressor and the condenser fan can be by-passed by jumpering the test pins on the defrost board control. Single Package Heat Pumps I (2) When the heating 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. (b) When high and low voltage has been applied to unit for more than 3 minutes (1) On a call for heating ......... : The compressor and condenser fan will energize immediately. The evaporator blower motor will have a delay on and will energize after 30 seconds. (2) When the heating 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. Defrost M ode:Energized (R,G,Y1) De-energized (13) Defrost Sensor Closed (1) On a call for defrost ......... When the defrost sensor closes (this can be simulated by jumpering across reset & common on the defrost board control) in the heating mode,there is a 30,60 or 90 minute defrost on delay before the defrost mode begins. This delay is determined by the jumper connecting to T1,T2 or T3 on the defrost board. This delay can be by-passed by jumpering the test pins on the defrost board control (this reduces the delay from 30 minutes to 7 seconds, from 60 minutes to 14 seconds and from 90 minutes to 21 seconds). In the defrost mode the reversing valve will energize and the condenser fan will de-energize. (2) When defrost has been completed ......... This condition will be maintained until the defrost sensor opens (this can be simulated by removing the jumper across reset & common on the defrost board control) or until the defrost mode operates for 10 minutes (or 2 seconds if test pins are jumpered), whichever comes first. I Single Package Heat Pumps FIGURE 13 Installation Instructions Blower Motor Speed Taps (4-Speed Motors) BE SURE TO CHECK BLOWER MOTOR SPEED DATA IN THE Parts List. NOTE: THE 21/2 CANNOT BE RUN AT THE LOW SPEED TAP SETTING. SEE Parts List FOR MORE INFORMATION. I I IMPORTANT NOTE: THE BLACK AND RED LEADS ARE UNDER 1 INSULATED QUICK CONNECT AT THE MOTOR TERMINAL BLOCK. THE RED LEAD IS FOR ELECTRIC HEATACCESSORY THE COOLING/HEAT PUMP/ELECTRIC THUS, HEAT MOTOR SPEED TAP WILL ALWAYS BE ON ONE SPEED TAP. IF THE SPEED TAP IS ADJUSTED, THE COOLING/HEAT PUMP/ELECTRIC SAME AIRFLOWS. BLOWER INTERLOCK. HEAT WILL ALL BE ADJUSTED TO THE _ Installation Instructions Single Package Heat Pumps I 9. Operation Defrost Control Time Interval Adjustment Electrical shock hazard. Electrical shock hazard. Turn OFF electric power supply at disconnect switch or service panel before removing any access or service panel from unit. 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 can result in property damage, personal injury, and/or death. Failure to follow this warning can result in property damage, personal injury, and/or death. To adjust defrost interval: Features Scroll Anti-Cycle Timer All single phase heat pumps with scroll compressors are equipped with a defrost control board which features an internal anti-short cycle timer that delays the start of the compressor in the event of a power interruption. This feature is to allow pressure equalization throughout the system and prevent possible reverse rotation of the scroll compressor. 1. Turn off all power to Heat Pump. 2. Remove control box cover. 3. Locate electronic defrost control board. 4. The Defrost Control Board has a jumper wire connected from Wl to T1, T2, or T3. To change the time interval, unplug the jumper wire at T1, T2, or T3 ONLY and connect it to terminal for desired time interval: T1 = 30 minutes, T2 = 60minutes, T3 = 90 minutes. Cooling Adjust thermostat setting to desired temperature and set thermostat Heat-Cool switch to COOL. The unit will come Thermal Expansion Valves on and operate automatically under control of the thermostat. Close all doors and windows. The unit may run contin- The evaporator and condenser coil each have a Thermal Expansion Valve for refrigerant metering. All of the valves used on evaporator coils have internal check valves for reverse flow. The valves on the condenser coils may have internal or external check valves for reverse flow. There is also a strainer tube located just in front of each valve for contaminant protection, along with the system bi-flow driers. uously for several hours or longer on the initial run because of residual heat and moisture in the house. This is normal for any air conditioning system. CAUTION Do NOT operate unit on cooling when the outdoor temperature is below 40°F (4.4°C). This is necessary to prevent possible damage to the compressor. Turning The Unit Off Loss of Charge Pressure Switch 1. Set the thermostat selector switch to OFF and set the fan switch to AUTO. To restart, set thermostat selector switch to COOL and set thermostat to temperature desired. A low pressure switch on the liquid line (high side) has been installed to prevent system damage due to a loss of charge. The switch will open and de-energize the contactor if the high side pressure drops below the set point of the switch. 2. To shut the unit down completely, turn electric power OFF. I Single Package Heat Pumps Installation Instructions Thermostat Fan Switch Operation FIGURE 14 Typical Branch Duct Dampers FIGURE 15 Typical Access Ports With the thermostat fan switch in the ON position, the circulating air blower will run continuously. With the thermostat fan switch in the AUTO position, the circulating air blower will only run during a cooling or heating cycle and when the electric heat accessory is required if the electric heat accessory is installed. Adjusting RoomTemperatures If the temperature in individual rooms is not as desired, balance the system by adjusting the dampers in the branch ducts. Adjust a little at a time and wait a day after each change to judge the effect. Once the dampers are adjusted for normal weather conditions, it is best to leave them that way. Compensate for temporary weather changes by adjusting the thermostat setting. 10.Maintenance Air Filters, Condenser Coil and Condensate Drain Maintenance Refer to Home Owners Manual supplied with your heat pump for information on filter sizes, condenser coil clearances from shrubbery and condensate ances. drainage allow- CAUTION Do NOT operate unit without filters in place. Inspect filters monthly and clean and/or replace as needed. Refrigeration Access Ports This unit is equipped with refrigeration access ports mounted on the side of the unit. Refer to FIGURE 15 for identification of ports. This unit is also equipped with internal access ports on the suction and discharge tubing line which can be used for evacuation, pull down and recharging of the refrigeration system. High Side Single Package Heat Pumps I I Installation Instructions Annual Maintenance and Inspection od 2 to replace or repair blower wheel, blower housing, or any unreachable components behind blower assembly. Electrical shock hazard. FIGURE 16 Blower Motor and Housing 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 can result in property damage, personal injury, and/or death. Condenser Fan Motor CAUTION Do NOT use 3 in 1 oil, penetrating oil, WD40 or similar oils to oil motor bearings. Oil the condenser fan motor after five years of operation and every five years thereafter. Use SAE 10W30 motor oil. To oil, remove the hole plugs from the motor end bells and add several drops (approximately 1/2 teaspoonful) of oil with a squeeze type, flexible tube oiler. Replace hole plugs after oiling. Do NOT over oil. Clean the surrounding area and the condenser and evaporator coils. Use caution to avoid damage to coil fins. Do not use an acid-based cleaner on coated fin material. Blower Motor Removal Using Method 1 1. Turn electric power OFF. 2. Remove the blower access panel. 3. Remove the four screws securing the blower housing to blower deck. If the unit has a support bracket, remove the two screws securing the support bracket to the blower housing. 4. Slide entire housing toward you. This will allow easier access to the speed tap block, motor, and wires. 5. Reach behind blower housing and locate blower wheel set nut. Loosen blower wheel set nut. 6. Disconnect all wires from motor and remove the four pins securing the blower motor mounting cradle to blower housing. 7. Pull motor towards you and remove. 8. When finished, reassemble in reverse order. Blower Motor Access To remove the blower motor and/or the blower motor housing assembly, refer to Method 1 and Method 2 below. Refer to FIGURE 16 for a view of blower motor and compartment. Method 1 and Method 2 Blower Motor and Blower Housing Removal Using Method 2 1. Turn electric power OFF. 2. Remove the blower access panel. 3. Remove four screws securing blower housing to blower deck. If the unit has a support bracket, remove the two screws securing the support bracket to the blower housing. 4. Slide entire housing toward you. 5. Remove screws securing corner and front of unit top (see FIGURE 17). Method 1 allows the motor to be removed without removing the entire blower housing assembly. If it is desirable to remove the entire blower housing assembly to work on the motor, use Method 2. With Method 2, the top of the unit is lifted up so that the entire blower housing assembly can be removed. Use Meth- CAUTION Do NOT place fingers between unit top and unit. I Single Package Heat Pumps 6. Raise corner of unit top at least 2" (50.8mm). Place a sturdy brace at least 2" (50.8mm) thick between corner and unit top. A 2X4 piece of wood is ideal for this. 7. Disconnect all wires from blower housing and slide blower housing out of unit. When finished, reassemble in reverse order. 8. FIGURE 17 Blower Access Showing Lid Propped with 2X4 Installation Instructions Circulating Air Blower 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 will be necessary to remove the blower assembly. CAUTION Do NOT use 3 in 1 oil, penetrating oil, WD40 or similar oils to oil motor bearings. Oil the blower motor by adding 1/2 teaspoonful (1cc) of SAE 10W30 to each motor bearing. The blower motor should be oiled after five years of operation and every five years thereafter. Blower Wire Color Identification Use FIGURE 18 on page 23 to identify wires on blower motor. To change speed tap settings, see Speed Taps in the Startup Procedures section of this manual. FIGURE 18 Wire Colors S Installation Instructions Single Package Heat Pumps I 11. Rigging Instructions FIGURE 19 Rigging Instructions RIGGING INSTRUCTIONS AWARNING - PROPERTY DAMAGE, PERSONAL INJURY AND/OR DEATH. All panels MUST be in place when rigging and lifting. Hook rigging shackles through holes in base rail, as shown in DetaiI-A. Use spreader bars, when rigging, to prevent unit damage. Be sure rigging and shackles are sufficient to handle weight listed below. SARS CABINET COOLING CAPACITY RANGE LENGTH WIDTH DETAIL HEIGHT A MAX. WEIGHT IN MM IN MM IN MM LB KG B 2.0 - 3 TONS 48.00 1219 48.00 1219 33.00 838 430 195 C 3.5-5 TONS 73.00 1854 48.00 1219 36.50 927 670 303 CORNER WEIGHTS in LBS. (KG) CORNER WEIGHTS MODEL OPERATING WEIGHT A B C D 2 TON 380(172.25) 81 (36.75) 111 (50.25) 108 (49) 80 (36.25) 21/2TON 387(175.50) 83(37.75) 113 (51.25) 110 (50) 81 (36.75) 396 (179.50) 84(38) 117 (53) 113 (51.25) 82 (37) 540(245.0) 113(51.0) 146(66.0) 158(72.0) 123(56.0) 4 TON 600(272.25) 116(52.85) 163(74.0) 187(84.85) 134(60.6) 5 TON 600(272.25) 116(52.85) 163(74.0) 187(84.85) 134(60.6) 3 TON 31/2 TON
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