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FX4C DIRECT EXPANSION FAN COIL UNITS
FY4A FOR PURON®REFRIGERANT
SIZES 018 TO 060
Installation Instructions
NOTE:Read the entire instruction manual before starting the
installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 1
INTRODUCTION 1
HEATER PACKAGES 1
INSTALLATION 1
Step 1 -Check Equipment 1
Step 2 -Mount Unit 2
Step 3 -Air Ducts 4
Step 4 -Electrical Connections 4
Step 5 -Refrigerant Tubing Connection and Evacuation .7
Step 6 -Refrigerant Flow-Control Device 8
Step 7 -Condensate Drains 8
Step 8 -Accessories 9
Step 9 -Sequence of Operation 10
START-UP PROCEDURES 10
CARE AND MAINTENANCE 10
AIRFLOW PERFORMANCE TABLES 11
PURON®(R-410A)QUICK REFERENCE GUIDE 12
SAFETY CONSIDERATIONS
Improper installation,adjustment,alteration,service,maintenance,
or use can cause explosion,fire,electrical shock,or other
conditions which may cause personal injury or property damage.
Consult a qualified installer,service agency,or your distributor or
branch for information or assistance.The qualified installer or
agency must use factory—authorized kits or accessories when
modifying this product.Refer to the individual instructions
packaged with kits or accessories when installing.
Follow all safety codes.Wear safety glasses and work gloves.Use
quenching cloth for brazing operations.Have fire extinguisher
available.Read these instructions thoroughly and follow all
warnings or cautions attached to the unit.Consult local building
codes and National Electrical Code (NEC)for special
requirements.
Recognize safety information.This is the safety—alert symbol 4
When you see this symbol on the unit and in instruction manuals,
be alert to the potential for personal injury.
Understand the signal words DANGER,WARNING,CAUTION,
and NOTE.These words are used with the safety-alert symbol.
DANGER identifies the most serious hazards which will result in
severe personal injury or death.WARNING signifies hazards
which could result in personal injury or death.CAUTION is used
to identify unsafe practices which may result in minor personal
injury or product and property damage.NOTE is used to highlight
suggestions which will result in enhanced installation,reliability,or
operation.
INTRODUCTION
Models FX4C and FY4A are designed for flexibility and can be
used for upflow,horizontal,or downflow (kit required)and
manufactured and mobile home applications.These units are
designed to meet the low air leak requirements currently in effect.
Because of this,the units need special attention in the condensate
pan and drain connection area and when brazing tubing.These
Units are designed specifically for Puron®refrigerant and must be
used only with Puron®refrigerant air conditioners and heat pumps
as shipped.These units are available for systems of 18,000 through
60,000 Btuh nominal cooling capacity.Factory-authorized,
field—installed electric heater packages are available in sizes 5
through 30kW.See Product Data literature for available accessory
kits.
HEATER PACKAGES
This unit may or may not be equipped with an electric heater
package.For units not equipped with factory—installed heat,a
factory-approved,field—installed,UL listed heater package is
available from your equipment supplier.See unit rating plate for a
list of factory—approved heaters.Heaters that are not factory
approved could cause damage which would not be covered under
the equipment warranty.If fan coil contains a factory-installed
heater package,minimum circuit ampacity (MCA)and maximum
fuse/breaker may be different than units with a same size
field-installed accessory heater.The differences is not an error and
is due to calculation difference per UL guidelines.
INSTALLATION
Step 1 —Check Equipment
Unpack unit and move to final location.Remove carton taking care
not to damage unit.Inspect equipment for damage prior to
installation.File claim with shipping company if shipment is
damaged or incomplete.
Locate unit rating plate which contains proper installation
infonnation.Check rating plate to be sure unit matches job
specifications.
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
Before installing or servicing unit,always turn off all power
to unit.There may be more than 1 disconnect switch.Turn
off accessory heater power,if applicable.
Step 2—Mount Unit
Unit can stand or lie on floor,or hang from ceiling or wall.Allow
space for wiring,piping,and servicing unit.
IMPORTANT:When unit is installed over a fmished ceiling
and/or living area,building codes may require a field—supplied
secondary condensate pan to be installed under the entire unit.
Some localities may allow as an alternative,the running of a
separate,secondary condensate line.Consult local codes for
additional restrictions or precautions.
A.Upflow Installation
If return air is to be ducted through a floor,set unit on floor over
opening and use 1/8 to 1/4”(3 to 6 mm)thick fireproof resilient
gasket between duct,unit,and floor.
Side return is a field option on slope coil models.Cut opening per
dimensions.(See Fig.1.)A field-supplied bottom closure is
required.
Fig.1 -Slope Coil Unit in Upflow Application
B.Downllow Installation
A07565
In this application,field conversion of the evaporator is required
using accessory downflow kit along with an accessory base kit.
Use fireproof resilient gasket,1/8 to 1/4”(3 to 6 mm)thick,
between duct,unit,and floor.
NOTE:To convert units for downflow applications,refer to
Installation Instructions supplied with kit for proper installation.
For slope fan coils,use kit Part No.KFADCO2O1SLP.For A-coils,
use kit Part No.KFADCO4O1ACL.Use fireproof resilient gasket,
1/8 to 1/4”(3 to 6 mm)thick,between duct,unit,and floor.
NOTE:Gasket kit number KFAHDOIO1SLP is also required for
all downflow applications to maintain low air leak/low sweat
performance.
C.Horizontal Installation
Units must not be installed with access panels facing up or down.
All other units are factory built for horizontal left installation.(See
Fig.2 and 3.)When suspending unit from ceiling,dimples in
casing indicate suitable location of screws for mounting metal
support straps.(See Fig.2.)
For horizontal applications having high return static and humid
return air,the Water Management Kit,KFAHCO125AAA,may
need to be used to assist in water management.
LOW VOLT
ENTRy
OPTIONS
Fig.2 -Slope Coil Unit in Horizontal Left Application
A00072
Fig.3 -A-Coil in Horizontal Left Application (Factory
Ready)
A CAUTION
010-048 21 538 no,)FRONT SERVICE
060-060 2V (6106,6)CLEARANCE
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or property
damage.
For optimum condensate drainage performance in horizontal
installations,unit should be leveled along its length and width.
A CAUTION
UNIT OR PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or property
damage.
The conversion of the fan coil to downflow requires special
procedures for the condensate drains on both A-coil and slope
units.The vertical drains have an overflow hole between the
primary and secondary drain holes.This hole is plugged for all
applications except downflow,but must be used for downflow.
During the conversion process,remove the plastic cap
covering the vertical drains only and discard.Remove the plug
from the overflow hole and discard.At completion of the
downflo-w installation,caulk around the vertical pan fitting to
door joint to retain the low air leak performance of the unit.
A07566
2
NOTE:Modular units can be disassembled and components
moved separately to installation area for reassembly.This process
accommodates small scuttle holes and limiting entrances to
installation sites.(See Fig.4.)
A95293
Fig.4 -Removal of Brackets on Modular Units
Horizontal Right Conversion of Units With Slope Coils
NOTE:Gasket kit number KFAHDO1O1SLP is required for
horizontal slope coil conversion to maintain low air leak/low sweat
performance.
1.Remove blower and coil access panel and fitting panel.(See
Fig.5.)
2.Remove coil mounting screw securing coil assembly to
right side casing flange.
3.Remove coil assembly.
4.Lay fan coil unit on its right side and reinstall coil assembly
with condensate pan down.(See Fig.5.)
5.Attach coil to casing flange using coil mounting screw pre
viously removed.
6.Make sure the pan cap in the fitting door is properly seated
on the fitting door to retain the low air leak rating of the
unit.
7.Add gaskets from kit KFAHD per kit instructions.
8.Align holes with tubing connections and condensate pan
connections,and reinstall access panels and fitting panel.
Make sure liquid and suction tube grommets are in place to prevent
air leaks and cabinet sweating.Install after brazing.
Horizontal Right Conversion of Units With A-Coils
1.Remove blower and coil access panels.(See Fig.6.)
A00071
Fig.6 -Conversion for Horizontal Right Applications Using
A-Coil
2.Remove metal clip securing fitting panel to condensate pan.
Remove fitting panel.
3.Remove 2 snap-in clips securing A-coil in unit.
4.Slide coil and pan assembly out of unit.
5.Remove horizontal drain pan support bracket from coil sup
port rail on left side of unit and reinstall on coil support rail
on right side of unit.(See Fig.7.)
Fig.7 -Drain Pan Support Bracket
6.Convert air-seal assembly for horizontal right.
a.Remove air—seal assembly from coil by removing 4
screws.(See Fig.6.)
b.Remove air splitter (B)from coil seal assembly by re
moving 3 screws.(See Fig.3-factory shipped inset.)
c.Remove filter plate (A)and install air splitter (B)in
place of filter plate.
d.Install filter plate (A)as shown in horizontal right ap
plication.
e.Remove condensate troughs (C)and install on opposite
tube sheets.
f.Install hose onto plastic spout.
COIL
SUPPORT
RAIL
COIL
BRACKET
PRIMARY DRAIN
HORIZONTAL RIGHT
SECONDARY DRAIN
HORIZONTAL RIGHT
H
A07571
COG
SUPPORT
RAIL
SLOPE 0011.
A03001
Fig.5 -Conversion for Horizontal Right Applications Using a
Slope Coil
3
7.Install horizontal pan on right side of coil assembly.
8.Slide coil assembly into casing.Be sure coil bracket on each
corner of vertical pan engages coil support rails.
9.Reinstall 2 snap—in clips to correctly position and secure
coil assembly in unit.Be sure clip with large offsets is used
on right side of unit to secure horizontal pan.
10.Remove two oval fitting caps from the left side of the coil
door and fitting panel.
11.Remove insulation knockouts on right side of coil access
panel.
12.Remove 2 oval coil access panel plugs and reinstall into
holes on left side of coil access panel and fitting panel.
13.Install condensate pan fitting caps (from item 10)in the
right side of the coil door making sure that the cap snaps
and seats cleanly on the back side of the coil door.Make
sure no insulation interferes with seating of the cap.
14.Reinstall access fitting panels,aligning holes with tubing
connections and condensate pan connections.Be sure to re
install metal clip between fitting panel and vertical conden
sate pan.
Make sure liquid and suction tube grommets are in place to prevent
air leaks and cabinet sweating.
D.Manufactured and Mobile Home Housing Applications
1.Fan coil unit must be secured to the structure using field—
supplied hardware.
2.Allow a minimum of 24”(610 mm)clearance from access
panels.
3.Recommended method of securing for typical applications:
a.If fan coil is away from wall,attach pipe strap to top of
fan coil using no.10 self-tapping screws.Angle strap
down and away from back of fan coil,remove all slack,
and fasten to wall stud of structure using 5/16-in,lag
screws.T’pical both sides of fan coil.
4 (O2mm)MJ’(
SECURE FAN COILTO STRUCTURE
UNIT AWAY FROM WALL.
PIPE STRAP
(TYPICAL BOTH SIDES)
OR
urr AGAINST WALL
.125’(3mm)
MOUNTING BRACKET
(TYPICAL BOTH SIDES)
Fig.8 -A-Coil
A07567
b.If fan coil is against wall,secure fan coil to wall stud
using 1/8”(3 mm)thick right-angle brackets.Attach
brackets to fan coil using no.10 self—tapping screws
and to wall stud using 5/16-in,lag screws.(See Fig.8.)
Step 3 —Air Ducts
Connect supply-air duct over the outside of 3/4”(19 mm)flanges
provided on supply-air opening.Secure duct to flange,using
proper fasteners for type of duct used,and seal duct—to-unit joint.
If return—air flanges are required,install factory-authorized
accessory kit.
Use flexible connectors between ductwork and unit to prevent
transmission of vibration.When electric heater is installed,use
heat—resistant material for flexible connector between ductwork
and unit at discharge connection.Ductwork passing through
unconditioned space must be insulated and covered with vapor
barrier.
Units equipped with 20—30kW electric heaters require a 1”(25
mm)clearance to combustible materials for the first 36”(914 mm)
of supply duct.
Ductwork Acoustical Treatment
Metal duct systems that do not have a 90°elbow and 10’(3m)of
main duct to first branch takeoff may require internal acoustical
insulation lining.As an alternative,fibrous ductwork may be used
if constructed and installed in accordance with the latest edition of
SMACNA construction standard on fibrous glass ducts.Both
acoustical lining and fibrous ductwork shall comply with National
Fire Protection Association as tested by IJL Standard 181 for Class
1 air ducts.
Step 4—Electrical Connections
All products from the factory utilize a printed-circuit board (PCB)
which has a low voltage circuit protective fuse (5 amp),fan motor
speed tap selection terminal (SPT),and time delay relay (TDR)
jumper.To disable the TDR feature,sever the jumper wire JW1.
(See Fig.9 and 10.)
When a factory-approved accessory control package has been
installed,check all factory wiring per unit wiring diagram and
inspect factory wiring connections to be sure none were loosened
in transit or installation.If a different control package is required,
see unit rating plate.
C8
RiO-FR9C7R7
R3 -1Th-C3
R6 t
Ri 1
RB
C5
C2 Ci R5-F’-
I \__I tNQ1D2E
O6i
A030)O
Fig.9 -Fan Coil Printed Circuit Board for FY4A Model
DOWN FLOW
-BASE KIT (KFACB)
SECURE UNIT TO FLOOR
ANGLE BRACKET OR PIPE STRAP
4
Before proceeding with electrical connections,make certain that
supply voltage,frequency,phase,and ampacity are as specified on
the unit rating plate.See unit wiring label for proper field high—
and low-voltage wiring.Make all electrical connections in
accordance with the NEC and any local codes or ordinances that
may apply.Use copper wire only.
The unit must have a separate branch electric circuit with a
field-supplied disconnect switch located within sight from,and
readily accessible from,the unit.
On units with a factory-installed disconnect with pull-out
removed,service and maintenance can be safely performed on only
the load side of the control package.
A.Line Voltage Connections
If unit will contain accessory electric heater,remove and discard
power plug from fan coil and connect male plug from heater to
female plug from unit wiring harness.(See Electric Heater
Installation Instructions.)
For units without electric heater:
1.Connect 208/230v power leads from field disconnect to yel
low and black stripped leads.
2.Connect ground wire to unit ground lug.
NOTE:Units installed without electric heat should have a
field—supplied sheet metal block—off plate covering the heater
opening.This will reduce air leakage and formation of exterior
condensation.
B.24-v Control System
Connection To Unit
Wire low voltage in accordance with wiring label on the blower.
(See Fig.11 through 16.)Use no.18 AWG color-coded,insulated
(35CC minimum)wire to make the low-voltage connections
between the thermostat,the unit,and the outdoor equipment.If the
thermostat is located more than 100’(30 m)from the unit (as
measured along the low—voltage wire),use no.16 AWO
color-coded,insulated (35CC minimum)wire.All wiring must be
NEC Class 1 and must be separated from incoming power leads.
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or
death.
Field wires on the line side of the disconnect found in the fan coil
Unit remain live,even when the pull-out is removed.Service and
maintenance to incoming wiring cannot be performed until the
main disconnect switch (remote to the unit)is turned off.
A05181
Fig.10 -Fan Coil Printed Circuit Board
for FX4C Model
A CAUTION
H
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
If a disconnect switch is to be mounted on unit,select a
location where drill or fastener will not contact electrical or
refrigerant components.
FigS 11 -Wiring Layout Air Conditioning Unit
(Cooling Only)
A94058
5
Fig.12 -Wiring Layout Air Conditioning Unit
(Cooling and 1-Stage Heat)
FAN COIL
(CONTROL)HEAT PUMP
(CONTROL)-——c--
—-C_;;:Qtjj W2
/hi w
C—
THERMOSTAT
Fig.13 -Wiring Layout Heat Pump Unit
(Cooling and 2-Stage Heat with
No Outdoor Thennostat)
FAN COIL
(CONTROL)
Fig.14 -Wiring Layout Heat Pump Unit
(Cooling and 2-Stage Heat with
1 Outdoor Thermostat)
Fig.15 -Wiring Layout Heat Pump Unit
(Cooling and 2-Stage Heat with 2
Outdoor Thermostats)
FAN COIL
(CONTROL)
A03068
Fig.16 -Wiring Layout Heat Pump Unit
(Cooling and 2-Stage Heat for Manufactured Housing)
Refer to outdoor unit wiring instructions for any additional wiring
procedure recommendations.
Transformer Information
Transformer is factory—wired for 230v operation.For 208v
applications,disconnect the black wire from the 230v terminal on
transformer and connect it to the 208v terminal.(See Fig.17.)
EMERGENCY HEAT RELAY
w2
0
Y
A94062
A94059
A94060
A94061
6
The controls are factory circuited for single-stage operation.For
2-stage operation,use outdoor thermostat kit Part No.
KHAOTO3O1FST,and for 3-stage use both kits Part No.
KHAOTO2O1SEC and KHAOTO3O1FST.
When 2 stages are desired,cut W3 at the W2 wire nut,strip and
reconnect per the thermostat kit instruction.(See Fig.14.)When 3
stages are desired,cut the W2 wire nut off and discard.Strip W2,
W3,and B and reconnect per thermostat kit instructions.(See Fig.
15.)
NOTE:When 3 stages are used or anytime the B terminal is not
tied to W2,the emergency heat relay,part of outdoor kit Part No.
KHAOTO2O1SEC must be used.
C.Manufactured Housing
In manufactured housing applications,the Code of Federal
Regulations,Title 24,Chapter XX,Part 3280.714 requires that
supplemental electric heat be locked out at outdoor temperatures
above 40°F (4°C),except for a heat pump defrost cycle.Refer to
Fig.16 for typical low voltage wiring with outdoor thermostat.
D.Ground Connections
NOTE:Use UL-listed conduit and conduit connector for
connecting supply wire(s)to unit to obtain proper grounding.
Grounding may also be accomplished by using grounding lugs
provided in control box.
E.Minimum CFM and Motor Speed Selection
Units with or without electric heaters require a minimum CFM.
Refer to the unit wiring label to ensure that the fan speed selected is
not lower than the minimum fan speed indicated.
FY4A fan speed selection is done at the fan relay printed—circuit
board.To change motor speeds,disconnect fan lead used on relay
terminal (SPT)and replace with motor speed tap desired.(See Fig.
18.)Save insulating cap and place on motor lead removed from
NOTE:lii low static applications,lower motor speed tap should
be used to reduce possibility of water being blown off coil.
Most units have 3 motor speed taps.Low speed (red)is designed
for mismatched outdoor unit applications.Medium speed (blue)is
designed for straight matched operations.High speed (black)is
used with high external static duct systems of straight matched
systems.
The fan speed selection on the FX4C models is done at the motor.
To change motor speeds,disconnect fan lead from terminal 2 and
move to desired speed tap;Low speed (one),Medium (two),and
High (three).
Step 5 —Refrigerant Tubing Connection and
Evacuation
Use accessory tubing package or field-supplied tubing of
refrigerant grade.Suction tube must be insulated.Do not use
damaged,dirty,or contaminated tubing because it may plug
refrigerant flow-control device.ALWAYS evacuate the coil and
field-supplied tubing to 500 microns before opening outdoor unit
service valves.
Heater Staging
relay.
Fig.17 -Transformer Connections
A05182
A CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
If W2,W3,and E on any 3 stage heater (18,20,24,or
30kW)are individually connected as with outdoor
thermostats or any other situation,emergency heat relay must
be used.This relay is in kit Part No.KHOTO2O1SEC and is
normally used with kit Part No.KHAOTO3O1FST for 2
outdoor thermostat systems.
H
Aa7529
Fig.18 -Fan Coil Relay and Speed Tap Terminal for FY4A
Models
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
According to NBC,ANSI/NFPA 70,and local codes,the
cabinet must have an uninterrupted or unbroken ground to
minimize personal injury if an electrical fault should occur.
The ground may consist of electrical wire or metal conduit
when installed in accordance with existing electrical codes.If
conduit connection uses reducing washers,a separate ground
wire must be used.
7
Units have sweat suction and liquid tube connections.Make
suction tube connection first.
1.Cut tubing to correct length.
2.Insert tube into sweat connection on unit until it bottoms.
3.Braze connection using silver bearing or non—silver bearing
brazing materials.Do not use solder (materials which melt
below 800F /427CC).Consult local code requirements.
4.Evacuate coil and tubing system to 500 microns using deep
vacuum method.
Step 6—Refrigerant Flow-Control Device
The FX4C and FY4A are equipped with Puron®refrigerant TXV.
Use outdoor units designed for Puron®refrigerant only.
Step 7—Condensate Drains
To connect drains,the cap openings must be removed.Use a knife
to start the opening near the tab and using pliers,pull the tab to
remove the disk.Clean the edge of the opening if necessary and
install the condensate line.Finally caulk around the lines where
they exit the fitting to retain the low leak rating of the unit.
Units are equipped with primary and secondary 3/4-in.FPT drain
connections.For proper condensate line installations see Fig.1,2,
3,5 and 6.To prevent property damage and achieve optimum
drainage performance,BOTH primary and secondary drain lines
should be installed and include properly-sized condensate traps.
(See Fig.19 and 20.)Factory-approved condensate traps are
available.It is recommended that PVC fittings be used on the
plastic condensate pan.Finger-tighten plus 1-1/2 turns.Do not
over-tighten.Use pipe dope.
Fig.19 -Recommended Condensate Trap
At3002
A CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
A brazing shield MUST be used when tubing sets are being
brazed to the unit connections to prevent damage to the unit
surface and condensate pan fitting caps.
A CAUTION
UNIT OR PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
The conversion of the fan coil to downflow requires special
procedures for the condensate drains on both A—coil and
slope units.The vertical drains have an overflow hole
between the primary and secondary drain holes.This hole is
plugged for all applications except downflow,but must be
used for downflow.During the conversion process,remove
the plastic cap covering the vertical drains only and discard.
Remove the plug from the overflow hole and discard.At
completion of the downflow installation,caulk around the
vertical pan fitting to door joint to retain the low air leak
performance of the unit.
A CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
Wrap a wet cloth around rear of fitting to prevent damage to
TXV and factory-made joints.
A CAUTION
A CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in product or
property damage.
Shallow running traps are inadequate and DO NOT allow
proper condensate drainage.(See Fig.21.)
PRODUCT OPERATION HAZARD
Failure to follow this caution may result in improper product
operation.
If using a TXV in conjunction with a single-phase
reciprocating compressor,a compressor Start capacitor and
relay are required.Consult outdoor unit pre-sale literature for
start assist kit part number.
8
cESS ALTER
PANEL
SECONDARY OP-MN WITH
APPROPRIATE TRAP REQUIRED
(USE FACTORY AT OR
PRIMARY TRAP REQUIR
FIOLD-SUPPUED TRAP)
(USE FACTORY KIT OR
FIELa-SEPPLIED TRAP OF
SUFFICIENT DEPTH
STRUDRAD P-TRAPS ARE
NOT SUFFICIENT SEC
F1S(JREOF RECtKIMDSOED
CONDENSATE TRAP)
Fig.20 -Condensate Trap and Unit
A03003
A03013
Fig.21 -Insufficient Condensate Trap
NOTE:When connecting condensate drain lines,avoid blocking
filter access panel,thus preventing filter removal.After connection,
prime both primary and secondary condensate traps.
NOTE:If unit is located in or above a living space where damage
may result from condensate overflow,a field—supplied,external
condensate pan should be installed underneath the entire unit,and a
secondary condensate line (with appropriate trap)should be run
from the unit into the pan.Any condensate in this external
condensate pan should be drained to a noticeable place.As an
alternative to using an external condensate pan,some localities
may allow the use of a separate 3/4”(19 mm)condensate line (with
appropriate trap)to a place where the condensate will be
noticeable.The owner of the structure must be informed that when
condensate flows from the secondary drain or external condensate
pan,the unit requires servicing or water damage will occur.
Install traps in the condensate lines as close to the coil as possible.
(See Fig.20.)Make sure that the outlet of each trap is below its
connection to the condensate pan to prevent condensate from
overflowing the drain pan.Prime all traps,test for leaks,and
insulate traps if located above a living area.Condensate drain lines
should be pitched downward at a minimum slope of 1”(25 mm)
for every 10’(3 m)of length.Consult local codes for additional
restrictions or precautions.
Step 8 —Accessories
A.Electronic Air Cleaner
The Electronic Air Cleaner may be connected to fan coil as shown
in Fig.22.This method requires a field supplied transformer.See
Electronic Air Cleaner literature for kit requirements.
B.Humidifier
Connect humidifier and humidistat to fan coil unit as shown in Fig.
23 and Fig.24.The cooling lockout relay is optional.
A03011
Fig.22 -Wiring Layout of Electronic Air Cleaner to Fan Coil
for FY4A Models Only
A95294
Fig.23 -Wiring Layout of Humidifier to Heat Pump
H
DO NOT USE ShALLOW RUNN)NG TRAPS!
208/
230
FROM MOLEX
PLUG AND
TRANSFORMER
(IN UNIT)
9
THERMOSTAT START-UP PROCEDURESFANCOIL
(CONTROL)
Refer to outdoor unit Installation Instructions for system start-up
instructions and refrigerant charging method details.
CARE AND MAINTENANCE
To continue high performance and minimize possible equipment
failure,it is essential that periodic maintenance be performed on
this equipment.Consult your local dealer as to the proper
A95295 frequency of maintenance contract.
Fig.24 -Wiring Layout of Humidifier to Fan Coil The ability to properly perform maintenance on this equipment
With Electric Heat requires certain mechanical skills and tools,If you do not possess
these,contact your dealer for maintenance.The only consumer
Step 9 —Sequence of Operation service recommended or required is filter replacement or cleaning
on a monthly basis.A.Continuous Fan
Thermostat closes R to G.G energizes fan relay on PCB which
completes circuit to indoor blower motor.When 0 is de—energized,
there is a 90-sec delay before relay opens.
B.Cooling Mode
Thermostat energizes R to 0,R to Y,and R to 0 (heat pump only).
G energizes fan relay on PCB which completes circuit to indoor
blower motor.When G is de—energized,there is a 90—sec delay
before fan relay opens.
C.Heat Pump Heating with Auxiliary Electric Heat
Thermostat energizes R to 0,R to Y,and R to W.G energizes fan
relay on PCB which completes circuit to indoor blower motor.W
energizes electric heat relay(s)which completes circuit to heater
element(s).When W is dr—energized,electric heat relay(s)open,
turning off heater elements.When G is de—energized there is a
90—sec delay before fan relay opens.
D.Electric Heat or Emergency Heat Mode
Thermostat closes R to W.W energizes electric heat relay(s)which
completes circuit to heater element(s).Blower motor is energized
through normally closed contacts on fan relay.When W is
de-energized,electric heat relay(s)opens.
A CAUTION
UNIT COMPONENT HAZARD
Failure to follow this caution may result in product damage.
Never operate unit without a filter.Damage to blower motor
or coil may result.Factory authorized filter kits must be used
when locating the filter inside the unit.For those applications
where access to an internal filter is impractical,a
field—supplied filter must be installed in the return duct
system.
10
AIRFLOW PERFORMANCE TABLES
FX4C BLOWER f TOTAL EXTERNAL STATIC PRESSUREZESPEEDrib2010.30
High
I
766 739 706 666 619 566
018 Medium 701 659 619 578 538 499
Low 614 572 530 486 441 396
High 941 905 868 830 792 753
024 Medium 823 786 747 707 665 622
Low 633 583 533 482 431 378
High 1130 1097 1063 1028 992 955
030 Medium 1033 1000 965 928 888 846
Low 840 802 760 713 663 609
High 1437 1398 1354 1308 1257 1204
036 Medium 1282 1238 1192 1142 1090 1036
Low 1168 1118 1067 1014 959 903
High 1616 1578 1533 1480 1420 1353
042 Medium 1479 1437 1392 1344 1293 1240
Low 1303 1258 1211 1161 1108 1054
High 1805 1772 1739 1704 1669 1632
048 Medium 1652 1617 1581 1543 1504 1463
Low 1458 1418 1377 1335 1292 1248
High 2057 2024 1989 1954 1916 1878
060 Medium 1799 1766 1731 1695 1658 1618
Low 1667 1633 1596 1558 1517 1475
—Airflow outside 450 ofrn/ton.
NOTES:
FY4A BLOWER TOTAL EXTERNAL STATIC PRESSURE
SIZE SPEED 0.10 0.20 0.30 0.40 0.50 0.60
018 High £‘PL
Low 633 620 588 538 468 380
024 High 1055 991 926 860 793 724
Low 934 878 818 754 686 614
030 High 1070 1032 978 908 822 721
Low 910 888 849 791 715 621
036 High 1352 1316 1273 1223 1167 1103
Low 1137 1112 1081 1043 998 946
High 1720 1521 1426 1316
042 Medium 1576 1540 1488 1421 1338 1239
Low 1388 1367 1330 1278 1209 1124
High 1902 1824 1743 1659 1571 1479
048 Medium 1830 1763 1690 1611 1527 1436
Low 1625 1584 1531 1465 1387 1296
High 2128 1965 1875 1778 1674
060 Medium 1959 1898 1829 1750 1663 1566
Low 1748 1709 1659 1598 1525 1442
1.Airflow based upon dry coil at 230v with factory—approved filter and electric heater (2 element heater sizes 018 through 036,3 element
heater sizes 042 through 060).Airflow at 208 volts is approximately 10%lower for FY4A models.For FX4C models,airflow at 208 volts
is approximately the same as 230 volts because the X13 motor is a constant torque motor.The torque doesn’t drop off at the speeds the
motor operates.
2.To avoid potential for condensate blowing out of drain pan prior to making drain trap:
Return static pressure must be less than 0.40 in.wc.
Horizontal applications of 042 -060 sizes must have supply static greater than 0.20 in.wc.
H
3.Airflow above 400 cfm/ton on 048-060 size could result in condensate blowing off coil or splashing out of drain pan.
Table 2—Air Delivery Performance Correction Component Pressure Drop (in.we)at Indicated Airflow (Dry to Wet Coil)
FYFX CFM
SIZE 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
018 0.034 0.049 0.063 ————
024 0.016 0.027 0.038 0.049 0.059 ——————————
030 0.049 0.059 0.070 0.080 ——————
036 ————0.055 0.064 0.073 0.081 ————————
042 0.049 0.056 0.063 0.070 ————
048 ————————————0.038 0.043 0.049 0.054 0.059 ————
060 ————.——————0.027 0.031 j039 0.043
Table 3—Factory-Installed Filter Static Pressure Drop (in.wc)
FY,FX CFM
SIZE 400 600 800 1000 1200 1400 1600 1800 2000
018 0.020 0.044 0.075 ——————
024,030 —0.022 0.048 0.072 0.100 ————
036,042,048 ———0.051 0.070 0.092 0.120 0.152 —
060 ————I ——0.086 0.105 0.130
Table 4—Electric Heater Static Pressure Drop (in.wc)
FX,FY FX,FY
018—036 042—060
HEATE EXTERNAL STATIC EXTERNAL STATICRkWPRESSUREHEATERkWPRESSUREELEMENTSCORRECTIONELEMENTSCORRECTION
0 0 +02 0 0 +04
1 3,5 +01 2 8,10 +02
2 8,10 0 3 9,15 0
3 9,15 —.02 4 20 —.02
4 20 -.04 6 18,24,30 —.10
Table 1 —Airflow Performance (CFM)
11
PURON®(R-410A)QUICK REFERENCE GUIDE
•Puron refrigerant operates at 50-70 percent higher pressures than R-22.Be sure that servicing equipment and replacement
components are designed to operate with Puron refrigerant.
•Puron refrigerant cylinders are rose colored.
•Recovery cylinder service pressure rating must be 400 psig,DOT 4BA400 or DOT BW400.
•Puron refrigerant systems should be charged with liquid refrigerant.Use a commercial type metering device in the manifold hose
when charging into suction Line with compressor operating
•Manifold sets should be 700 psig high side and 180 psig low side with 550 psig low-side retard.
•Use hoses with 700 psig service pressure rating.
•Leak detectors should be designed to detect HFC refrigerant.
•Puron refrigerant,as with other HFCs,is only compatible with POE oils.
•Vacuum pumps will not remove moisture from oil.
•Do not use liquid-line filter driers with rated working pressures less than 600 psig.
•Do not leave Puron refrigerant suction line filter driers in line longer than 72 hours.
•Do not install a suction—line filter drier in liquid line.
•POE oils absorb moisture rapidly.Do not expose oil to atmosphere.
•POE oils may cause damage to certain plastics and roofing materials.
•Wrap all filter driers and service valves with wet cloth when brazing.
•A factory approved liquid—line filter drier is required on every unit.
•Do NOT use an R-22 TXV.
•If indoor unit is equipped with a R-22 TXV or piston metering device,it must be changed to a hard-shutoff Puron refrigerant TXV.
•Never open system to atmosphere while it is under a vacuum.
•When system must be opened for service,recover refrigerant,evacuate then break vacuum with dry nitrogen and replace filter driers.
Evacuate to 500 microns prior to recharging.
•Do not vent Puron refrigerant into the atmosphere.
•Do not use capillary tube coils.
•Observe all warnings,cautions,and bold text.
•All indoor coils must be installed with a hard-shutoff Puron refrigerant TXV metering device.
CopyrIght 2007 CAC/BDP•7310W,Morris St.•Indianapolis,IN 46231 Printed mU S.A.EdiSon Date:06/07 Catalog No:IM—FX4C—03
Manufacturer reserves the right to change,at any time,specifications and designs without notice and without obligations.Replaces IM—FX4C—02
24ABABase Series Air Conditioners with Puron®
Sizes 18 To 60
1 1/2 To 5 Nominal Tons
Installation Instructions
Fig.1 -Z4ABA
A05176
TABLE OF CONTENTS
Page
Safety Considerations 2
Installation Recommendations 2
Installation 3 -9
Step I -Check Equipment &Jobsite 3
Step 2 -Install on Solid Pad 3
Step 3 -Clearance Requirements 3
Step 4 -Operating Ambient 3
Step5-InstallTXV 3-4
Step 6 -Make Piping Connections 5 -7
Step 7 -Make Electrical Connections 7 -8
Step 8 -Compressor Crankcase Heater 8
Step 9 -Install Electrical Accessories 8
Step 10 -Start-Up 8 -9
Step 11 -Check Charge 9
Step 12 -Final Checks 9
Care and Maintenance 9 -11
Puron®Quick Reference Guide 12
r (Eer
J
Turn to the Expert
NOTE:Read the entire instruction manual before starting the
installation.
SAFETY CONSIDERATIONS INSTALLATION RECOMMENDATIONS
Improper installation,adjustment,alteration,service,
maintenance,or use can cause explosion,fire,electrical shock,or
other conditions which may cause death,personal injury,or
property damage.Consult a qualified installer,service agency,or
your distributor or branch for information or assistance.The
qualified installer or agency must use factory—authorized kits or
accessories when modifying this product.Refer to the individual
instructions packaged with the kits or accessories when installing.
Follow all safety codes.Wear safety glasses,protective clothing,
and work gloves.Use quenching cloth for brazing operations.
Have fire extinguisher available.Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit.Consult local building codes
and National Electrical Code (NEC)for special requirements.
Recognize safety information.This is the safety—alert symbol
When you see this symbol on the unit and in instructions or
manuals,be alert to the potential for personal injury.Understand
these signal words;DANGER,WARNING,and CAUTION.
These words are used with the safety-alert symbol.DANGER
identifies the most serious hazards which will result in severe
personal injury or death.WARNING signifies hazards which
could result in personal injury or death.CAUTION is used to
identify unsafe practices which would result in minor personal
injury or product and property damage.NOTE is used to
highlight suggestions which will result in enhanced installation,
reliability,or operation.
NOTE:In some cases noise in the living area has been traced to
gas pulsations from improper installation of equipment.
1.Locate unit away from windows,patios,decks,etc.where
unit operation sound may disturb customer.
2.Ensure that vapor and liquid tube diameters are
appropriate for unit capacity.
3.Run refrigerant tubes as directly as possible by avoiding
unnecessary turns and bends.
4.Leave some slack between structure and unit to absorb
vibration.
5.When passing refrigerant tubes through the wall,seal
opening with RTV or other pliable silicon-based caulk.
(See Fig.2.)
6.Avoid direct tubing contact with water pipes,duct work,
floor joists,wall studs,floors,and walls.
7.Do not suspend refrigerant tubing from joists and studs
with a rigid wire or strap which comes in direct contact
with tubing.(See Fig.2.)
8.Ensure that tubing insulation is pliable and completely
surrounds vapor tube.
9.When necessary,use hanger straps which are 1 in.wide
and conform to shape of tubing insulation.(See Fig.2.)
10.Isolate hanger straps from insolation by using metal
sleeves bent to conform to shape of insulation.
NOTvoid contact between tubing and structure
OUTDOOR WA INDOOR WAL
LIQUID TUBELqI/
\—INSULATION-’
VAPOR TUBE
THROUGH THE WALL
Fig.2 -Connecting Tube Installation
Outdoor unit contains system refrigerant charge for operation
with ARI rated indoor unit when connected by 15 ft.of
field—supplied or factory accessory tubing.For proper unit
operation,check refrigerant charge using charging information
located on control box cover and/or in the Check Charge section
of this instruction.
IMPORTANT:Maximum liquid—line size is 3/8-in.OD for all
residential applications including long line.
IMPORTANT:Always install the factory—supplied liquid-line
filter drier.If replacing the filter drier,refer to Product Data
Digest for appropriate part number.Obtain replacement filter
driers from your distributor or branch.
:0
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing,modifying,or servicing system,main
electrical disconnect switch must be in the OFF position.
There may be more than 1 disconnect switch.Lock out
and tag switch with a suitable warning label.
Ak WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could result in personal injury
or equipment damage.
Puron®systems operate at higher pressures than standard
R-22 systems.To avoid damage to the unit or possible
personal injury,do not use R-22 service equipment or
components on Puron equipment.
TUBE
1”MIN.
SUSPENSION
A94026
2
INSTALLATION
Specifications for this unit in residential new construction market
require the outdoor unit,indoor unit,refrigerant tubing sets,
metering device,and filter drier listed in presale literature.There
can be no deviation.Consult the Application Guideline and
Service Manual —Air Conditioners and Heat Pumps Using
Puron®Refrigerant to obtain required unit changes for specific
applications and for R—22 retrofit.
STEP 1 .—Check Equipment and Job Site
UNPACK UNIT
Move to final location.Remove carton taking care not to damage
unit.
INSPECT EOUIPMENT
File claim with shipping company prior to installation if shipment
is damaged or incomplete.Locate unit rating plate on unit corner
panel.It contains information needed to properly install unit.
Check rating plate to be sure unit matches job specifications.
STEP 2.—Install on a Solid,Level Mounting Pad
If conditions or local codes require the unit be attached to pad,tie
down bolts should be used and fastened through knockouts
provided in unit base pan.Refer to unit mounting pattern in Fig.
3 to determine base pan size and knockout hole location.
For hurricane tie downs -contact your local distributor for
details and PE (Professional Certification),if required by local
authorities.
On rooftop applications,mount on level platform or frame.Place
unit above a load—bearing wall and isolate unit and tubing set
from structure.Arrange supporting members to adequately
support unit and minimize transmission of vibration to building.
Consult local codes governing rooftop applications.
Roof mounted units exposed to winds may require wind baffles.
Consult the Application Guideline and Service Manual -
Residential Split System Air Conditioners and Heat Pumps Using
Puron®Refrigerant for wind baffle construction.
NOTE:Unit must be level to within ±2°(±3/8 in/ft.)per
compressor manufacturer specifications.
STEP 3.—Clearance Requirements
When installing,allow sufficient space for airflow clearance,
wiring,refrigerant piping,and service.Allow 30—in,clearance to
service end of unit and 48 in.above unit.For proper airflow,a
6-in,clearance on 1 side of unit and 12 in.on all remaining sides
must be maintained.Maintain a distance of 24 in.between units.
Position so water,snow,or ice from roof or eaves cannot fall
directly on unit.
3/8—in.Dia.Tiedown
Knockouts in Base
(2)Places
-°°,
View From Top
UNIT BASE PAN TIEDOWN KNOCKOUT LOCATIONS
DIMENSIONS A I B
I
C
26 X 26 9—1/8 4-7/16 21—1/4
31—1/2 X 31—1/2 9—1/8 6—9/16 24—11/16
35 X 35 9—1/8
I
6—9/16 28—7/16
A05177
On rooftop applications,locate unit at least 6 in.above roof
surface.
STEP 4.—Operating Ambient
The minimum outdoor operating ambient in cooling mode is
55°F,and the maximum outdoor operating ambient in cooling
mode is 125°F.
STEP 5.—Install TXV
NOTE:Applies to non-TXV and R-22 TXV indoor units only.
If installing a rated and approved indoor coil without a factory
installed Puron®TXV,remove and replace the fixed orifice or
R-22 TXV expansion device with a hard shutoff Puron TXV.
The thermostatic expansion valve is specifically designed to
operate with Puron.Do not use an R-22 TXV.An existing R-22
TXV must be replaced with a factory—approved TXV specifically
designed for Puron.Refer to Product Data Sheet for the
appropriate TXV kit number.
IMPORTANT:The TXV should be mounted as close to the
indoor coil as possible and in a vertical,upright position.Avoid
mounting the inlet tube vertically down.Valve is more
susceptible to malfunction due to debris if inlet tube is facing
down.A factory—approved filter drier must be installed in the
liquid line.
B
Fig.3 -Tiedown Knockout Locations
A CAUTION
UNIT OPERATION HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
To avoid improper performance and possible
equipment failure,all indoor coil units must be
installed with a hard shut off Puron®TXV metering
device.
3
INSTALLING TXV IN PLACE OF PISTON REPLACING TXV ON R-22 INDOOR COIL
I
1.Pump system down to 2 psig and recover refrigerant.
2.Remove hex nut from piston body.Use backup wrench on
fan coils.
3.Remove and discard factory—installed piston.Be sure
Teflon seal is in place.
4.Reinstall hex nut.Finger tighten nut plus 1/2 turn.
NOTE:If the piston is not removed from the body,TXV will not
function properly.
5.Install TXV on indoor coil liquid line.Sweat swivel
adapter to inlet of indoor coil and attach to TXV outlet.
Use backup wrench to avoid damage to tubing or valve.
Sweat inlet of TXV,marked “IN”to liquid line.Avoid
excessive heat which could damage valve.
6.Install vapor elbow with equalizer adapter to suction tube
of line set and suction connection to indoor coil.Adapter
has a 1/4-in,male connector for attaching equalizer tube.
7.Connect equalizer tube of TXV to 1/4-in,equalizer fitting
on vapor line adapter.
8.Attach TXV bulb to horizontal section of suction line
using clamps provided.Insulate bulb with field—supplied
insulation tape.See Fig.4 for correct positioning of
sensing bulb.
9.Proceed with remainder of unit installation.
IC O’CLOCK
2 O’CLOCK-
LARGER THAN 7/BIN.00
A81032
1.Pump system down to 2 psig and recover refrigerant.
2.Remove coil access panel and fitting panel from front of
cabinet.
3.Remove TXV support clamp using a 5/16-in,nut driver.
Save the clamp.
4.Remove R-22 TXV using a backup wrench on flare
connections to prevent damage to tubing.
5.Using wire cutters,cut equalizer tube off flush with vapor
tube inside cabinet.
6.Remove bulb from vapor tube inside cabinet.
7.Braze equalizer stub—tube closed.Use protective barrier as
necessary to prevent damage to drain pan.
IMPORTANT:Route the equalizer tube of Puron TXV through
suction line connection opening in fitting panel prior to replacing
fitting panel around tubing.
8.Install TXV with 3/8-in,copper tubing through small hole
in service panel.Use wrench and backup wrench,to avoid
damage to tubing or valve,to attach TXV to distributor.
9.Reinstall TXV support clamp (removed in item 3).
10.Attach TXV bulb to vapor tube inside cabinet,in same
location as original was when removed,using supplied
bulb clamps (nylon or copper).See Fig.4 for correct
positioning of sensing bulb.
11.Route equalizer tube through suction connection opening
(large hole)in fitting panel and install fitting panel in
place.
12.Sweat inlet of TXV,marked “IN”to liquid line.Avoid
excessive heat which could damage valve.
13.Install vapor elbow with equalizer adapter to vapor line of
line set and vapor connection to indoor coil.Adapter has
a 1/4—in.male connector for attaching equalizer tube.
14.Connect equalizer tube of TXV to 1/4-in.equalizer fitting
on vapor line adapter.Use backup wrench to prevent
damage to equalizer fitting.
15.Proceed with remainder of unit installation.
A CAUTION
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
To prevent damage to the unit,use a brazing shield
and wrap TXV with wet cloth or use heat sink
material.
7/8 IN.OD &SMALLER
Fig.4 -Position of Sensing Bulb
STEP 6.—Make Piping Connections
Outdoor units may be connected to indoor section using
accessory tubing package or field-supplied refrigerant grade
tubing of correct size and condition.Rated tubing diameters
shown in Table 1 recommended up to 80 ft.See Product Data
for acceptable alternates vapor diameters and associated capacity
losses.For tubing requirements beyond 80 ft.,substantial
capacity and performance losses can occur.Following the
recommendations in the Longline Guideline —Residential
Split-System Air Conditioners and Heat Pumps Using Puron®
Refrigerant will reduce these Losses.Refer to Table 1 for field
tubing diameters.Refer to Table 2 for accessory requirements.
There are no buried—line applications greater than 36 in.
If refrigerant tubes or indoor coil are exposed to atmosphere,they
must be evacuated to 500 microns to eliminate contamination and
moisture in the system.
OUTDOOR UNIT CONNECTED TO FACTORY-APPROVED
INDOOR UNIT:
Outdoor unit contains correct system refrigerant charge for
operation with factory approved ARI rated indoor unit when
connected by 15 ft.of field-supplied or factory-accessory tubing,
and factory supplied filter drier.Check refrigerant charge for
maximum efficiency.
Table 1—Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters (In.)
RATED VAPOR
LIQUID (up to 80 ft.*)
UNIT SIZE
Connection Tube Connection Tube
Diameter Diameter Diameter Diameter
018,024 3/8 3/8 5/8 5/8
030,036 3/8 3/8 3/4 3/4
042,048 3/8 3/8 7/8 7/8
060 3/8 3/8 7/8 1-1/8
INOles:
1.Tube diameters are for total equivalent lengths up to 80 ft.
2.Do not apply capillary tube or fixed orifice indoor coils to these units.
*For Tubing Set lengths between 80 and 200 ft.horizontal or 20 ft.vertical differential (250 ft.Total Equivalent Length),refer to the Longline
Guideline—Air Conditioners and Heat Pumps using Puron.
A WARNING CAUTION
PERSONAL INJURY AND ENVIRONMENTAL
HAZARD
Failure to follow this warning could result in personal
injury or death.
Relieve pressure and recover all refrigerant before
system repair or final Unit disposal to avoid personal
injury or death.Use all service ports and open all
flow-control devices,including solenoid valves.
UNIT DA11AGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
To prevent damage to unit or service valves observe the
following:
•Use a brazing shield.
•Wrap service valves with wet cloth or use a heat sink
material.
A CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
To prevent improper performance and/or unit component
failures,do not leave system open to atmosphere any longer
than minimum required for installation.POE oil in
compressor is extremely susceptible to moisture absorption.
Always keep ends of tubing sealed during installation.
A CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
If ANY refrigerant tubing is buried,provide a 6 in.vertical
rise at service valve.Refrigerant tubing lengths up to 36 in.
may be buried without further special consideration.Do
not bury lines longer than 36 in.
5
ThbIe 2—Accessory Usage
REQUIRED FOR LOW—AMBI-REQUIRED FOR SEAREQUIREDFORLONGLINEAccessoryENTAPPLICATIONSCOASTAPPLICATIONSAPPLICATIONS*(Over 80 Ft.)(Below 55 °F)(Within 2 miles)
Crankcase Heater Yes Yes No
Evaporator Freeze Thermostat Yes No No
Winter Start Control Yes t No No
Accumulator No No No
Compressor Start Assist Capacitor
Yes Yes NoandRelay
Motor Master®Control
or Yes No No
Low—ambient Pressure Switch
Support Feet Recommended No Recommended
See Long—Line ApplicationLiquidLineSolenoidValveNo NoGuideline
Ball Bearing Fan Motor Yes No No
*For Tubing Set lengths between 80 and 200 ft.horizontal or 20 ft.vertical differential (250 ft.Total Equivalent Length),refer to the Long-
line Guideline —Air Conditioners and Heat Pumps using Puron®
fRequired for low—ambient controller (full modulation feature)and Motor Master®control only.
REFRIGERANT TUBING CONNECTION OUTDOOR
Connect vapor tube to fitting on outdoor unit vapor service
valves (see Table 1.)Connect and braze the 3/8”coupling
(provided with the filter drier)to the liquid service valve and
connect and braze the liquid tubing to the other end of this
coupling.Use refrigerant grade tubing.
SWEAT CONNECTION
Service valves are closed from factory and ready for brazing.
After wrapping service valve with a wet cloth,braze sweat
connections using industry accepted methods and materials.
Consult local code requirements.Refrigerant tubing and indoor
coil are now ready for leak testing.This check should include all
field and factory joints.
EVACUATE REFRIGERANT TUBING AND INDOOR COIL
Refrigerant tubes and indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns.The
alternate triple evacuation method may be used if the procedure
outlined below is followed.Always break a vacuum with dry
nitrogen.
I
INSTALL LIQUID-LINE FILTER DRIER INDOOR
A CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage
or improper operation.
To avoid performance loss and compressor failure,installation
of filter drier in liquid line is required.
A CAUTION
A CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
To avoid valve damage while brazing,service valves
must be wrapped in a heat—sinking material such as a
wet cloth.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
To avoid filter drier damage while brazing,filter drier must
be wrapped in a heat—sinking material such as a wet
cloth.
Refer to Fig.5 and install filter drier as follows:
1.Braze 5-in,liquid tube to the indoor coil.
2.Wrap filter drier with damp cloth.
3.Braze filter drier to above 5”liquid tube.Flow arrow
must point towards indoor coil.
4.Connect and braze liquid refrigerant tube to the filter drier.
A05178
A CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
To avoid compressor damage,never use the system
compressor as a vacuum pump.
Fig.5 -Liquid Line Filter Drier
6
DEEP VACUUM METHOD FINAL TUBING CHECK
The deep vacuum method requires a vacuum pump capable of
pulling a vacuum of 500 microns and a vacuum gage capable of
accurately measuring this vacuum depth.The deep vacuum
method is the most positive way of assuring a system is free of air
and liquid water.(See Fig.6)
________________VACUUM
TIGHT
TOO WET
____________________TIGHT
DRY SYSTEM
01 23456 7
MINUTES
Fig.6 -Deep Vacuum Graph
TRIPLE EVACUATION METHOD
The triple evacuation method should only be used when vacuum
pump is only capable of pumping down to 28 in.of mercury
vacuum and system does not contain any liquid water.Refer to
Fig.7 and proceed as follows:
1.Pump system down to 28 in.of mercury and allow pump
to continue operating for an additional 15 minutes.
2.Close service valves and shut off vacuum pump.
3.Connect a nitrogen cylinder and regulator to system and
open until system pressure is 2 psig.
4.Close service valve and allow system to stand for 1 hr.
During this time,dry nitrogen will be able to diffuse
throughout the system absorbing moisture.
5.Repeat this procedure as indicated in Fig.7.System will
then be free of any contaminants and water vapor.
IEVACUATE I
V
IBREAK VACUUM WITH DRY NITROGEN I
V
IWAIT
I
V
EVACUATE I
V
IMPORTANT:Check to be certain factory tubing on both
indoor and outdoor unit has not shifted during shipment.Ensure
tubes are not rubbing against each other or any sheet metal.Pay
close attention to feeder tubes,making sure wire ties on feeder
tubes are secure and tight.
STEP 7.—Make Electrical Connections
Be sure field wiring complies with local and national fire,safety,
and electrical codes,and voltage to system is within limits shown
on unit rating plate.Contact local power company for correction
of improper voltage.See unit rating plate for recommended
circuit protection device.
NOTE:Operation of unit on improper line voltage constitutes
abuse and could affect unit reliability.See unit rating plate.Do
not install unit in system where voltage may fluctuate above or
below permissible limits.
NOTE:Use copper wire only between disconnect switch and
unit.
NOTE:Install branch circuit disconnect of adequate size per
NEC to handle unit starting current.Locate disconnect within
sight from and readily accessible from unit,per Section 440-14
of NEC.
ROUTE GROUND AND POWER WIRES
Remove access panel to gain access to unit wiring.Extend wires
from disconnect through power wiring hole provided and into
unit control box.
IBREAK VACUUM WITH DRY NITROGEN I
V
WAIT I
V
IEVACUATE I
V
CHECK FOR TIGHT,DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
I
CHARGE SYSTEM
I
Fig.7 -Triple Evacuation Method
A95425
-
p
5YS IbM
2000
1500
1000
500
A WARNING
ELECR1CAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Do not supply power to unit with compressor terminal box
cover removed.
A95424
0
A WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury
or death.
The unit cabinet must have an uninterrupted or unbroken
ground to minimize personal injury if an electrical fault
should occur.The ground may consist of electrical wire or
metal conduit when installed in accordance with existing
electrical codes.
7
CONNECT GROUND AND POWER WIRES STEP 10.—Start-Up
Connect ground wire to ground connection in control box for
safety.Connect power wiring to contactor as shown in Fig.9.
DISCONNECT
PER N.E.C.AND/OR
LOCAL CODES
CONTACTOR
FIELD POWER
I WIRING
FIELDGROUND
WIRiNG]GROUND
CONNECT CONTROL WIRING
Route 24—v control wires through control wiring grommet and
connect leads to control wiring.
Use No.18 AWG color-coded,insulated (35CC minimum)wire.
If thermostat is located more than 100 ft.from unit,as measured
along the control voltage wires,use No.16 AWG color-coded
wire to avoid excessive voltage drop.
All wiring must be NEC Class 1 and must be separated from
incoming power leads.
Use furnace transformer,fan coil transformer,or accessory
transformer for control power,24-v/40-va minimum.
NOTE:Use of available 24—v accessories may exceed the
minimum 40-va power requirement.Determine total transformer
loading and increase the transformer capacity or split the load
with an accessory transformer as required.
FINAL WIRING CHECK
IMPORTANT:Check factory wiring and field wire connections
to ensure terminations are secured properly.Check wire routing
to ensure wires are not in contact with tubing,sheet metal,etc.
STEP 8.—Compressor Crankcase Heater
When equipped with a crankcase heater,furnish power to heater a
minimum of 24 hr before starting unit.To furnish power to heater
only,set thermostat to OFF and close electrical disconnect to
outdoor unit.
A crankcase heater is required if refrigerant tubing is longer than
80 ft.Refer to the Longline Guideline Section -Residential
Split-System Air Conditioners and Heat Pumps Using Puron
Refrigerant.
STEP 9.—Install Electrical Accessories
Refer to the individual instructions packaged with kils or
accessories when installing.
FOLLOW THESE STEPS TO PROPERLY START UP THE
1.After system is evacuated,fully open liquid and vapor
service valves.
2.Unit is shipped with valve stem(s)front seated (closed)
and caps installed.Replace stem caps after system is
opened to refrigerant flow.Replace caps finger—tight and
tighten with wrench an additional 1/12 turn.
3.Close electrical disconnects to energize system.
4.Set room thermostat at desired temperature.Be sure set
point is below indoor ambient temperature.
5.Set room thermostat to COOL and fan control to ON or
AUTO mode,as desired.Operate unit for 15 minutes.
Check system refrigerant charge.
A CAUTION
I
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this caution may result in minor personal
injury,equipment damage or improper operation.
To prevent compressor damage or personal injury,observe the
following:
•Do not overcharge system with refrigerant.
•Do not operate unit in a vacuum or at negative pressure.
•Do not disable low pressure switch in scroll compressor
applications.
•Dome temperatures may be hot.
Fig.8 -Line Power Connections
A91 056
A CAUTION
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal
injury.
Wear safety glasses,protective clothing,and gloves when
handling refrigerant and observe the following:
Front seating service valves are equipped with Schrader
valves.
A CAUTION
ENVIRONMENTAL HAZARD
Failure to follow this caution may result in environmental
damage.
Federal regulations require that you do not vent
refrigerant to the atmosphere.Recover during system
repair or final unit disposal.
SYSTEM:
8
SQUENCE OF OPERATION
Turn on power to indoor and outdoor units.Transformer is
energized.
On a call for cooling,thermostat makes circuits R-Y and R-G.
Circuit R-Y energizes contactor,starting outdoor fan motor and
compressor circuit.R.-G energizes indoor unit blower relay,
starting indoor bLower motor on high speed.
NOTE:To achieve the rated system performance,the indoor unit
or the thermostat must be equipped with a time delay relay
circuit.
When thermostat is satisfied,its contacts open,de—energizing
contactor and blower relay.Compressor and motors stop.If
indoor unit is equipped with a time-delay relay circuit,the indoor
blower will run an additional 90 sec to increase system efficiency.
STEP 11 .—Check Charge
UNIT CHARGE
Factory charge and charging method are shown on unit
information plate.Charge Puron units with cylinder in upright
position and a commercial-type metering device in manifold
hose.Charge refrigerant into suction line.
NOTE:If subcooling charging conditions are not favorable,
charge must be weighed in accordance with unit rating plate,±0.6
oz/ft.of 3/8—in,liquid line above or below 15 ft.,respectively.
Favorable conditions fall within the ranges given on the charging
chart on the outdoor unit plate.
NOTE:In longline applications,see Application Guideline for
special charging requirements.
EXAMPLE:
To calculate additional charge required for a 25—ft.line set:
25 ft.-15 ft.=10 ft.X 0.6 oz/ft.=6 oz.of additional charge.
COOLING ONLY PROCEDURE
This system requires charging by the subcooling method.
1.Operate unit a minimum of 10 minutes before checking
charge.
2.Measure liquid service valve pressure by attaching an
accurate gage to service port.
3.Measure liquid line temperature by attaching an accurate
thermistor type or electronic thermometer to liquid line
near outdoor coil.
4.Refer to unit rating plate for required subcooling
temperature.
5.Refer to Table 3.Find the point where required subcooling
temperature intersects measured liquid service valve
pressure.
6.To obtain required subcooling temperature at a specific
liquid line pressure,add refrigerant if liquid line
temperature is higher than indicated or reclaim refrigerant
if temperature is lower.Allow a tolerance of ±3°F.
STEP 12.—Final Checks
IMPORTANT:Before leaving job,be sure to do the following:
1.Ensure that all wiring is routed away from tubing and
sheet metal edges to prevent rub-through or wire
pinching.
2.Ensure that all wiring and tubing is secure in unit before
adding panels and covers.Securely fasten all panels and
covers.
3.Tighten service valve stem caps to 1/12—turn past finger
tight.
4.Leave Owner’s Manual with owner.Explain system
operation and periodic maintenance requirements outlined
in manual.
5.Fill out Dealer Installation Checklist and place in
customer file.
CARE AND MAINTENANCE
For continuing high performance and to minimize possible
equipment failure,periodic maintenance must be performed on
this equipment.
Frequency of maintenance may vary depending upon geographic
areas,such as coastal applications.See Owner’s Manual for
information.
V
9
Table 3—Required Liquid-Line Temperature (CF)
LIQUID
PRESSURE REQUIRED SUBCOOLING TEMPERATURE (SF)
AT SER
VICE
VALVE 8 10 12 14 16 18
(PSIG)
189 58 56 54 52 50 48
195 60 58 56 54 52 50
202 62 60 58 56 54 52
208 64 62 60 58 56 54
215 66 64 62 60 58 56
222 68 66 64 62 60 58
229 70 68 66 64 62 60
236 72 70 68 66 64 62
243 74 72 70 68 66 64
251 76 74 72 70 68 66
259 78 76 74 72 70 68
266 80 78 76 74 72 70
274 82 80 78 76 74 72
283 84 82 80 78 76 74
291 86 84 82 80 78 76
299 88 86 84 82 80 78
308 90 88 86 84 82 80
317 92 90 88 86 84 82
326 94 92 90 88 86 84
335 96 94 92 90 88 86
345 98 96 94 92 90 88
354 100 98 96 94 92 90
364 102 100 98 96 94 92
374 104 102 100 98 96
384 106 104 102 100 98 96
395 108 106 104 102 100 98
406 110 108 106 104 102 100
416 112 110 108 106 104 102
427 114 112 110 108 106 104
439 116 114 112 110 108 106
450 118 116 114 112 110 108
462 120 118 116 114 112 110
474 122 120 118 116 114 112
486 124 122 120 118 116 114
499 126 124 122 120 118 116
511 128 126 124 122 120 118
10
AJC
THERMOSTAT
24VAC HOT
EEl—
24VACCOM
HEAT STAGE I
COOLSTAGE1
INDOOR FAN
AIR
CONDITIONER
Typical
FURNACE
-EEl--
NC
THERMOSTAT
24VAC HOT
24VACCOM [El—
HEAT STAGE 1 W/W1
COOLSTAGE1 YIY2
INDOOR FAN G
Typical
FAN COIL
AIR
CONDITIONER
A02326
V
LEGEND
24-V FACTORY WIRING
——24-VFIELD WIRING
FIELD SPLICE CONNECTION
CONTACTOR
A97368
Fig.9 -Generic Wiring Diagrams
(See Thermostat Installation Instructions for specific unit combinations)
11
PURON®(R-410A)QUICK REFERENCE GUIDE
•Puron refrigerant operates at 50—70 percent higher pressures than R-22.Be sure that servicing equipment and replacement
components are designed to operate with Puron
•Puron refrigerant cylinders are rose colored.
•Recovery cylinder service pressure rating must be 400 psig,DOT 4BA400 or DOT BW400.
•Puron systems should be charged with liquid refrigerant.Use a commercial type metering device in the manifold hose when charging
into suction line with compressor operating
•Manifold sets should be 700 psig high side and 180 psig low side with 550 psig low-side retard.
•Use hoses with 700 psig service pressure rating.
•Leak detectors should be designed to detect HFC refrigerant.
•Puron,as with other HFCs,is only compatible with POE oils.
•Vacuum pumps will not remove moisture from oil.
•Do not use liquid—line filter driers with rated working pressures less than 600 psig.
•Do not leave Puron suction line filter driers in line longer than 72 hours.
•Do not install a suction—line filter drier in liquid line.
•POE oils absorb moisture rapidly.Do not expose oil to atmosphere.
•POE oils may cause damage to certain plastics and roofing materials.
•Wrap all filter driers and service valves with wet cloth when brazing.
•A factory approved liquid—line filter drier is required on every unit.
•Do NOT use an R-22 TXV.
•If indoor unit is equipped with an R—22 TXV or piston metering device,it must be changed to a hard shutoff Puron TXV.
•Never open system to atmosphere while it is under a vacuum.
•When system must be opened for service,recover refrigerant,evacuate then break vacuum with dry nitrogen and replace filter driers.
Evacuate to 500 microns prior to recharging.
•Do not vent Puron into the atmosphere.
•Do not use capillary tube coils.
•Observe all warnings,cautions,and bold text.
•All indoor coils must be installed with a hard shutoff Puron TXV metering device.
Copyrighl 2005 Cmor Corp..7510W.Mons St.•Indianapolis,IN 46231 Printed in U.S.A.edition dale:10,05 Catalog No:24A0A-ISI
Manufacturer reserves tI right to change,at any time,speciflcations and designs without notice and without obligations.Replacns:NEW
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