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Home My WebLink AboutINSTALLATION INSTRUCTIONLENNOX 02013 Lennox Industnes Inc. Dallas, Texas, USA SCANNED BY St. Luce County THIS MANUAL MUST BE LEFT WITH THE HOMEOWNER FOR FUTURE REFERENCE These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities having jurisdiction before installation. t NftRTANT These units must be installed as a matched system as specified in the Lennox Engineering Handbook. INSTALLATION INSTRUCTION MS8 Series Units (208-230V) MINI -SPLIT SINGLE -ZONE SYSTEMS 506916-01 3/2013 Technical Supersedes 9/2012 Publiceticns TABLE OF CONTENTS Shipping and Packing List ...................... 2 Required Tools and Supples ..........:......... 3 Model Number Identification ........ :........... 3 Unit Dimensions - inches (mm) and Weights ...... 3 Typical System Components .................... 5 General ...................................... 6 Clearances ................................... 6 Setting Outdoor Unit . . � ........................ 6 Repositioning Indoor A)rTemperature Sensor ..... 7 Indoor Unit Placement and Preparation ........... 8 Indoor Unit Cable Connections .................. 12 Outdoor Unit Cable Connections ................ 14 Operating Valves .............................. 16 Line Set Requirements ......................... 17 Leak Test and Evacuation ...................... 19 Unit Start -Up ................................. 19 Adding Refrigerant for Longer Line Sets .......... 19 Checking Suction / Vapor Operating Pressures .... 19 Wrapping Bundle .............................. 21 Maintenance ................................... 22 Indoor and Outdoor Error Codes ................. 23 Indoor Unit Front Cover Removal ...................... 31 Optional Condensate Pump Wiring Connection .......... 33 IMPORTANT INSTALLER INFORMATION • Stranded wire must be used to connect the outdoor unit to the indoor unit. The stranded wire is necessary to ensure proper system communication and operation. • The included remote control could be shipped in various locations in the unit packaging. Locate remote control be- fore discarding packaging (i.e. bag assembly, Styrofoam', etc.). Unit cannot be properly operated without the in- cluded remote control. • Check indoor to outdoor field wiring to confirm (N) 1 from indoor goes to (N) 1 outdoor, terminal 2 from indoor goes to terminal 2 outdoors and terminal 3 indoors goes to terminal 3 in outdoor. "ILE A"'OPY 66129912681 F LE COP*mil g" Shipping and Packing List Check the unit components for shipping damage. If you find any damage, immediately contact the last carrier. 1 — ASSEMBLED INDOOR UNIT The assembled indoor unit will include the following items: Parts Figure Quantity Parts Figure Quantity Flare nut 1/4" for Remote control 1 small line on all size units except 1 30K which uses 5/8". \�Y Cable routing Batteries (AAA) yyy*�� 2 guide with mounting 1 hardware 09, 12 and 18 Wall mounting bracket kBtu (5) User guide �� screws 24-30K kBtu 10 ( ) 1 r`I Foam tube insulation (for Warranty_— _ '� 1 condensate line 1 certificate -- attached to indoor unit) 1 — ASSEMBLED OUTDOOR UNIT The assembled outdoor unit will include the following items which are located with the unit: Parts Figure Quantity Parts Figure Quantity Auxiliary drain hole plugs (heat pump only) 1 3 Drain plug (heat pump only) 4 1 �.,, Page 2 Required Tools and Supplies INSTALLATION TOOLS Tool Picture Tool Name Tool Picture Tool Name OO Screw driver Multimeter Allen wrench set Electric drill (metric) Measuring tape and ® Flaring tool and pipe cutter knife Hole core drill Refrigerant leak detector or a bottle of soapy water a Adjustable wrench o p Level 500 A 5/16" female flare to 1/4" male flare adapter (order Lennox catalog '- Micron gauge number Y0576) SUPPLIES The following field -provided supplies may be required for installation • Line set (see table 5 for requirements) • Foam insulation (line set and condensate line) • UV rated protective tape (used to maintain positioning of bundle). Bundle consists of line set, condensate line and wiring between indoor and outdoor units. • UV rated cable ties • Outdoor unit pad • Outdoor disconnect switch (indoor unit disconnect switch may be required by local code) • Cable (4conductor for all systems. All need to be rated 208-230V and sized per NEC). NOTE — Stranded wire must be used to connect the outdoor unit to the indoor unit. The stranded wire is necessary to ensure proper system communication and operation. r Plastic wall screw anchors • Exterior wall channel (optional) • Wall sleeve or PVC tubing material to field fabricate a wall sleeve for line set, condensate line and wiring (utility bundle). Page 3 r , ' Model Number Identiflc o MS 8 - CI -09 P 1 A Series Type I L--Minor Revision MS = Mini -Split u I Number of Zones Series 1 = One Zane Unit Type Voltage Cl = Air Conditioner Indoor Unit P = 230-208/230V -1 phase - 60hz HI = Heat Pump Indoor Unit CO = Air Conditioner Outdoor Unit HO = Heat Pump Outdoor Unit Cooling Capacity - BTUH 09 = 9,000 12=12,000 18 = 18,000 24 = 24,000 30 = 30,000 Unit Dimensions - inches (mm) and Weights INDOOR UNIT ss_eao LINE SET, CONDENSATE DRAIN AND ELECTRICAL CONNECTIONS Table 1. Indoor Unit Dimensions — Inches (millimeters) and Weight Model Size _ A B C Unit Gross Weight Air Conditioner Heat Pump -09 and -12 - 33 (838) 10-7/8 (275) 7 (180) 31 Ibs (14 kg) 29,lbs (13 kg) -18 37 (940) 12 (305) 8 (203) 37-1/2 lbs (16 kg) 37-1/2 lbs (16 kg) -24 39-3/4 (1008) 12.318 (315) 8-1/2 (218) 46 lbs (21) 561bs (25.6 kg) -30 53 (1350) 12-7/8 (326) _ 10 (253) N/A 60 lbs (27 kg) LECTRICAL CONNECTIONS (UNDER COVER) LINE SET CONNECTIONS (COVER REMOVED) =_— LINE SET COVER C Table 2. Outdoor Unit Dimensions — Inches (millimeters) Model Size A a C Unit Gross Weight Air Conditioner Heat Pump -09 21 (533) 33 (838) 12-5/8 (320) 91 Ibs (41 kg) 91 Ibs (41 kg) -12 23 (584) 33 (838) 12-5/8 (320) 97 Ibs (44 kg) 97 Ibs (44 kg) -18 - 27-1/2 (699) 37-112 (952) 15-1/2 (394) 110 lbs (50 kg) 110 lbs (50 kg) -24 31-1/8 (790) 38 (980) 16-7/8 (427) 132 lbs (60 kg) 134 lbs (61 kg) -30 31-1/8 (790) 38 (980) 16-7/8 (427) N/A 163 lbs (74 kg) 8. Remove the access cover. Optional Condensate Pump Wiring Connection In order to use one of the condensate pumps available from Lennox, the pump will need to be wired as illustrated in the following diagram. Mini Orange INCOMING 115V m POWER WIRES BLACK LINE 1 ; PERMANENTLY LIVE COMMUNICATION r- N a PURPLE INC) 0 GROUND 0 n z M m o Z TERMINAL r N M BLOCK IN 1 2 3 G CONDENSER M m RED WIRE NUT csi x D 1 AMP FUSE ai PUMP GRAY (COM) 5 AMPS MAX WIRE NUT ORANGE (WO) DO NOT USE (ISOLATE WITH WIRE NUT) , Figure 49. Installing Condensate Pump Page 4 Page 33 5. Lift the screw cover to access the screws that secure the lower portion of the front cover to the unit. 6. Remove the two screws that secure the display to the front panel. 7. Remove the screws that secure the upper portion of the front cover to the unit. Typical System Components RETURN AIR B i t /K INDOOR UNIT D DISPLAY INDICATORSAV i YJ,Y COOL r' S PLVAIR DRY FAN - A F HEAT WIRELESS REMOTE CONTROL U RUN BBTEMPERATURE SETTING, INDOOR AMBIENT TEMPERATURE OR ERROR CODE NOTE — Temperature can be displayed in either Fahrenheit or E G o O TAPE H REFRIGERANT LINE SET, CONDENSATE LINE F AND INDOOR/OUTDOOR CABLE IMPORTANT - The refrigerant metering device for this system is UTILITY 'located in the outdoor unit. This aurIDLE makes it necessary to insulate the refrigerant lines individually to prevent sweating. 0 OUTDOOR UNIT (AIR CONDITIONER OR HEAT PUMP) Celsius. AIR IN � f A. Remote control B. Front panel C. Filters D. Guide louver with display E. Line set (wrapped in foam insulation) F. UV -rated tape (field -provided) G. Wiring (field -provided) H. Condensate drain line (field -provided) (wrapped in foam insulation). Recommend installation of a vent when making long horizontal runs on condensate line. I. 3-way service and 2-way shutoff valves J. Access cover for power and control wiring connections K. Indoor unit wiring connections (under access plate) AIR OUT LA 0 IT SERVICE VALVE tr�nc CONNECTION) Figure 1. Typical System Components Page 32 Page 5 U RUN BBTEMPERATURE SETTING, INDOOR AMBIENT TEMPERATURE OR ERROR CODE NOTE — Temperature can be displayed in either Fahrenheit or E G o O TAPE H REFRIGERANT LINE SET, CONDENSATE LINE F AND INDOOR/OUTDOOR CABLE IMPORTANT - The refrigerant metering device for this system is UTILITY 'located in the outdoor unit. This aurIDLE makes it necessary to insulate the refrigerant lines individually to prevent sweating. 0 OUTDOOR UNIT (AIR CONDITIONER OR HEAT PUMP) Celsius. AIR IN � f A. Remote control B. Front panel C. Filters D. Guide louver with display E. Line set (wrapped in foam insulation) F. UV -rated tape (field -provided) G. Wiring (field -provided) H. Condensate drain line (field -provided) (wrapped in foam insulation). Recommend installation of a vent when making long horizontal runs on condensate line. I. 3-way service and 2-way shutoff valves J. Access cover for power and control wiring connections K. Indoor unit wiring connections (under access plate) AIR OUT LA 0 IT SERVICE VALVE tr�nc CONNECTION) Figure 1. Typical System Components Page 32 Page 5 E G o O TAPE H REFRIGERANT LINE SET, CONDENSATE LINE F AND INDOOR/OUTDOOR CABLE IMPORTANT - The refrigerant metering device for this system is UTILITY 'located in the outdoor unit. This aurIDLE makes it necessary to insulate the refrigerant lines individually to prevent sweating. 0 OUTDOOR UNIT (AIR CONDITIONER OR HEAT PUMP) Celsius. AIR IN � f A. Remote control B. Front panel C. Filters D. Guide louver with display E. Line set (wrapped in foam insulation) F. UV -rated tape (field -provided) G. Wiring (field -provided) H. Condensate drain line (field -provided) (wrapped in foam insulation). Recommend installation of a vent when making long horizontal runs on condensate line. I. 3-way service and 2-way shutoff valves J. Access cover for power and control wiring connections K. Indoor unit wiring connections (under access plate) AIR OUT LA 0 IT SERVICE VALVE tr�nc CONNECTION) Figure 1. Typical System Components Page 32 Page 5 r- General The MS7 air conditioners and heat pumps are matched with an indoor evaporator unit to create a ductless system that uses HFC-410A refrigerant. Clearances SYSTEM CLEARANCES Refer to figure 2 for mandatory installation clearance requirements. Figure 2. Minimum Installation Clearances Table 3. Minimum System Clearances ID Location Clearance Required A - Clearance between unit and ceiling. 6 in. 152 mm) B Clearance between unit and floor. 6 ft.(1829 mm) CID Clearance to the right and left of unit. 6 in. (152 mm) E Clearance above unit. 2 ft. (610 mm) F Clearance between air inlet and structure. 12 in. (305 Trim) G Clearance between unit and structures 12 in. (305 mm) H 4 ft. 1219 mm) I 12 in. 305 mm Setting Outdoor Unit t � � In order to avoid lifting heavy injury, take proper precaution when objects. t � � Physical contact applying excessive personal injury. with metal edges and corners while force or rapid motion can result in Be aware of, and use caution when working near, servicing this these areas during installation or while equipment. OUTDOOR UNIT POSITIONING CONSIDERATIONS (AIR CONDITIONER OR HEAT PUMP) Consider the following when positioning the unit: • Some localities are adopting sound ordinances based on the unit's sound level -registered from the adjacent property, not from the property where the unit is installed. Install the unit as far as possible from the property line. • When possible, do not install the unit directly outside a window. Glass has a very high level of sound transmission. For proper placement of unit in relation to a window see the provided illustration in figure 2. • Install unit level or, if on a slope, maintain slope tolerance of 2 degrees (or 2 inches per 5 feet (50 mm per 1.5 m)] away from building structure. • Install the unit high enough above the ground or roof to allow adequate drainage of defrost water and prevent ice or snow build-up (required for heat pumps). • In heavy snow areas, do not locate the unit where drifting will occur. The unit base should be elevated above the depth of average snows. • When installed in areas where low ambient temperatures exist, locate unit so winter prevailing winds do not blow directly onto outdoor unit.. • Locate unit away from overhanging roof lines which would allow water or ice to drop on, or in front of, coil or into unit. CONDENSATE DRAINAGE REQUIREMENT (HEAT PUMP ONLY) Condensate formed during the heating and defrost processes must be drained from heat pump units. Drain holes are provided in the base of the units to ensure proper drainage. Heat pumps must be raised when installed on a concrete pad or the ground to allow drainage to occur. If the heat pump unit is installed on a wall mounting bracket, insert the provided drain connector into one of the 1 inch (25mm) drain holes and attached a Feld -provided insulated drain hose to the connector. Use the provided rubber plugs to cover any unused drain holes (figure 3). Indoor Unit Front Case Removal This section describes how to remove the indoor unit front case. NOTE — This procedure may vary slightly on differently sized units. REMOVING AIR FILTER AND FRONT PANEL 1. Lift front panel out and up to remove. 2. Remove the air filters. 3. Loosen the clasps that secure the louvers to the case cover. Bend the louver slightly to remove it. 4. Remove the screw(s) that secure the indoor terminal strip access cover. Page 6 Page 31 Continued — 18 - 24 kBtu System Status or Error Codes — Indoor Character Display and Outdoor LEDs Outdoor Unit LED Status Indoor Troubleshooting for Possible This unit has three display 'status Unit indicators Error Description System Status Causes Display ❑OFF ■ ON 0 BLINKS D40 D41 D42 D43 • Check input voltage on outdoor unit terminal strip (N and L termi- nals). If lower than 175 VAC, cor- rect voltage problem. U7 ■ ❑ t ❑ Reversing valve malfunction • Check reversing valve wiring Al system functions are terminated connection for damage. except indoor fan. • If voltage and wiring connections are correct, replace reversing valve. Ug 0 N 0 ❑ Outdoor unit zero cross Replace outdoor control. detection error Figure 3. Condensate Drainage (Heat Pumps Only -- Unit Installed on Field -Provided Wall -Mounting Frame) SLAB OR ROOF MOUNTING Install the unit a minimum of 4 inches (102 mm) above the roof or ground surface to avoid ice build-up around the unit. Locate the unit above a load beating wall or area of the roof that can adequately support the unit. Consult local codes for rooftop applications (figure 4). GROUND LEVEL Install unit level or maintain slope tolerance of 2 degrees (or 2 inches per 5 feet [50 mm per 1.5 m]) away from building structure. Figure 4. Slope Tolerance SECURING OUTDOOR UNIT TO SLAB OR FRAME -If the outdoor unit is installed on a field -provided slab or frame, use lag bolts or equivalent to secure the outdoor unit to the slab or frame (figure 5). Figure 5. Securing Outdoor Unit to Slab PREVAILING WINDS (HEAT PUMP ONLY) If unit coil cannot be installed away from prevailing winter winds, a wind barrier should be constructed. Size barrier at least the same height and width as outdoor unit. Install barrier 12 inches minimum (305 mm) from the sides of the unit in the direction of prevailing winds as illustrated in figure 6. WIND BARRIER INLETAIR 12' (305 MM) MINIMUM DISTANCE DISCHARGE AIR Figure 6. Prevailing Wind Barrier Repositioning Indoor Air Temperature Sensor The indoor temperature sensor may be installed in an alternate location to facilitate shipping (figure 7). If necessary, relocate sensor to the proper position shown in figure 8. Refer to the procedure on page 31 for removal of the front cover. Figure 7. Sensor Shipping Location Page 30 Page 7 Figure B. Correct Sensor Location Indoor Unit Placement and Preparation INDOOR UNIT LOCATION Minimum clearances must be maintained as specified in figure 2. In addition, the following items should be considered: AVOID 1. Direct sunlight if possible. 2. Locating unit less than 3-1/4" (1 meter) away from combustible materials and vapors. 3. Locating unit near heat sources which could affect system performance. DO: 1. Locate the indoor unit where the room can be uniformly cooled. Install unit as high as possible on the wall for best performance. 2. Select a wall location that can support the weight of the unit. 3. Select a location where line set and condensate line will have the shortest run to the outside of the structure. 4. Allow sufficient space around unit for proper operation and maintenance. 5. Consider vertical rise between the indoor unit and outdoor unit. Do not exceed the maximum vertical line rise of the line set between the indoor unit and outdoor unit (table 5). 6. Install the indoor unit a minimum of 36 inches (914 mm) away from any antenna, power cord (line), radio, telephone, security system, or intercom. Electrical noise and radio frequencies from any of these sources may affect operation. DETERMINING WALL MOUNTING BRACKET LOCATION 1. Remove the wall mounting bracket from the indoor unit. A. Remove the shipping screw that secures the wall mounting bracket to the rear of the unit. B. Remove bracket from rear panel of indoor unit. Figure 9. Wall Mounting Bracket Removal from Indoor Unit 2. Determine the best exit location for utility bundle (line set, condensate line and wiring). Figure 10. Determining Exit Location NOTE — If opposite -side exit is preferred, see figure 18 to switch condensate line and drain cap. 3. Use the wall mounting bracket as a template to determine the exit point for utility bundle (figure 11 or 12). Continued — 18 - 24 kBtu System Status or Error Codes — Indoor Character Display and Outdoor LEDs Outdoor Unit LED Status Indoor This unit has three display Unit status indicators Error Description System Status Troubleshooting for Possible Display ❑ OFF ■ ON • BLINKS - Causes D40 D41 D42 D43 Check for proper wiring and loose connections at outdoor control in- H3 ❑ 0 ❑ Compressor overload protection All system functions are terminated put plug. Also, check for continuity sensor malfunction except indoor fan. across overload protection sensor terminals mounted at top of com- pressor. H4 ■ ❑ ■ ■ System operating abnormally See unit information manual. Intelligent Power Module protection error can result from any of the following: H5 ❑ - 0 ❑ ■ Intelligent Power Module proteo- All system functions are terminated except indoor fan. . Loss of cooling to the heat sink • Low voltage lion • High ambient temperature " • Loose screws fastening the outdoor control to the heat sink Check all and correct, if necessary. Lc ❑ # ❑ ! Unit start-up failure See unit start-up troubleshooting charts. • Check input voltage on outdoor unit terminal strip IN and L terminals). All system functions are termi- • If voltage is higher than 265VAC, nated. disconnect power to unit. Correct PH ❑ ■ ❑ • High voltage protection input voltage problem before reapplying power to system. • If voltage is within normal range, test capacitor output. If capacitor range is between 200-208VAC, replace outdoor control. • Check input voltage on outdoor unit terminal strip (N and L termi- nals). • If voltage is lower than 150VAC, PL ❑ ■ ■ ❑ Low voltage protection restart system and check power again. All system functions are termi- - Check reactor (choke) line con- 'termi- nated. nection on outdoor control nal marked INDC1. PU ❑ ■ ❑ ■ Capacitor charge failure See unit information manual for further information. P5 ❑ ❑ ❑ Compressor overcurzent proteo- lion P7 ❑ ❑ ■ ♦ Outdoor control failure Replace outdoor control. Intelligent Power Module high temperature error can result from any of the following: P8 ■ ❑ ■ Intelligent Power Module All system functions are terminated • Loss of cooling to the heat sink . Low voltage temperature is too high except indoor fan. . High ambient temperature • Loose screws fastening the outdoor control to the heat sink - Check all and correct, if necessary. U1 ❑ ■ ❑ Compressor current test circuit malfunction All system functions are terminated Replace outdoor control. except indoor fan. U3 ❑ ■ ■ ■ Unstable DC voltage protection Input voltage is not stable. U5 ❑ ■ 0 ■ Entire unit current monitoring All system functions are terminated Outdoor control has malfunction. malfunction except indoor fan. Replace control. Page 8 Page 29 Continued — 18 - 24 kBtu System Status or Error Codes — Indoor Character Display and Outdoor LEDs Outdoor Unit LED Status Indoor Troubleshooting for Possible This unit has three display Unit status indicators Error Description System Status Causes Display ❑ OFF ■ ON ♦ BLINKS D40 I D41 D42 D43 Intelligent Power Module protection limit error can result from any of the following: • Loss of cooling to the heat sink Intelligent Power Module proter, System will continue to run; howev- . Low voltage EU ■ ■ ■ lion limit er at reduced compressor speed . High ambient temperature until issue is corrected. . Loose screws fastening the out- door control to the heat sink Check all and correct, if necessary. See figure 92 for troubleshooting. ' The indoor coil sensor (RT2) mon- itors the coil temperature continu- Anti-freezing upper and lower System will continue to run; howev- ously. Any time the coil tempera- FH ■ ■ ■ ❑ limit range er at reduced compressor speed ture falls between 42.8°F (6°C) until issue is corrected. and 30.2°F (-10C), the micropro- cessor will initiate anti -freeze protection operation. Indoor ambient sensor (RTt) Sensor input is out of acceptable Ft open or short-circuited Cooling and dehumidify will contin- input range. Check sensor for ued to operate as well as indoor proper resistance. Replace sensor F2 Indoor coil sensor (RT2) open fan. Heating will not operate. if shorted, open or out-of-calibra- or short-circuited tion. ❑ ❑ ♦ ■ Outdoor ambient sensor (RT4) Sensor input is out of acceptable F3 open or short-circuited All system functions are terminated input range. Check sensor for except indoor fan. proper resistance. Replace sensor if shorted, open or out-of-calibra- Outdoor coil sensor (RT3) open F4 ❑ ❑ ❑ or short-circuited tion. Sensor input is out of acceptable Discharge line sensor (RT5) All system functions except indoor input range. Check sensor for F5 11❑ ■' fan will be terminated after 3-minute proper resistance. Replace sensor error delay. if shorted, open or out-of-celibra- tion. • Check outdoor ambient air tem- perature. Could be too high. • Check for locked compressor ro- Normal operational stale with com- for - Check for locked refrigeration pressor speed automatically adjust for exam- F6 ■ ❑ '■ Compressor overload limit for operational conditions. System pie) issue issue will continue to operate at reduced . Check for blocked or restricted compressor speed until issue is outdoor air Flow. Clear, if neces- corrected. sary. • Check for low refrigerant charge. See unit information manual for further information. F8 ■ ■ ❑ ■ High current limit issue System will continue but will reduce Check input voltage. It may be ei- ther too low or too high. F9 ■ ■ ❑ ❑ Discharge temperature too high Discharge line temperature is compressor speed to correct issue high. See figure 72. Power factor correction protec- See unit information manual for NC ❑ ■ lion further information. HO ■ ❑ Heating mode anti -high See unit information manual for temperature protection further information. H1 Defrosting (heat pump only) Normal operation d Normac operation to defrost out- oil. System protection feature. All sys- Excessive electrostatic charge H2NNIN Electrostatic protection tem functions are terminated ex- present. Correct, if possible. - cept indoor fan. 09 - 12 kBtu 21-5/16"(542) 27-5/16" 2-1/8" (694) 7-3/4" _ (55) (197) 11- 14" 18 kBtu (296) 2-3/16" (55) 5/8" (16) 3-1/4" (82). 0 0 l o , , " " "ri " ri" 011011 0 II 0 0 0 II o U 0 0 Q " Q, U 0 1 0: m n oe 00. 0� � 2-3116" °0 IIQQn I°0 (55) -----------------ILLA' - (5L 5/8" (16),J 22-3/16" 6-1/4" (563) — (160) 33-1/4" (945) Figure 11. Utility Bundle Rear Exit Locations 5-5/16" (136) (45) 4-7/8" (124) Page 28 Page 9 Table 10. 18-24 IcRfn Svcfem Stafus and Frrnr rnrinc _ Inrinnr r6.rnrrnr n;�ri . --A 24 kBtu 30 kBtu 40-1/8"(1018) 7-7/16" (189) 27 (685) o o o Q p p o 0 o Q o ° 0 0 0 0 0 0 0® 0 0 0 n 0 0 ° 2-9/16" ° ° 2-9/16" (65) o0 . 11 v0 . (65) Bo 0 Bo B 1- 22-5/8" (' Iwo) 2-1/2" (90) 1-7/16"(36) (65) o o ;0 °�o O o0 oeV 0 0 0o00 0 0 1" (25) 0 0 0 0 0 0 2-9/16" • �e �o (65) 00 to 0� t0 0f o Oo po 0 (i 4^ I(102) Figure 12. Utility Bundle Rear Exit Locations (Continued) INSTALLING WALL SLEEVE 1. Prior to making the hole and installing wall sleeve for the utility bundle, check to ensure that neither studs nor plumbing are directly located behind the hole location. A CAUTION inside2. Use either a sabre saw, key hole saw or hole -cutting drill attachment to cut a 2-1/2-inch (65 mm) diameter hole in the wall. Hole should be at a slight downward slant - 3/16" to 3/8" (5 to 10 mm) to the outdoor side. 2-9/16" (65) 1" (25) 4" (102) INSIDE OUTSIDE Figure 13. Boring Hole for Wall Sleeve 3. Measure the thickness of the wall from the inside edge to the outside edge and cut a field -provided PVC pipe Outdoor Unit LED Status Indoor This unit has three display Unit status indicators Error Description System Status Troubleshooting for Possible Display ❑ OFF ■ ON ♦ BLINKS Causes D40 D41 642 D43 NONE ■ ■ ■ 1 ■ System is operating within normal parameters Indoor control jumper is missing or C5 Indoor control jumper is missing Is not installed correctly. (Indoor No= (labeled JUMP) - control jumper location is labeled All system functions are terminated. JUMP.) EE ❑ ❑ ❑ ■ EEPROM failure Replace outdoor control. Check for low refrigerant charge, Et ❑ 0 • # System high pressure blocked coil or excessively high outdoor ambient temperature. The indoor coil sensor (RT2) moni- tors the coil temperature continu- ously. When the coil temperature drops below 30.2°F - (-1°C), the compressor and outdoor Check for reduced indoor airflow E2 ■ El❑ ■ Indoor coil freeze fan (30 seconds later) am switched (restricted cted cted filter), restricted refrig- protection off until the coil temperature rises (rest( low ambient tempera - e ra- ra- above above 42.8 F (6 C) and the cem- turn (outdoor) and low indoor sys- pressor has tem load. Correct, if necessary. - been off for a minimum of three minutes. All system functions are terminated except indoor fan. The compressor discharge line sensor (RT5) monitors the temper- ature continuously and communi- cates with the outdoor unit micro- processor. Depending on the tem- perature measured, the compres- E4 ■ ❑ ■ Discharge line temperature sor speed will be increased to meet the load or will continue to ran at Check for low system refrigerant protection the existing speed. If the discharge charge. Check capillary tubes for line temperature becomes exces- blockage. Correct, if necessary. sively high, the compressor will be de -energized. When the compres- sor discharge temperature drops below 194°F (900C), the unit will re- sume normal operation. See figure 72. Over -current protection error can result due to any of the following: • Ambient temperature is too high. Check for locked rotor on the E5 ❑ ■ • ❑ Compressor over -current All system functions are terminated compressor. protection except indoor fan. • Check for blocked refrigeration circuit (capillary tubes for exam- ple). Correct, if necessary. • Check for blocked or restricted outdoor air. Correct, if necessary. If error is displayed on outdoor E6 El ❑ ❑ Communication failure between All system functions except indoor unit, check communications cable /wire at indoor and outdoor con- indoorunit and outdoor unit fan are terminated after a 3-minute delay. trols to verify proper connection. See unit information manual for further information. Ell ■ ❑ ■ ■ Compressor high temperature All system functions are terminated See unit information manual for protection except indoor fan. further information. Page 10 Page 27 Continued — 09 through 12 and 30 kBtu System Status and Error Codes — Indoor Character Display and Outdoor LEDs Indoor Outdoor LED Displays Character (number of blinks) Error Description System Status Troubleshooting for Possible Display Causes yellow Red Green • Check input voltage on outdoor unit - terminal strip (N and L terminals). • If voltage is higher than 265VAC, disconnect power to unit. Correct input voltage problem before reap- plying power to system. • If voltage is below 265VAC, then PH 13 OFF OFF High voltage protec- All system functions are check capacitor while unit is turned off. lion terminated. • If voltage is between 200-208V, ca- pacitor is working properly • If voltage is some other value, re- place capacitor.- If voltage is some other value, replace capaci- tor. • If input voltage and capacitor are normal, replace outdoor control. • Check input voltage on outdoor unit terminal strip IN and L terminals). • If voltage is lower than 150VAC, PL 12 OFF OFF Low voltage protec- All system functions are restart system and check power lion terminated. again. •9-12 kBtu, 208-230VAC systems only— Check reactor (choke) line connection on outdoor control terminal marked AC-L2. • Check input voltage on outdoor unit terminal strip (N and L terminals). If lower than 175 VAC, correct U7 OFF OFF OFF Reversing valve voltage problem. • Check reversing valve wiring malfunction - connection for damage. All system functions are terminated • If voltage and wiring connections except indoor fan. are correct, replace reversing valve. • Check connections between com- NONE 1 OFF OFF Compressor has an pressor and outdoor control con - V open circuit. trol terminals are marked U, and w). Outdoor ambient air Status indicator. System functioning NONE OFF 8 OFF temperature is not Normal status indicator when unit is property Outdoor unit will not oper- within the outdoor turned off. ate if outdoor ambient temperature is units start up range out of range. NONE OFF 11 OFF Frequency limiting All system functions are terminated ' Verify proper attachment of heat sink. module temperature except indoorfan. • Clean heat sink, if necessary. NONE OFF 13 OFF Power issue Compressor speed automaticallor- y malion power further to match conditions. tion. at,a slight angle 1/4" (6 mm) shorter than the thickness of the wall. CUT PVC FOR WALL SLEEVE AT SLIGHT ANGLE Figure 14. Cutting PVC for Wall Sleeve 4. Place a field -provided plastic cover over the end of the pipe that will be visible from the inside wall and insert the pipe in the wall. PVC PIPE _ SLIGHT PLASTIC COVER - ANGLE (FIELD PROVIDED) INSIDE OUTSIDE WALL Figure 15. PVC Wall Sleeve Installation SECURE WALL MOUNTING BRACKET TO WALL Determine that wall will support the weight of the indoor unit. See table 1 for indoor unit weight. Install the wall mounting bracket so that is is correctly positioned horizontally and vertically. The indoor unit must be installed level on the wall to allow proper condensate drainage. 1. Use a carpenter's level or tape measure to verify the wall mounting bracket is horizontally level. 2. Secure the wall mounting bracket to the wall using the provided screws. If possible, align the rear panel screw holes with wall stud locations marked on the wall. HINT — Use the wall mounting bracket as a template to mark locations where screws will be used. 3. Secure the wall mounting bracket to the wall using as many screws into studs as possible. All other screws must be secured using plastic wall anchors. NOTE— It is important to use all screws provided to secure the wall mounting bracket to the wall. Additional holes may be drilled through the. metal wall mounting bracket to better secure wall bracket to wall studs. 0 o 0 c °o/ q0o° % WALL MOUNTING ®' t• BRACKET °0 Figure 16. Securing Wall Mounting Bracket to Wall 4. The wall mounting bracket must be installed flush against the wall so that the indoor unit will be flush after installation. Any space between the wall and unit will cause noise and vibration. 5. The wall mounting bracket must be installed horizontally level on the wall. 6. If the wall is made of brick, concrete or other similar material, then drill pilot holes in the wall. Insert field -provided plastic anchors for mounting screws. DRILL PILOT HOLES 4— USE ANCHORS INSTALL ANCHORS Figure 17. Masonry Applications CONDENSATE DRAIN CONFIGURATION If the condensate line needs to be moved, use the procedure provided in figure 18 to change the drain line exit location. Care must betaken when moving the condensate line to the opposite position to prevent damaging the condensate line or connector. Page 26 Page 11 , 1. Locate the condensate line and the drain Gap located on unit. 2. Remove the clamp which secures the condensate line to the drain outlet and pull the line to remove it. 3. Apply moderate force to pull off the drain cap from the unit. REAR VIEW OF UNIT qCONDENSATE DRAIN CAP 4. Re -install the drain cap on the opposite side drain outlet. REAR VIEW OF UNIT 9:: DRAIN CAP 5. Slide the condensate line over the opposite drain outlet and use the clamp to secure the line. REAR VIEW OF UNIT DRAIN PAN OUTLET CLAMP HOOK , LATCH CLAMP CLAMP HOOK CONDENSATE LINE - IMPORTANT— Keep horizontal runs of condensate line external to unit as short as possible. Condensate line should be properly sloped to ensure proper drainage. Figure 18. Changing Condensate Drain Location (If necessary) PREPARING INDOOR UNIT FRAME FOR LEFT- OR RIGHT -SIDE EXIT OF UTILITY BUNDLE 1. Right- or Left -Side Utility Bundle Exit —Cutout the corner of the righttleft plastic cabinet with a hacksaw or similar tool (A or B). 2. Right -Rear or Left -Rear Utility Bundle Exit — The corner of the plastic cabinet does not need to be modified. A PLASTIC CABINET LEFT -SIDE TUBING OUTLET B PLASTIC CABINET RIGHT -SIDE TUBING OUTLET Figure 19. Left- or Right -Side Utility Exit Indoor Unit Cable Connections INDOOR / OUTDOOR CABLE Wiring must conform to local and national codes. NOTE — Stranded wire must be used to connect the outdoor unit to the indoor unit. The stranded wire is necessary to ensure proper system communication and operation. 1. Route the cable (4-conductor, stranded wire, line voltage, sized per National Electric Code) through the wall sleeve. Refer to unit nameplate for rated voltage. INDOOR UNIT WALL MOUNTING BRACKET WALL 00 0 . • • o • a: 0 °0 0 / i i i WIRING FIELD -PROVIDED PVCWALLSLEEVE Figure 20. Feed Cable through Wall Sleeve Continued — 09 through 12 and 30 kBtu System Status and Error Codes — Indoor Character Display and Outdoor LEDs Indoor Outdoor LED Displays Character (number of blinks) Error Description System Status Troubleshooting for Possible Display Causes Yellow Red Green All system functions will continue to • Check sensor for proper resist- FS- OFF 7 OFF Discharge line run for 3 minutes, then terminate. once. Sensor should be in accept - sensor (RT5) error Indoor fan will continue to run. able range. Replace sensor if shorted, open or out -of -calibration. • Check outdoor ambient air Normal operational state with temperature. Could be too high. compressor speed automatically • Check for locked compressor rotor. F6 OFF 3 OFF Compressor over- adjust for operational conditions. • Check for blocked refrigeration load limit issue System will continue to operation at circuit (capillary tubes for example). reduced compressor speed until • Check for blocked or restricted issue is corrected. outdoor air flow. Clear, if necessary. • Check for low refrigerant charge. High current limit • Check for low or high input voltage. F8 OFF 1 OFF Correct if necessary. Could be too issue high. System will continue to operate at reduce compressor speed until F9 OFF 2 OFF Discharge line • Check discharge line temperature. temperature too high issue is corrected. Correct if to high. HC 14 OFF OFF Power factor See unit information manual for fur - correction protection ther information. H1 2 OFF OFF Defrosting (heat pump only) Normal operation Normal defrost operation. Compressor H3 8 OFF OFF overload protection • Check for proper wiring connec- sensor (CT1,2) tions and loose wires at outdoor malfunction. control (CT1, 2) input plug. • Check for continuity across over - load protection sensor terminals Compressor high H4 6 OFF OFF temperature mounted at top of compressor. protection All system functions are terminated This can be caused by any of the fol- - except indoor fan. lowing: • Loss of cooling to the heat sink Intelligent Power • Low voltage. H5 4 OFF OFF Module (IPM) • High ambient temperature module protection • Loose screws fastening the outdoor control to the heat sink See unit information manual for further information. - Possible Indoor control failure or in- door motor failure. Indoorfan not • Check wiring between fan motor H6 OFF OFF OFF communicating and indoor control. • Check wiring between fan motor and terminal marked OFFAN. - • Replace one or both, if necessary. Indoor and outdoor The two system components are LP 16 OFF OFF unit mismatch mis-matched. Refer to engineering All system functions are terminated. handbook for correct match -up. • Check wiring between fan motor Outdoor DC fan and outdoor control terminal L3 OFF 14 OFF motor malfunction marked OFFAN. • If wiring is correct, replace outdoor DC fan motor. Indoor unit is experiencing either a L9 9 OFF OFF Power factor protec- high or low input voltage condition. tion Vedfy proper input voltage at terminal strip N(1) and 3. Page 12 Page 25 Continued — 09 through 12 and 30 kBtu System Status and Error Codes — Indoor Character Display and Outdoor LEDs Indoor Outdoor LED Displays Character (number of blinks) Error Description System Status Troubleshooting for Possible Dis la P Y Causes Yellow Red Green All system functions are terminated except indoor fan. The indoor coil sensor (RT2) monitors the coil temperature continuously. If coil .Check for restricted indoor airflow Indoor coil freeze temperature drops below 30.20E (A'C), the compressor and the and change filter, if necessary. E2 3 OFF OFF protection outdoor fan (30 seconds later) are • Check for restricted refrigerant flow. switched off. Condition is cleared • Check for low outdoor ambient tem- when indoor coil temperature rises perature or low indoor system load. above 42.80F (60C) and the compressor has been off for a minimum of three minutes. Outdoor coil • Check for proper clearances E3 OFF 9 OFF blockage or low All system functions are terminated around outdoor unit. refrigerant due to except indoor fan. • Check outdoor coil for and clean, if leak. necessary. Sensor RT5 monitors compressor discharge line temperature and communicates with outdoor unit microprocessor. Depending on the temperature measured, the compressor speed will be Discharge line increased to meet the load or will continue to run at the existing .Check for low refrigerant h carg e. rant argflow E4 7 OFF OFF temperature speed. If the temperature becomes • Check for restricted ant protection excessively high, the compressor due to blocked capillary. will be de -energized. When the compressor discharge temperature drops below 1940F (900C), the unit will resume normal operation. See _ unit information manual for further information. • Check for locked compressor rotor due to excessively high ambient ES 5 OFF OFF Compressor over -current All system functions are terminated temperature. • Check for restricted refrigerant flow protection except indoor fan. due to blocked capillary tubing. • Check outdoor unit to make sure that coil is not blocked. • If error is displayed on outdoor unit, Communication All system functions are terminated check communications cable / wire E6 OFF OFF OFF failure between after three -minute delay except at indoor and outdoor controls to indoor unit and indoor fan. verify proper connection. See unit outdoorunit information manual for further information. FH OFF 4 OFF Anti -freezing upper Compressor will run at reduced • Wait for temperature to increase above 42.8 F (6 C), then recheck and lower limit range speed until temperature increases. operation status. • Pump refrigerant into outdoor unit. FO OFF OFF OFF Indoor coil is All system functions are terminated Check 2-way shut-off valve in small gathering refrigerant except indoor fan. line to see if it is closed or if flow is restricted. Correct, if necessary. F1 OFF OFF OFF Indoor ambient sensor open •Check sensor to ensure that it is in or short circuited circuited Cooling and dehumidification acceptable range. modes will continue to operate as well as indoor fan. Unit will not • Check sensor for proper resistance. Indoor coil sensor F2 OFF OFF OFF (RT2) open or short operate in heating mode. • Replace sensor if shorted, open or circuited out -of -calibration. F3 OFF 6 OFF Outdoor ambient sensor (RT4) open •Check sensor to ensure that it is in or short circuit acceptable range. All system functions are terminated except indoor fan. • Check sensor for proper resist - ance. Outdoor coil sensor F4 OFF 4 OFF (RT3) open or short • Replace sensor if shorted, open or circuit out -of -calibration. 2. Make sure to provide a sufficient length of cable so that connections are made to the unit before it is secured to the wall mounting bracket. 3. Lift indoor unit front panel to access the control box cover. Remove the screw(s) securing the cover plate. Remove the plate. TYPICAL INDOOR UNIT CONTROL BOX COVER TERMINAL BLOCK TYPICAL WIRING o STRAIN RELIEF Figure 21. Accessing the Indoor Unit Terminal Block 4. Feed cable /wiring through conduit routing guide on 09 - 24 kBtu units. NOTE - 09-12 kBtu Systems Only — A cable routing guide has been factory -installed. NOTE - 18-30 kBtu Systems Only — A cable routing guide has been provided in the bag assembly. Install the guide as shown in figure 22. Figure 22. Typical Indoor Unit (18- 30 kBtu Indoor Unit) — Securing Cable / Wires 5. Strip the wire insulation to expose the stranded wire. 6. Tightly twist each wire end. 7. Terminal designations for the indoor unit terminal block are illustrated in figure 23. Figure 23. All 208-230V Indoor Terminal Designations (Indoor/ Outdoor Cable) 8. Use the provided strain relief plate to secure the terminal block wiring. Figure 24. Typical Indoor Unit Terminal Block and Strain Relief Securing Indoor Unit to Wall Mounting Bracket 1. Shape the refrigerant line set so that it can be guided either out the back of the indoor unit or through either side of the indoor unit frame, then through the wall sleeve to the outside unit. 2. Use field -provided tape to bundle the cable, refrigerant line set and condensate line together as shown in figure 1. 3. Feed the bundle through the wall sleeve and slide indoor unit onto upper mounting hooks. c Page 24 Page 13 r r K „ UPPER MOUNTING HOOKS PASS BUNDLE THROUGH WALL Figure 25. Feed Bundle through Wall Sleeve 4. Secure the indoor unit to the wall bracket using the lower mounting hooks. LOWER MOUNTING HOOKS Figure 26. Secure Indoor Unit to Wall Mounting Bracket 5. Carefully bend the bundle (line set, condensate line and cable) to run along the outside wall toward the outdoor unit. Downward slope of wall sleeve will ensure proper condensate drainage. INDOOR UNIT SLOPE BUNDLETHROUGH WALL SLEEVE Figure 27. Installed Indoor Unit CONDENSATE LINE - 1. Use the provided foam insulation to wrap the factory -installed condensate line. , 2. Connect indoor unit factory -installed condensate line to field -provided condensate drain pipe. 3. Use tape approved for waterproofing line connections to secure the field -provided pipe to the factory -installed condensate line. NOTE — Use a clean, dry cloth to wipe the indoor unit after installation is complete to remove fingerprints. Do not use wet cloth, cleansers or solutions. Outdoor Unit Wiring Connections In the U.S.A., wiring must conform with current local codes and the current National Electric Code (NEC). In Canada, wiring must conform with current local codes and the current Canadian Electrical Code (CEC). Refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size. Indoor and Outdoor Error Codes This section identifies error codes that appear on the front panel of the indoor unit or outdoor unit control. Many of the error codes will automatically dear themselves when the error no longer exists. However some error codes may require disconnecting power to the system at the unit disconnect switch or circuit breaker in order to clear them and to resume normal system operation. . The temperature readout (either temperature setpoint or indoor ambient) will be replaced by an error code if there is a malfunction. If multiple errors are detected, the display will alternate between each error code. NOTE - No history is kept on past error codes. v w 6 e 72 W ❑tea: 0 0 o°o coZ> �cooL) O z O z KZ W w W o o O w = Figure 48. Indoor Unit Front Panel Indicators Table 9. 09 through 12 and 30 kBtu System Status and Error Codes — Indoor Character Display and Outdoor LEDs Indoor Outdoor LED Displays Character (number of blinks) Description System Status Yellow Red Green Display SYSTEM STATUS LEDs Indoor and outdoor operating normally. The blinking interval is 1 second on,1 NONE-'� BLINKING units are communicating second oft Compressor is System is operating normally. The blinking interval is 1 second on, 1 NONE BLINKING + W� '7 running second off. NONE °,,�- 8 - System has a heating or cooling System is operating normally. The blinking interval is 1 second on, 1 second off and up to three second pause between repeating blinks. - demand SYSTEM ERROR DISPLAY AND LEDs Indoor Outdoor LED Displays Character (number of blinks) Error Description System Status Troubleshooting for Possible Causes Yellow Red Green Display • Check connections between NONE 1 OFF OFF Compressor has an All system functions are terminated compressor and outdoor control open circuit. except indoor fan. (control terminals are, marked U, V and W). Frequency limiting All system functions are terminated • Verify proper attachment of heat NONE OFF 11 OFF module temperature except indoor fan. sink. • Clean heat sink, it necessary. NONE OFF 13 OFF Power issue Compressor speed automatically adjusted to match conditions. System power issue. Indoor control • Check indoor control jumper con- 05 OFF OFF OFF jumper is missing All system functions are nections and replace jumper, if (labeled JUMP) terminated. missing. EE 11 OFF OFF EEPROM failure • Replace outdoor control. Page 14 Page 23 2. Apply sealant around the utility bundle on the outside of the wall sleeve to prevent rain and outdoor air from entering the room. APPLY SEALANT HERE BUNDLE Figure 47. Seal Wall Sleeve Around Utility Bundle 3. An optional field -provided exterior wall channel may be used in lieu of taping the utility bundle to protect the bundle from UV rays, weather, etc. Maintenance OUTDOOR UNIT 1. Ensure power is off before cleaning. 2. It may be necessary to wash the outdoor coil more frequently if it is exposed to substances which are corrosive or which block airflow, across the coil (e.g., pet urine, cottonwood seeds, fertilizers, fluids that may contain high levels of corrosive chemicals such as salts). 3. Outdoor Coil (Sea Coast) — Moist air in ocean locations can carry salt, which is corrosive to most metal. Units that are located near the ocean require frequent inspections and maintenance. These inspections will determine the need to wash the unit including the outdoor coil. Consult your installing contractor for proper intervals/procedures for your geographic area or service contract. 4. Outdoor unit fan motor is pre -lubricated and sealed. No further lubrication is needed. 5. Visually inspect all connecting lines, joints and coils for evidence of oil leaks. 6. Check all wiring for loose connections. 7. Check for correct voltage at unit (unit operating). INDOOR UNIT 1. Clean or change filters. 2. Check all wiring for loose connections 3. Check for correct voltage at unit (blower operating). 4. Clean coil, if necessary. 5. Check connecting lines and coils for signs of oil leaks. 6. Check condensate line and clean, if necessary. NOTE — The filter must be in place and the front panel must be closed any time the unit is in operation. MAIN SYSTEM CIRCUIT BREAKER AND OUTDOOR UNIT DISCONNECT SWITCH The main 'system circuit breaker and outdoor unit disconnect switch should be sized per local codes and unit requirements. Local codes may require a disconnect between the indoor and outdoor units. INDOOR / OUTDOOR CABLE Wiring must conform to local and national codes. NOTE— Stranded wire must be used to connect the outdoor unit to the indoor unit. The stranded wire is necessary to ensure proper system communication and operation. SUPPLY POWER Size per unit nameplate and local and national codes. WIRING CONNECTIONS 1. Remove access panel. 2. Route all wiring to outdoor unit through the wire routing plate. 3. Connect the control wiring and power supply wiring per the figures that follow. 4. The unit must be grounded according to local codes. 5. Secure wiring using built-in wire strain relief. ROUTING PLATE 11 1 LIU 0 I I ACCESS PLATE Figure 30. Outdoor Unit Electrical Connections COMMUNICATION OUTDOOR UNIT N(1 2 1 3 1 L1 I L2 L1 L2 POWER GROUND N(1) 2 3 O (LI) (LZ) (COMMUNICATION) INDOOR UNIT TERMINAL LEGEND N(1) = L1 2 = Communication line 3=L2 �+ = Ground IMPORTANT Check indoor to outdoor field wiring to confirm (N) 1 from indoor goes to (N)1 outdoor, terminal 2 from indoor goes to terminal 2 outdoors and terminal 3 indoors goes to terminal 3 in outdoor. Figure 31. Outdoor Unit Terminal Designations A CAUTION 6. Use the strain relief to secure the cabling (figure 32). OUTDOOR BLOCKTERMINAL �n_anga;x; 10i' j zLI Ca=o7 Co=o] TO INDOOR UNIT TO POWER SUPPLY Figure 32. Typical Unit Strain Relief Page 22 Page 15 Operating Valves The outdoor unit suction ( vapor 2-way service valve is used to purge air, test for leaks, check operating pressures and add refrigerant to system. This valve is equipped with a service port which has a factory -installed valve core. Figure 33 provides information on how to access and operate the 2-way angle -type service valve and 2-way shut-off valve. Table 4. Valve Caps Torque Recommendations Outside Diameter Recommended Torque No torque wrench available? Finger tighten and use an 1 2 appropriatelysized wrench to turn an 9 —. — 1/4 TURN additional: Inches mm U.S. Metric 1/4" 6.35 11-14-3/4 ft.- lb. 15 - 20 N'm 114 turn 3/8" 9.52 26 - 29-1/2 ft: Ib. 35 - 40 N'm 1/2 turn 1/2" 12.70 44-1/4 - 48 8: lb. 60 - 65 N`m 7/8 turn 518" 16 51-5/8 - 55-1/4 ft.- lb. 70 - 75 N'm 1 full turn ACfIOn 2-Way 3-Way 3-WAY VALVEVICE Shut -Off Valve Service Valve HOSE WITH SCHRADER VALVE CLOSED �r_� _ PUSH Evacuating with a vacuum pump REQUIRES FIELD -PROVIDED 5116" FEMALE FLARE TO 1/4" MALE FLARE ADAPTER. VALVE CAP 9SERVICE ITION FULLY OPEN FLARE CAPOSITION Outdoor unit PIN running TO LINE SET FULLY PORT CAP PORT OPEN TO OUTDOOR UNIT Checking pressure and FAWRCH adding refrigerant ( FLARECAPN TO LINEION SET." — TO OUTDOOR UNIT Figure 33. Valve Operations IMPORTANT! To prevent stripping of the various caps, use an appropriately sized wrench and fit the wrench snugly over the cap before tightening. WEIGH IN Amount specified on nameplate Adjust amount. for variation in line set length listed on line _ set length listed in table 7. Total charge NOTE —The above nameplate is for illustration purposes only. • m. Go to actual nameplate on outdoor unit forcharge information. Figure 41. Using HFC-410A Weigh -In Method Wrapping Utility Bundle After system has been tested for leaks and proper operation has been verified, use tape to bundle the control wiring, line set and condensate line. 1. Wrap insulation material around the line set connection between the indoor and outdoor units. 2. Insulate remaining sections of line set and condensate line. INDOORPLASTIC WIRE TIES INSULATION MATERIAL TO . OUTDOOR Figure 42. Insulate and Tape Line Set Connection INSULATION MATERIAL MINIMUM MINIMUM 5/16" (8 MM) 5116" (8 MM) LINE SET Figure 43. Insulate Line Set 3. Start from the bottom at the outdoor unit and use tape to bundle the insulated line set together with tape (figure 44). LINE SET —� WIDE VINYL WRAP WITH VINYLTAPE TAPE Figure 44. Tape Line Set INSULATE AND TAPE LINE SET CONTROL WIRING WRAP WITH VINYL TAPE BETWEEN INDOOR AND (NARROW) OUTDOOR UNITS Figure 45. Control Wiring Bundling 4.. Tape the control wiring to the line set bundle (figure 45). 5. Start from the bottom of the bundle at the outdoor unit and use tape to bundle the condensate line with the control wiring and line set (figure 46). INSULATED LINE SET CONDENSATE LINE WRAP WITH VINYL TAPE CABLE (NARROW)(CABLE) BETWEEN INDOOR AND OUTDOOR UNITS WRAP WITH VINYL TAPE (WIDE) Figure 46. Utility Bundle (Cable, Line Set and Condensate Drain Line) 1. Clamp bundle to wall. Use one clamp approximately every 47" (1194 mm). Page 16 Page 21 5. Allow the system to operate for a minimum of 10 minutes before doing system checks: Indoor air coil temperature drop (Range of 18 to 240F (10 to 13°C). Refrigerant pressure on big line. (Use pressure ranges noted in table 8 for general guides. Minor variations in these pressures may be expected due to differences in installations). HEATING 1. Indoor temperatures should be between 61°F and 70°F (16°C and 21°C). Outdoor temperatures should be between 5°F to 80°F (-15°C to 27°C) 2. Set all indoor zone remote controls to highest setting 860F {30°C) in the Heat mode. 3. Turn the remote control I FEEL function ON. 4. Turn ON the TURBO function. (Note: Allow 3 minutes for compressor delay to time out). - 5. Allow the system to operate for a minimum of 10 minutes before doing system before checking: Refrigerant pressure on big .line. (Use pressure ranges noted in table 8 for general guides. Minor - variations in these pressures may be expected due to differences in installations). IMPORTANT If the operating pressures do not fall within the ranges given in the pressure table: A. Check the indoor or outdoor unit displays for error code(s). B. Refer to troubleshooting procedure diagrams in Service and Installation manual to verify component operation. If no issues are found, follow the weigh-in charging procedure below to charge the system. son LOW HIGH MICRON GAUGE (REQUIRED FOR 'R E EVACUATION A34000114 SAE TEE WITH I MANIFOLD GAUGE SET PROCEDURE ONLY) SWIVEL COUPLER O 3 «. O 4 4. i ° z 00 VACUUM PUMP NITROGEN HFC-410A Figure 40. Typical Gauge Set Connections for Leak Testing, Evacuation and Charging Table 8..Operating Pressures Temperature Condition °F (°C) System Size .(kBtu) Indoor Fan Mode Outdoor Fan Mode Standard Suction I Vapor Operating Pressure Ranges Line Set Length Indoor Outdoor Cooling Mode 67 to 80 (19.4 to 26.7) 75 to 95 (23.9 to 35) 09K TurboEHigh 152 PSIG (1.05 MPa) 25 feet (7.62 m) 12K Turbo 135 PSIG (0.93 MPa) 18K Turbo 131 to 160 PSIG (0.9 to 1.1 MPa) 24K Turbo 116 to 145 PSIG (0.810 1.0 MPa) 30k Turbo 131 PSIG (0.9 MPa) Heating Mode 67 to 80 (19.4 to 26.7) 43 to 47 (6.1 to 8.3) 09K Turbo High 380 PSIG (2.62 MPa) 25 feet (7.62 m) 12K Turbo High 402 PSIG (2.77 MPa) 18K Turbo High 319 to 348 PSIG (2.2 to 2.4 MPa) 24K Turbo High 363 to 392 PSIG (2.5 to 2.7 MPa) 30K Turbo High 535 PSIG (3.1 MPa) Line Set Requirements t IMPORTANT Mineral oils are not compatible with HFC-410A. This section provides information on installation of the field -provided line set. LINE SET INSTALLATION Seal and isolate the opening. where the bundle (including refrigerant lines) passes through the wall so vibration is not transmitted to the building. Both lines must be individually insulated. LINE SET LENGTH AND ELEVATION Each system size has a limited line set length and vertical elevation limit as reference in table 5. Minimum line set length for all sizes is 10 feet (3 meters). Field piping consists of two lines from the outdoor unit to LINE SET CONNECTIONS the indoor unit. Use field -fabricated line set will require Line connections are made between the indoor and flare connections and diameter sizes as listed in table 5. outdoor units using provided flare nuts. Table 5. Refrigerant Line Set Requirements, Length and Height Limitations and Outdoor Unit Refrigerant Metering Device Type (Air Conditioner and Heat Pump Systems) System Size (kBtu) Line Set Diameters Maximum Line Set Elevation Maximum Line Set Length Refrigerant Metering Device Type Small Line Large Line -09 1/4 in. (6 mm) 318 in. (9.5 mm) 33 feet (10 m) 66 Feet (20 m) -12 -18 1/4 in. (6 mm) 1/2 in. (12 mm) 49 feet (15 m) 98 Feet (30 m) Electronic Expansion Valve -24 114 in. (6 mm) 5/8 in. (16 mm) -30 1/4 in. (6 mm) 5/8 in. 16 mm) 33 feet (10 m) 98 Feet (30 m) Note - Minimum line set length for all sizes is 10 feet (3 meters). Maximum Line Set INDOOR UNIT Length Maximum Line Set OUTDOORUNIT Length Maximum Line INDOOR UNIT Maximum Line Set Elevation Set Elevation OUTDOOR UNIT Figure 34. Line Set Length and Elevation Table 6. Flare Nut Torque Recommendations Outside Diameter Recommended Torque No torque wrench available Finger tighten and use an appropriatelysized wrench to turn an additional: 1 2 9 -y -114 TURN � 6 5 Inches mm U.S. Metric (Newton Meter) 114" 6.35 15 ft.- lb. - 20 1/4 turn 3/8" 9.52 26 ft: Ib. 35 1/2 turn 1/2" 12.70 41 ft-lb. 55 7/8 turn 1518, 15.88 48 ft.* Ito. 65 1 full turn Page 20 Page 17 USING MANIFOLD GAUGL or=T When checking the system charge, only use a manifold gauge set that features low -loss and anti -blow -back fittings. Manifold gauge set used for HFC-410A refrigerant systems must be capable of handling the higher system operating pressures. The manifold gauges should be rated for: • High side - Pressure range of 0 - 800 pound -force per square inch gauge (psig); • Low side - Use with 30" vacuum to 250 psig with dampened speed to 500 psig; • Manifold gauge set hoses must be rated for use up to 800 psig of pressure with a 4000 psig burst rating. FLARING PROCEDURE 1. Use a tube cutter to cut the copper line set to the required length. Cut the lines approximately 12" to 20" (305mm to 508mm) longer than the estimated required length. 2. Use a pipe reamer or file to remove burrs at the end of the line set. BEFORE AFTER I Figure 35. Deburring Line Set 3. Remove flare nut from outdoor unit and slide it onto the copper tube. 4. Use a flaring tool to flare the end of the copper tube. Figure 36. Flaring Tools CONNECTING LINE SET TO OUTDOOR UNIT - 1. Apply a sealing cap or water -proof tape to prevent dust or water from getting into the refrigerant piping before it is connected. 2. Apply refrigerant lubricant to the matching surfaces of the flared line set and union before connecting them together (figure 37 -- A). This will reduce refrigerant leaks. 3. Align the flared refrigerant line with valve connection, then tighten the flare nut lightly at first to obtain a smooth match (figure 37 - B). Figure 37. Typical Line Set Connection to Outdoor Unit 4. Tighten flare nuts. Do not over -tighten a flared joint. Once snug, continue another half turn on each nut. That should provide a gas -tight joint. You may also use a torque wrench to tighten nuts using table 6 recommendations. CONNECTING LINE SET BETWEEN INDOOR AND OUTDOOR UNITS 1. Apply a sealing cap or water -proof tape to prevent dust or water from getting into the refrigerant piping before it is connected. 2. Apply refrigerant lubricant to the matching surfaces of the flared line set and union before connecting them together (figure 38 -- A). 3. Align the union tube and flared refrigerant line with each other, then tighten the flare nut lightly at first to obtain a smooth match (figure 38 - B). A APPLY REFRIGERANT LUBRICANT HERE MALE FLARE �y CONNECTION B Figure 38. Making Connections at Indoor Unit (Male to Female Connection) 4. Tighten flare nuts (see figure 39). Do not over -tighten a flared joint. Once snug, continue another half -turn on each nut which should create a leak -free joint. A torque wrench may be used to tighten flare nuts using table 6 recommendations. TORQUE WRENCH TO INDOOR _ ' O BACKUP UNIT WRENCH TO OUTDOOR UNIT Figure 39. Tighten Flare Nut Leak Test and Evacuation Air and moisture remaining in the refrigerant system will have undesirable effects as indicated below: • Pressure in the system rises • Operating current _rises • Cooling or heating efficiency drops • Moisture in the refrigerant circuit may freeze and block capillary tubing (30 kBtu size only) • Water may lead to corrosion of parts in the refrigeration system The line set between the indoor and outdoor units must be leak tested and evacuated to remove any non- condensables and moisture from the system. LEAK,TEST Use the following procedure to test for system leaks: 1. Connect the manifold gauge set and dry nitrogen gas cylinder to the suction / vapor service port (see figure 40). 2. Open valve on nitrogen cylinder. 3. Pressurize the system to no more than 150 PSIG with dry nitrogen. 4. Check for leaks using soapy water. 5. After the system is found to be free of leaks: • Close valve on nitrogen cylinder. • Relieve the nitrogen pressure by: loosening the charge hose connector at the nitrogen cylinder. • When the system pressure is reduced to normal, disconnect the hose from the cylinder. EVACUATION 1. Connect the manifold gauge set, micron gauge and vacuum pump as shown in figure 40. 2. The operation time for evacuation varies with the line set length and capacity of the pump. Allow the pump to operate until the system has been evacuated down to 300 microns. Allow the pump to continue running for an additional 15 minutes. 3. Turn off the pump and leave the connection secured to the 3-way service port. After five minutes, if the system fails to hold 500 microns or less, check all connections for tight fit and repeat the evacuation procedure. 4. When the desired vacuum is reached, close the low knob of the manifold valve and stop the vacuum pump. Unit Start -Up A IMPORTANT • •. • . . •- energized 24 hours before unit start-up to prevent compressor damage as a result of slugging. UNIT START-UP 1. Inspect all factory- and field -installed wiring for loose connections. 2. Verify that the manifold gauge set is connected as illustrated in figure 40. 3. Open the 3-way service and 2-way shut off valves to release the refrigerant charge contained in outdoor unit into the system. 4. Replace the stem caps and tighten to the value listed in table 6. 5. Check voltage supply at the outdoor unit terminal strip. The voltage must be within the range listed on the unit's nameplate. If not, do not start the equipment until you have consulted with the power company and the voltage condition has been corrected. 6. Refer to the included user guide to operate the system using the provided remote control. 7. Visually check for binding of both indoor and outdoor fans. Adding Refrigerant for Longer Line Set 1. Open the 3-way service valve and weigh. in liquid refrigerant. Use table 7 to calculate the correct weigh-in charge. 2. Close manifold gauge valves. Table 7. Line Set Length and Adding Refrigerant System Base Charge (outdoor Size unit is sufficient for up Add Refrigerant (kBtu) to listed length below) -09 1 ounces per 40 inches (30 grams per meter) -12 -18 0.71 ounces per 40 inches (20 26 feet (8 m) grams per meter) -24 1 ounces per 40 inches (30 grams per meter) . -30 2 ounces per 40 inches (50 grams per meter) Checking Suction 1 Vapor Operating Pressures Connect gauge set to service port as illustrated in figure 40. 1. Indoor temperatures should be between 70OF and 86°F (21 °C and 30°C). Outdoor temperatures should be between 230F to 1180F (-5°C to 480C). 2. Turn the remote control I FEEL function ON. 3. Set all indoor zone remote controls to lowest setting 61 OF {16°C} in the Cool mode. 4. Turn ON the TURBO function. (Note: Allow 3 minutes for compressor delay to time out). Page 18 Page 19