Trane R410a Split System Air Conditioner And Heat Pump Installation Guide (+ PDF)

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1 R410A Split System Air Conditioner and Heat Pump

R410A Split System Air Conditioner and Heat Pump

Product Information:
Product Name: Split System Air Conditioner & Heat Pump
Model: 16 SEER
Capacity: 1.5-5 Tons
Refrigerant Type: R410A
Appearance: The appearance of the unit may vary. Product
Usage Instructions:
1. Safety Precautions: – This product should only be installed,
adjusted, and operated by qualified licensed service personnel. –
Read all the instructions thoroughly before attempting installation
or operation. – Failure to follow these instructions may result in
improper installation, adjustment, service, or maintenance, which
can lead to fire, electrical shock, property damage, personal
injury, or death. 2. Compliance with Codes: – Ensure that all
phases of the installation comply with national, state, and local
codes. 3. Key to Symbols and Safety Instructions: – The warning
triangle symbol indicates important safety information. – The
keywords DANGER, WARNING, CAUTION, and NOTICE are defined as
follows: – DANGER: Indicates a hazardous situation that, if not
avoided, will result in death or serious injury. – WARNING:
Indicates a hazardous situation that, if not avoided, could result
in death or serious injury. – CAUTION: Indicates a hazardous
situation that, if not avoided, could result in minor to moderate
injury. – NOTICE: Used to address practices not related to personal
injury. 4. Safety: – This document is customer property and should
remain with the unit. Return it to the service information pack
upon completion of work. – These instructions do not cover all
system variations or every possible contingency. For further
information or specific problems, consult your installing dealer or
local distributor. – This document contains a wiring diagram and
service information. – Only individuals with adequate backgrounds
of electrical and mechanical experience should attempt to repair
the product. Improper repair attempts can result in personal injury
or property damage. 5. Hazardous Voltage Warning: – Disconnect all
electric power, including remote disconnects, before servicing. –
Follow proper lockout/tagout procedures to ensure that the power
cannot be inadvertently energized. 6. Refrigerant Oil Caution: –
Failure to follow this caution could result in property damage or
personal injury. – Do not touch the top of the compressor as it may
cause minor to severe burning. 7. Contains Refrigerant Caution: –
Follow proper procedures to avoid personal illness, injury, or
severe equipment damage. – The system contains oil and refrigerant
under high pressure. Always recover refrigerant to relieve pressure
before opening the system. Please refer to the complete user manual
for detailed installation, adjustment, and operation instructions
specific to your unit.

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INSTALLATION INSTRUCTIONS
16 SEER
Split System Air Conditioner & Heat Pump 1.5-5 Tons R410A
NOTE : Appearance of unit may vary.
RECOGNIZE THIS SYMBOL AS AN INDICATION OF IMPORTANT SAFETY INFORMATION
WARNING
These instructions are intended as an aid to qualified licensed service personnel for proper installation, adjustment and operation of this unit. Read these instructions thoroughly before attempting installation or operation. Failure to follow these instructions may result in improper installation, adjustment, service or maintenance possibly resulting in fire, electrical shock, property damage, personal injury or death.
DO NOT DESTROY THIS MANUAL Please read carefully and keep in a safe place for future reference by a serviceman.

TABLE OF CONTENTS
1. KEY TO SYMBOLS AND SAFETY INSTRUCTIONS……………………………………..1 2. UNIT LOCATION CONSIDERATIONS………………………………………………………..2 3. UNIT PREPARATION………………………………………………………………………………3 4. SETTING UP THE UNIT……………………………………………………………………………3 5. REFRIGERANT LINE CONSIDERATIONS…………………………………………………4 6. REFRIGERANT LINE ROUTING………………………………………………………………5 7. REFRIGERANT LINE BRAZING………………………………………………………………..7 8. REFRIGERANT LINE LEAK CHECK………………………………………………………….8 9. EVACUATION…………………………………………………………………………………………8 10. SERVICE VALVE…………………………………………………………………………………..8 11. ELECTRICAL – LOW VOLTAGE……………………………………………………………….9 12. ELECTRICAL – HIGH VOLTAGE…………………………………………………………….10 13. START UP…………………………………………………………………………………………..10 14. SYSTEM CHARGE ADJUSTMENT…………………………………………………………11 15. SYSTEM OPERATION AND TROUBLESHOOTING…………………………………16 16. WARRANTY………………………………………………………………………………………..19 17. WIRING DIAGRAMS……………………………………………………………………………20 18. MATCHING TABLE AND CHECKOUT PROCEDURES……………………………23

All phases of this installation must comply with NATIONAL, STATE, AND LOCAL CODES.
1. Key to symbols and safety instructions
1.1 Key to symbols
Warnings in this document are identified by a warning triangle. Keywords at the start of a warning indicate the type and seriousness of the ensuing risk if measures to prevent the risk are not taken.
This symbol indicates important information where there is no risk to people or property.
The following keywords are defined and can be used in this document: DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided, could result in minor to moderate injury. NOTICE is used to address practices not related to personal injury.
1.2 Safety
CAUTION:
This document is customer property and is to remain with this unit. Please return to service information pack upon completion of work. These instructions do not cover all variations in systems or provide for every possible contingency to be met in connection with the installation. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to your installing dealer or local distributor.
This document contains a wiring diagram and service information.
CAUTION:
This information is intended for use by individuals possessing adequate backgrounds of electrical and mechanical experience. Any attempt to repair a central air conditioning product may result in personal injury and/or property damage.

WARNING: HAZARDOUS VOLTAGE
Failure to follow this warning could result in property damage, severe personal injury or death.
Disconnect all electric power, including remote disconnects before servicing. Follow proper lockout/tagout procedures to ensure the power cannot be inadvertently energized.
WARNING: REFRIGERANT OIL
These units use R-410A refrigerant which operates at 50% to 70% higher pressures than R-22. Use only R-410A approved service equipments. Refrigerant cylinders are painted a “Rose” color to indicate the type of refrigerant and may contain a “dip” tube to allow for charging of liquid refrigerant into the system. All R-410A systems use a POE oil that readily absorbs moisture from the atmosphere To limit this “hygroscopic” action, the system should remain sealed whenever possible. If a system has been opening to the atmosphere for more than 4 hours, the compressor oil must be replaced. Never break a vacuum with air and always change the driers when opening the system for component replacement.
CAUTION: HOT SURFACE
May cause minor to severe burning. Failure to follow this Caution could result in property damage or personal injury. Do not touch the top of compressor.
CAUTION: CONTAINS REFRIGERANT
Failure to follow proper procedures can result in personal illness or injury or severe equipment damage. System contains oil and refrigerant under high pressure. Recover refrigerant to relieve pressure before opening system.
CAUTION: GROUNDING REQUIRED
Failure to inspect or use proper service tools may result in equipment damage or personal injury. Reconnect all grounding devices. All parts of this product that are capable of conducting electrical current are grounded. If grounding wires, screws, straps, clips, nuts or washers used to complete a path to ground are removed for service, they must be returned to their original position and properly fastened.
WARNING: SERVICE VALVES
Failure to follow this warning will result in abrupt release of system charge and may result in personal injury and/or property damage. Extreme caution should be exercised when opening the Liquid Line Service Valve. Turn valve stem counterclockwise only until the stem contacts the rolled edge. No torque is required.
WARNING: BRAZING REQUIRED
Failure to inspect lines or use proper service tools may result in equipment damage or personal injury. All outdoor unit and evaporator coil connections are copper-to-copper and should be brazed with a phosphorous-copper alloy material such as Silfos-5 or equivalent. Do not use soft solder.

WARNING: HIGH CURRENT LEAKAGE
Failure to follow this warning could result in property damage, severe personal injury or death. Grounding is essential before connecting electrical supply.

2. Unit location considerations

2.1 Unit dimensions

Model AC 18 24 30
/ 36/42/48/60 Table 1

Unit Dimensions

HP 18/24
30 36 42 48/60

H(Inchs )
24-15/16 24-15/16 24-15/16 33-3/16 33-3/16

W(Inchs )
23-5/8 28
29-1/8 28
29-1/8

L(Inchs )
23-5/8 28
29-1/8 28
29-1/8

The unit’s weight value is on the cardboard box.
When mounting the outdoor unit on a roof, be sure the roof will support the unit’s weight. Properly selected isolation is recommended to prevent sound or vibration transmission to the building structure.

Position unit where water, snow or ice from roof or overhang cannot fall directly on unit.
Position the outdoor unit a minimum of 12” from any wall or surrounding shrubbery to ensure adequate airflow.
See Figure 2 and Figure 3. Cold climate considerations (heat pump only)
Precautions must be taken for units being installed in areas where snow accumulation and prolonged below-freezing temperatures occur.
Units should be elevated 3-12 inches above the pad or rooftop, depending on local weather. This additional height will allow drainage of snow and ice melted during defrost cycle prior to its refreezing. Ensure that drain holes in unit base pan are not obstructed, preventing drainage of defrost water (Figure 4).
If possible, avoid locations that are likely to accumulate snow drifts. If not possible, a snow drift barrier should be installed around the unit to prevent a build-up of snow on the sides of the unit.
Avoid Install Near Bedrooms

Min. 60″ Unrestricted

Min. 12” to Shrubbery

Min. 24” Unrestricted

Access Panel

Figure 2

Figure 1
2.2 Location restrictions
Ensure the top discharge area is unrestricted for at least 60 inches above the unit.
Do not locate outdoor unit near bedrooms since normal operational sounds may be objectionable.
Position unit to allow adequate space for unobstructed airflow, wiring, refrigerant lines, and serviceability.
Maintain a distance of 24 inches between units.
24 inches clearance must be provided in front of the control box (access panels) and any other side requiring service.

Min. 12″ to Shrubbery

Figure 3 2

Min. 12″ to Wall

Min. 12″ Snow barrier
Figure 4

Snow legs 3- 12″ Elevation
pad

The pad must be high enough above grade to allow for drainage. The pad location must comply with National, State and Local codes.
These instructions are intended to provide a method to tie-down system to concrete slab as a securing procedure for high wind areas. Check Local Codes for tie-down methods and protocols.

3. Unit preparation
3.1 Pre-installation
STEP 1 – Check for damage and report promptly to the carrier any damage found to the unit (Figure 5).
STEP 2 – Instruments must be designed to install/serve R410A equipmens.
Gauge sets, hoses, refrigerant containers and recovery system must be designed to handle the POE type oils.
Manifold sets should be 800 PSIG high side and 250 PSIG low side.
All hoses must have a 700 PSIG service pressure rating.
Leak detectors should be disigned to detect R410A.
Recovery equipments (including refrigerant recovery containers ) must be specifically designed to handle R410A.
Do not use an R22 TXV.

Figure 6

The dimension see Unit Dimensions.

See Detail A

Figure 5
4. Setting up the unit
4.1 Pad installation
When installing the unit on a support pad, such as a concrete slab, consider the following:
The pad must be at least 1-2″ larger than the unit on all sides. The pad must be separate from any structure. The pad must be level.

#7 X 3/8″ Self Tapping Screws (Don’t Exceed 3/8″ long)
Detail A

Brackets: 2″ width, 1/16″ thickness, height as required. Available from distributor or in market place.

1/4″ ” Hex Washer Head Concrete Screws (3/16″ Pilot Hole Needed. Pilot Hole Should Be 1/4″ Deeper Than The Fastener Embedment)
Figure 7

5. Refrigerant line considerations

5.1 Service valve connection sizes

Model

Suction line connection

3/4

7/8

Table 2

Liquid line connection
3/8 3/8 3/8 3/8 3/8 3/8 3/8 3/8

Model

Suction line (Inches)

Total suction line length(Feet)

100

150

Coefficient

5/8 3/4

1.00 0.97 0.94 0.90 1.00 0.98 0.95 0.92

5/8 3/4

1.00 0.97 0.94 0.90 1.00 0.98 0.95 0.92

5/8

1.00 0.97 0.94 0.90

3/4

1.00 0.98 0.96 0.93

5/8

1.00 0.97 0.94 0.90

3/4

1.00 0.99 0.97 0.96

3/4 7/8

1.00 0.98 0.97 0.95 1.00 0.99 0.98 0.97

7/8

1.00 0.98 0.97 0.96

1-1/8

1.00 0.99 0.98 0.97

7/8 1-1/8

0.99 0.98 0.94 0.90 1.00 0.99 0.98 0.97

Table 5 Suction line length/size VS capcaity multiplier

Figure 8

Liquid line Suction line connection connection

Access valve for low pressure

5.2 Refrigerant line sizes

Model
18 24 30 36 42 48 60 Table 3

Suction line

optional standard

5/8

3/4

5/8

3/4

5/8

3/4

5/8

3/4

7/8

1-1/8

7/8

1-1/8

Liquid line

optional standard

5/16

3/8

5/16

3/8

5/16

3/8

5/16

3/8

5/16

3/8

1/2

3/8

1/2

3/8

5.3 Refrigerant piping limits and required refrigerant line length

Using suction line larger than shown in chart will result in poor oil return and is not recommended. For example: the system capacity published in AHRI is 17800 Btu/h. This data is based on the AHRI test condition and 25 feet line set with standard suction tube size (3/4″ tube). If you need to add the line set more than 25 feet or use the optional suction tube size, you need to recalculate the capacity with the coefficient in the table. For 50 feet line and 5/8″ suction tube, the capacity will be 17800*0.97=17266 Btu/h.
Determine required line length and lift. You will need this later in Section 14. Total Line Length = __________ Feet. Total Vertical Change(Lift) = __________ Feet.
Line Length

Liquid line Model (Inches)

5/16

3/8

Total equivalent length(Feet) 25 50 75 100 125 150
Maximum vertical length(Feet) 25 50 60 58 40 30 25 50 60 60 40 30

Figure 9
5.4 Refrigerant line insulation

5/16 25 36 29 23 16 9

3/8

25 50 60 60 40 30

5/16 25 49 38 27 17 6

3/8

25 50 60 60 40 30

5/16 25 50 37 22 7 N/A

3/8

25 50 60 60 40 30

The suction line must always be insulated. DO NOT allow the Liquid Line and Suction Line to come in direct (metal to metal) contact.

5/16 25 23 4 N/A N/A N/A

3/8

25 50 43 36 30 24

1/2

25 50 56 55 40 30

3/8

25 46 38 30 22 15

1/2

25 50 60 60 40 30

3/8

25 50 56 44 32 20

Table 4

Required

Optional

Figure 11

Figure 10
5.5 Reuse existing refrigerant lines
CAUTION:
If using existing refrigerant lines make certain that all joints are brazed, not soldered.
For retrofit applications, where the existing refrigerant lines will be used, the following precautions should be taken:
Ensure that the refrigerant lines are the correct size. Refer to Section 5.1 listed and Table 3. Ensure that the refrigerant lines are free of leaks, acid, and oil.
The manufacturer recommends installing only approved matched indoor and outdoor systems. All of the manufacturer’s split systems are AHRI certified. Some of the benefits of installing approved matched indoor and outdoor split systems are maximum efficiency, optimum performance and the best overall system reliability.

6. Refrigerant line routing
6.1 Precautions
Take precautions to prevent noise within the building structure due to vibration transmission from the refrigerant lines. For example:
When the refrigerant lines have to be fastened to floor joists or other framing in a structure, use isolation type hangers. Isolation hangers should also be used when refrigerant lines are run in stud spaces or enclosed ceilings. Where the refrigerant lines run through a wall or sill, they should be insulated and isolated. Isolate the lines from all ductwork. Minimize the number of 90º turns. Use PVC piping as a conduit for all underground installations as shown in Figure 15. Buried lines should be keep as short as possible. The lines should not obstruct service access to the coil, air handling system or filter. Care must also be taken to isolate the refrigerant lines to minimize noise transmission from the equipment to the structure.
Comply with National, State, and Local Codes when isolating line sets from joists, rafters, walls or other structural elements.

8 Feet Maximum

Jo ist/Raft er Isolator

Side View Figure 12

8 Feet Maximum Secure Suc tion li ne from joists us ing isolators every 8 feet . Secure Liquid Line directly to Suc tion li ne using tape, wire, or other appropriate method every 8 feet.
Isolation From Joist/Rafter
5

Line Set

8 Feet Maximum

Side View Figure 13

8 Feet Maximum
Secure Suc tion Line using isolators every 8 feet . Secure Liqu id Line directly to Suc tion Line using tape, wire, or other approp riate method every 8 feet.
Isolation In Wall Spaces

Wall Isolator Line Set

Wall Sealant Insulati on Suc tio n Line

Duc twork
Isolator Line Set

Isolation Through Wall Figure 14
To Indoor Coil

DO NOT Hang Line Sets From Ductwork To Outdoor Coil

Liquid Line

Insulated Suction Line

Cap

PVC Conduit

Figure 15 6

7. Refrigerant line brazing
7.1 Braze the refrigerant lines
1. Remove caps or plugs. Use a deburing tool to debur the pipe ends. Clean both internal and external surfaces of the tubing using an emery cloth.

4. Wrap a wet rag around the valve body to avoid heat damage and continue the dry nitrogen purge (Figure 19).
Braze the refrigerant lines to the service valves.
Check liquid line filter drier’s directional flow arrow to confirm correct direction of refrigeration flow (away from outdoor unit and toward evaporator coil) as illustrated. Brazing the filter drier to the Liquid Line.
Continue the dry nitrogen purge. Do not remove the wet rag until all brazing is completed.

Remove the wet rag before stopping the dry nitrogen purge.

Figure 16 2. Remove the pressure tap cap from both service valves.

Field supplied and installed
3-4″ from valve
Figure 19 5. Replace the pressure tap caps after the service valves have cooled.
Note: Do not over tighen (between 40 and 60 inch-lbs. maximum).

Figure 17 3. Purge the refrigerant lines and indoor coil with dry nitrogen.

This pipe must have a thimble
Figure 18

Figure 20 7

8. Refrigerant line leak check
8.1 Check for leaks
1. Pressurize the refrigerant lines and evaporator coil to 150 PSIG using dry nitrogen.
150 PSIG

1. Evacuate until the micron gauge reads no higher than 350 microns, then close off the valve to the vacuum pump.
0350
Microns ON OFF

Figure 23
2. Observe the micron gauge. Evacuation is complete if the micron gauge does not rise above 500 microns in one (1) minute.
Once evacuation is complete blank off the vacuum pump and micron gauge, and close the valves on the manifold gauge set.

Figure 21 2. Check for leaks by using a soapy solution or bubbles at each brazed
location.
Figure 24

1 MIN.

Figure 22 Remove nitrogren pressure and repair any leaks before continuing.
9. Evacuation
9.1 Evacuate the refrigerant lines and indoor coil
Do not open the service valves until the refrigerant lines and indoor coil leak check and evacuation are complete.

10. Service valves
10.1 Open the service valves
WARNING:
Extreme caution should be exercised when opening the Liquid Line Service Valve. Turn counterclock wise until the valve stem just touches the rolled edge. No torque is required. Failure to follow this warning will result in abrupt release of system charge and may result in personal injury and /or property damage.
Leak check and evacuation must be completed before opening the service valves.
1. Remove service valve cap (Figure 25).
2. Fully insert hex wrench into the stem and back out counterclockwise until valve stem just touches the rolled edge
3. Replace the valve stem cap to prevent leaks. Tighten finger tight plus an additional 1/6 turn.

Cap
Unit S ide of Service
Valve

5/16″ Hex Wrench for Sucti on Service Valve
3/16″ Hex Wrench for Liqu id Service Valve
Roll ed Edge to Capti vate Stem
Hex Headed Valve System

11. Electrical – low voltage

11.1 Low Voltage Maximum Wire Length
Table 6 defines the maximum total length of low voltage wiring from the outdoor unit to the indoor unit and to the thermostat.

24 Volts – Wire size

Table 6

18 AWG 16 AWG 14 AWG

Max. wire length 150 Ft. 225 Ft. 300 Ft.

Service Port
Figure 25
11.2 Low voltage hook-up diagrams

Figure 26

Low Voltage connection must be made inside the outdoor unit case.

Access Panel

GREEN RED
BLACK WHITE BLACK YELLOW GREEN RED BLACK WHITE BLACK YELLOW

W B C R Y G
FOR ONE STAGE HEAT THERMOSTAT

G R C w1 w2 INDOOR UNIT

CY OUTDOOR UNIT

W2 W1 B C
R Y G
FOR TWO STAGE HEAT THERMOSTAT

Control Wiring for AC Systems
Figure 27
Notes: ” ” The electric auxiliary heat connection(optional). W : Electric auxiliary heat signal. W1 : The first Electric auxiliary heat signal. W2 : The second Electric auxiliary heat signal.

G R C w1 w2 INDOOR UNIT

CY OUTDOOR UNIT

GREEN RED BLACK WHITE BLACK YELLOW BLUE PURPLE GREEN RED BLACK WHITE BLACK YELLOW BLUE PURPLE

Support 2H thermostat

Support 3H thermostat

W B C R Y G
THERMOSTAT

G R C w1 w2 INDOOR UNIT

OUTDOOR UNIT

W2 W1 B C R Y G
THERMOSTAT
G R C w1 w2
INDOOR UNIT

Control Wiring for 18K-48K HP Systems

Figure 28

Notes:

” ” The electric auxiliary heat connection(option). W : Electric auxiliary heat signal. W1 : The first Electric auxiliary heat signal. W2 : The second Electric auxiliary heat signal. D signal is connect to the Electric auxiliary heat or the first Electric auxiliary heat. ”
“: Outdoor unit signal. Only for single-stage compressor systems.

R C Y BD OUTDOOR UNIT

GREEN RED BLACK WHITE BLACK BLUE YELLOW WHITE GREEN RED BLACK WHITE BLACK BLUE YELLOW WHITE

Support 2H thermostat

Support 3H thermostat

W B C R Y G

THERMOSTAT
G R C w1 w2
INDOOR UNIT

OUTDOOR UNIT

W2 W1 B C R Y G
THERMOSTAT

G R C w1 w2 INDOOR UNIT

Control Wiring for 60K HP Systems

Figure 29

Notes:

” ” The electric auxiliary heat connection(option). W : Electric auxiliary heat signal,connect to the Electric auxiliary heat or the first Electric auxiliary heat. W1 : The first Electric auxiliary heat signal. W2 : The second Electric auxiliary heat signal.

C B YW OUTDOOR UNIT

12. Electrical – high voltage
12.1 High voltage power supply

WARNING: LIVE ELECTRICAL COMPONENTS!
During installation, testing, servicing, and trouble shooting of this product, it may be necessary to work with live electrical components. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury.

The high voltage power supply must agree with the equipment nameplate.

Power wiring must comply with National, State and Local Codes.

Follow instructions on unit wiring diagram located on the inside of the access panel.

Figure 30

nameplate

12.2 High voltage disconnect switch
Install a separate disconnect switch at the outdoor unit.
Field provided flexible electrical conduit must be used for high voltage wiring.

3. Turn on disconnect to apply power to the indoor and outdoor units.

ON O FF

Figure 34
4. Wait one (1) hour before starting the unit if compressor crankcase heater is used and the outdoor ambient temperature is below 70 ºF.

Figure 31
12.3 High voltage ground
Ground the outdoor unit per National, State and Local Code requirements.

60 MIN.
Figure 35 5. Set system thermostat to ON.

TUE Inside
EM HEAT O FF CO OL
DONE

Set To Following Schedule
CANCEL

Figure 32
13. Start up
13.1 System start up
1. Ensure Sections 7, 8, 9, 10, 11 and 12 have been completed. 2. Set System Thermostat to OFF.

OFF

DONE

CANCEL

Figure 36

14. System charge adjustment
14.1 Charging: Weigh-In Method
Weigh-In Method can be used for the initial installation, or anytime a system charge is being replaced. Weigh-In Method can also be used when power is not available to the equipment site or operating conditions (indoor/outdoor temperatures) are not in range to verify with the liquid line pressure charging method.

Model

Factory Charge

Charge multiplier for liquid line length

All models Table 7

The data on nameplate

0.54/1o6z”/ft

3/8” 0.6 oz/ft

1/2” 1.2 oz/ft

Figure 33 11

The factory charge in the outdoor unit is sufficient for 15 feet of standard size interconnecting liquid line.

New Installations — Calculating additional charge for lineset greater than 15 feet.

1. Total Line Length (ft)

(a)

2. Standard Line set (ft)

= 15 (b)

3. (a) minus (b)

(c)

4. Refrigerant Multiplier

(d)

5. Refrigerant Adder (c*d) =

(e*)

*If lineset is less than 15 feet, (e) = 0

Sealed-System Repairs — Calculating total system charge.

1. Total Line Length (ft)

(a)

2. Standard Line set (ft)

= 15 (b)

3. (a) minus (b)

(c)

4. Refrigerant Multiplier

(d)

5. Refrigerant Adder (c*d)

(e*)

6. Factory Charge (nameplate) =

(f)

7. Total System Charge (e+f) =

*If line set is less than 15 feet, (e) = 0

For best results the indoor temperature should be kept between 70ºF to 80ºF.
80ºF 70ºF
Indoor Temp. Figure 38 Note:The temperature tolerance for actual approach is ± 3ºF. 2. Ensure Sections 7, 8, 9, 10,11,12 and 13 have been completed. 3. Stabilize the system by operating for a minimum of 20 minutes.
At startup, or whenever charge is removed or added, the system must be operated for a minimum of 20 minutes to stabilize before accurate measurements can be made.

The only mode approved for validating system charge is while in Cooling Mode. Outdoor Temperature must be between 55°F and 115°F with Indoor Temperature kept between 70°F and 80°F.

20 MIN.

14.2 Liquid line pressure charging and refrigerant adjustment in cooling (above 55°F outdoor temp.)

For 5TON AC unit,the Outdoor Temperature must be between 65°F and 105°F

1. Check the outdoor ambient temperatures.
Liquid line pressure (in cooling mode) is the only recommended method of charging above 55ºF outdoor ambient temperatures.
For outdoor ambient temperatures below 55ºF , use weigh-in charge method.
Note:It is important to return in the spring or summer to accurately charge the system in the cooling mode when outdoor ambient temperature is above 55ºF.

Outdoor Temperature Above 55ºF

Outdoor Temperature Below 55ºF

Figure 39 Note:The pressure tolerance for actual approach is ± 5psig
4. Calculate liquid line pressure (According to Refrigerant Charging Chart) f Measured Suction Line Pressure = ________PSIG f Outdoor Ambient Temperature = _______ ºF f Calculate Liquid Line Pressure = ________PSIG

115ºF

55ºF
Outdoor Temp.1 Figure 37

55ºF

Figure 40

Outdoor Temp. 2 12

REFRIGERANT CHARGING CHART FOR AC SYSTEM

Suction Pressure at Large Service Valve(psig)

16 SEER R410A AC Charge Chart 1.5 TON

Cooling Mode

Outdoor Ambient Temperature( oF )

100

105

110

115

Liquid Pressrue at Small Service Value(psig)

165

252

269

286

306

326

350

373

395

419

442

467

161

250

267

284

304

324

348

371

393

417

440

464

157

248

265

282

302

322

345

368

390

414

437

461

153

228

244

262

280

300

320

342

365

387

411

435

459

149

226

242

260

277

298

318

339

362

385

409

432

457

145

224

240

258

275

296

316

337

360

382

406

430

455

141

205

222

238

255

272

293

314

334

357

380

404

428

453

137

203

220

236

253

269

291

312

332

355

377

402

426

451

133

201

218

234

250

266

288

310

330

353

375

400

424

449

129

199

216

232

248

264

286

308

328

351

374

398

422

447

125

198

214

230

246

262

284

306

326

349

372

396

420

445

121

196

212

228

244

260

282

304

324

347

370

394

418

443

117

194

210

226

242

258

280

302

322

345

367

392

416

441

113

192

208

224

240

256

278

300

320

343

365

390

414

439

109

190

206

222

238

254

276

298

318

340

362

387

412

437

105

188

204

220

236

252

273

295

316

338

360

385

410

435

Suction Pressure at Large Service Valve(psig)

16 SEER R410A AC Charge Chart 2 TON

Cooling Mode

Outdoor Ambient Temperature( oF )

100

105

110

115

Liquid Pressrue at Small Service Value(psig)

165

258

277

295

316

337

358

382

405

430

454

479

161

256

275

293

314

335

356

380

403

428

452

477

157

254

273

291

312

333

354

378

401

426

450

475

153

236

252

271

289

310

331

352

376

399

424

448

473

149

234

250

269

287

308

329

350

374

397

422

446

471

145

232

248

267

285

306

327

348

372

395

419

443

469

141

214

230

246

265

283

304

325

346

370

393

417

441

467

137

212

228

244

262

280

301

322

343

367

391

415

439

465

133

210

226

242

260

278

299

320

341

365

389

413

437

463

129

208

224

240

258

276

297

318

339

363

387

411

435

461

125

206

222

238

256

274

295

316

337

361

385

409

433

459

121

204

220

236

254

272

293

314

335

359

383

407

431

457

117

202

218

234

252

270

291

312

333

357

381

405

429

455

113

199

216

232

250

268

289

310

331

355

379

403

427

453

109

197

214

230

248

266

287

308

329

353

377

401

425

451

105

195

212

228

246

264

285

306

327

351

375

399

423

449

Suction Pressure at Large Service Valve(psig)

16 SEER R410A AC Charge Chart 2.5 TON

Cooling Mode

Outdoor Ambient Temperature( oF )

100

105

110

115

Liquid Pressrue at Small Service Value(psig)

165

261

280

299

319

340

360

382

404

431

457

483

161

259

278

297

317

338

358

380

401

428

455

481

157

257

276

295

315

336

356

377

398

426

453

479

153

240

255

274

293

313

333

353

375

396

424

451

477

149

238

253

272

291

311

331

351

373

394

422

449

475

145

236

251

270

289

309

329

349

371

392

420

447

473

141

218

234

249

268

287

307

327

347

369

390

418

445

471

137

216

232

247

266

285

305

325

345

367

388

416

443

469

133

214

230

245

264

283

303

323

343

364

385

413

441

467

129

212

228

243

262

281

301

321

341

362

383

411

439

465

125

210

226

241

260

279

299

319

339

360

381

409

437

463

121

207

223

239

258

277

297

317

337

358

379

407

435

461

117

204

221

237

256

275

295

315

335

356

377

405

433

459

113

202

219

235

254

273

293

313

333

354

375

403

431

457

109

200

217

233

252

271

291

311

331

352

373

401

429

455

105

198

215

231

250

269

289

309

329

350

371

399

427

453

Suction Pressure at Large Service Valve(psig)

16 SEER R410A AC Charge Chart 3 TON

Cooling Mode

Outdoor Ambient Temperature( oF )

100

105

110

115

Liquid Pressrue at Small Service Value(psig)

165

259

277

295

316

337

358

384

410

435

460

486

161

257

275

293

314

335

356

382

408

433

458

484

157

255

273

291

312

333

354

380

406

431

456

482

153

235

253

271

289

310

331

352

378

404

429

454

480

149

233

251

269

287

308

329

350

376

402

427

452

478

145

231

249

267

285

306

327

348

374

400

425

450

476

141

214

229

247

265

283

304

325

346

372

398

423

448

474

137

212

227

245

263

281

302

323

344

263

396

263

446

472

133

210

225

243

261

279

300

321

342

368

394

419

444

470

129

208

223

241

259

277

298

319

340

366

392

417

442

468

125

206

221

239

257

275

296

317

338

364

390

415

440

466

121

204

219

237

255

273

294

315

336

362

388

413

438

464

117

202

217

235

253

271

292

313

334

360

386

411

436

462

113

200

215

233

251

269

290

311

332

358

384

409

434

460

109

198

213

231

249

267

288

309

330

356

382

407

432

458

105

196

211

229

247

265

286

307

328

354

380

405

430

456

Suction Pressure at Large Service Valve(psig)

16 SEER R410A AC Charge Chart 3.5 TON

Cooling Mode

Outdoor Ambient Temperature( oF )

100

105

110

115

Liquid Pressrue at Small Service Value(psig)

165

258

277

296

314

332

350

376

401

427

452

478

161

256

275

294

312

330

348

374

399

425

450

476

157

254

273

292

310

328

346

372

397

423

448

474

153

237

252

271

290

308

326

344

370

395

421

446

472

149

235

250

269

288

306

324

342

368

393

419

444

470

145

233

248

267

286

304

322

340

366

391

417

442

468

141

215

231

246

265

284

302

320

338

364

389

415

440

466

137

213

229

244

263

281

299

318

336

362

387

413

438

464

133

211

227

242

260

278

297

315

334

360

385

411

436

462

129

209

225

240

258

275

294

313

332

358

383

409

434

460

125

207

223

238

256

273

292

311

330

356

381

407

432

458

121

205

221

236

254

271

290

309

328

354

379

405

430

456

117

202

218

234

252

269

288

307

326

352

377

403

428

454

113

199

216

232

250

267

286

305

324

350

375

401

426

452

109

197

214

230

248

265

284

303

322

348

373

399

424

450

105

195

212

228

246

263

282

301

320

346

371

397

422

448

Suction Pressure at Large Service Valve(psig)

16 SEER R410A AC Charge Chart 4 TON

Cooling Mode

Outdoor Ambient Temperature( oF )

100

105

110

115

Liquid Pressrue at Small Service Value(psig)

165

264

282

300

322

343

364

388

412

437

464

491

161

262

280

298

320

341

362

386

410

435

462

489

157

260

278

296

318

339

360

384

408

433

460

487

153

239

258

276

294

316

337

358

382

406

431

458

485

149

237

256

274

292

314

335

356

380

404

429

456

483

145

235

254

272

290

312

333

354

378

402

427

454

481

141

215

233

252

270

288

310

331

352

376

400

425

452

479

137

213

231

250

268

286

308

329

350

374

398

423

450

477

133

211

229

248

266

284

306

327

348

372

396

421

448

475

129

209

227

246

264

282

304

325

346

370

394

419

446

473

125

207

225

244

262

280

302

323

344

368

392

417

444

471

121

205

223

242

260

278

300

321

342

366

390

415

442

469

117

203

221

240

258

276

298

319

340

364

388

413

440

467

113

201

219

238

256

274

296

317

338

362

386

411

438

465

109

199

217

236

254

272

294

315

336

360

384

409

436

463

105

197

215

234

252

270

292

313

334

358

382

407

434

461

Suction Pressure at Large Service Valve(psig)

16 SEER R410A AC Charge Chart 5 TON

Cooling Mode

Outdoor Ambient Temperature( oF )

100

105

Liquid Pressrue at Small Service Value(psig)

165

273

294

317

339

361

383

404

431

458

161

271

292

314

336

358

381

403

430

457

157

269

289

311

334

356

379

401

428

455

153

267

287

308

331

353

377

400

426

453

149

266

285

306

328

350

374

398

424

451

145

264

283

304

326

348

373

397

423

450

141

262

281

302

324

346

371

395

421

448

137

260

279

300

322

344

369

393

419

446

133

259

278

298

320

342

367

392

418

443

129

257

276

296

318

340

365

390

415

440

125

255

274

294

316

338

363

388

413

438

121

253

272

292

314

336

361

386

411

435

117

252

271

291

313

335

360

384

409

433

113

250

269

290

312

334

358

382

407

431

109

248

268

289

311

333

357

380

404

428

105

246

266

288

310

331

355

378

402

426

REFRIGERANT CHARGING CHART FOR HP SYSTEM

Suction Pressure at Large Service Valve(psig)

16SEER R410A HP Charge Chart 1.5TON(Cooling mode)

Outdoor Ambient Temperature()

Cooling Mode

100

105

110

115

Liquid Pressure at Small Service Valve(psig)

165

246

265

284

303

323

343

364

390

416

441

467

161

244

263

282

301

321

341

362

388

414

439

465

157

242

261

280

299

319

339

360

386

412

437

463

153

221

240

259

278

297

317

337

358

384

410

435

461

149

219

238

257

276

295

315

335

356

382

408

433

459

145

217

236

255

274

293

313

333

354

380

406

431

457

141

196

215

234

253

272

291

311

331

352

378

404

429

455

137

195

213

232

251

269

288

309

328

350

376

402

427

453

133

193

211

230

249

267

286

306

326

347

373

399

425

451

129

191

209

228

247

265

284

304

323

344

370

397

423

449

125

190

209

227

245

264

282

302

320

341

368

394

421

447

121

190

208

226

244

262

280

300

320

341

367

393

419

445

117

188

206

224

242

260

278

298

318

339

365

391

417

443

113

186

204

222

240

258

276

296

316

337

363

389

415

441

109

184

202

220

238

256

274

294

314

335

361

387

413

439

105

182

200

218

236

254

272

292

312

333

359

385

411

437

Suction Pressure at Large Service Valve(psig)

16SEER R410A HP Charge Chart 2TON(Cooling mode)

Outdoor Ambient Temperature()

Cooling Mode

100

105

110

115

Liquid Pressure at Small Service Valve(psig)

165

255

274

294

313

335

358

381

407

434

461

486

161

253

272

292

311

333

356

379

405

432

459

484

157

251

270

290

309

331

354

377

403

430

457

482

153

230

249

268

288

307

329

352

375

401

428

455

480

149

228

247

266

286

305

327

350

373

399

426

453

478

145

226

245

264

284

303

325

348

371

397

424

451

476

141

204

224

243

262

282

301

323

346

369

395

422

449

474

137

203

222

241

260

279

298

320

344

367

393

420

447

472

133

201

220

239

258

277

296

318

342

365

391

418

445

470

129

199

218

237

256

275

294

316

340

363

389

416

443

468

125

197

216

235

254

273

292

314

338

361

387

414

441

466

121

195

214

233

252

271

290

312

336

359

385

412

439

464

117

193

212

231

250

269

288

310

334

357

383

410

437

462

113

191

210

229

248

267

286

308

332

355

381

408

435

460

109

189

208

227

246

265

284

306

330

353

379

406

433

458

105

187

206

225

244

263

282

304

328

351

377

404

431

456

Suction Pressure at Large Service Valve(psig)

16SEER R410A HP Charge Chart 2.5TON(Cooling mode)

Outdoor Ambient Temperature

Cooling Mode

100

105

110

115

Liquid Pressure at Small Service Valve(psig)

165

253

269

288

305

327

348

370

390

414

435

461

161

251

267

286

303

325

346

368

388

412

433

459

157

249

265

284

301

323

344

366

386

410

431

457

153

231

247

263

282

299

321

342

364

384

408

429

455

149

229

245

261

280

297

319

340

362

382

406

427

453

145

227

243

259

278

295

317

338

360

380

404

425

451

141

208

225

241

257

276

293

315

336

358

378

402

423

449

137

206

223

239

255

274

291

313

334

356

376

400

421

447

133

204

221

237

253

272

289

311

332

354

374

398

419

445

129

202

219

235

251

270

287

309

330

352

372

396

417

443

125

199

215

232

249

267

285

307

328

350

370

394

415

441

121

195

213

230

247

267

285

306

327

348

368

392

413

439

117

193

211

228

245

265

283

304

325

346

366

390

411

437

113

191

209

226

243

263

281

302

323

344

364

388

409

435

109

189

207

224

241

261

279

300

321

342

362

386

407

433

105

187

205

222

239

259

277

298

319

340

360

384

405

431

Suction Pressure at Large Service Valve(psig)

16SEER R410A HP Charge Chart 3TON(Cooling mode)

Outdoor Ambient Temperature( )

Cooling Mode

100

105

110

115

Liquid Pressure at Small Service Valve(psig)

165

260

278

296

314

336

359

381

402

427

454

482

161

258

276

294

312

334

357

379

400

425

452

480

157

256

274

292

310

332

355

377

398

423

450

478

153

236

254

272

290

308

330

352

374

395

420

448

476

149

234

252

270

288

306

328

350

372

393

418

446

474

145

232

250

268

286

304

326

347

369

390

416

444

472

141

212

230

248

266

284

302

323

345

366

388

413

442

470

137

210

228

246

264

282

300

321

342

363

385

411

439

468

133

208

226

244

262

280

298

319

339

360

382

408

437

466

129

206

224

242

260

278

296

316

337

357

379

406

435

464

125

204

222

240

258

276

294

314

335

355

377

404

433

462

121

202

220

238

256

274

292

312

333

353

375

402

431

460

117

200

218

236

254

272

290

310

331

351

373

400

429

458

113

198

216

234

252

270

288

308

329

349

371

398

427

456

109

196

214

232

250

268

286

306

327

347

369

396

425

454

105

194

212

230

248

266

284

304

325

345

367

394

423

452

Suction Pressure at Large Service Valve(psig)

16SEER R410A HP Charge Chart 3.5TON(Cooling mode)

Outdoor Ambient Temperature( )

Cooling Mode

100

105

110

115

Liquid Pressure at Small Service Valve(psig)

165

254

271

288

305

327

348

370

394

417

441

464

161

252

269

286

303

325

346

368

392

415

439

462

157

250

267

284

301

323

344

366

390

413

437

460

153

231

248

265

282

299

321

342

364

388

411

435

458

149

229

246

263

280

297

319

340

362

386

409

433

456

145

227

244

261

278

295

317

338

360

384

407

431

454

141

208

225

242

259

276

293

315

336

358

382

405

429

452

137

206

223

240

257

274

291

313

334

356

380

403

427

450

133

204

221

238

255

272

289

311

332

354

378

401

425

448

129

202

219

236

253

270

287

309

330

352

376

399

423

446

125

200

217

234

251

268

285

307

328

350

374

397

421

444

121

198

215

232

249

266

283

305

326

348

372

395

419

442

117

196

213

230

247

264

281

303

324

346

370

393

417

440

113

194

211

228

245

262

279

301

322

344

368

391

415

438

109

192

209

226

243

260

277

299

320

342

366

389

413

436

105

190

207

224

241

258

275

297

318

340

364

387

411

434

Suction Pressure at Large Service Valve(psig)

16 SEER R410A HP Charge Chart 4 TON(Cooling mode)

Cooling Mode

Outdoor Ambient Temperature( oF )

100

105

110

115

Liquid Pressrue at Small Service Value(psig)

165

249

265

281

302

324

345

365

385

412

438

465

161

247

263

279

300

322

343

363

383

410

437

463

157

245

261

277

298

320

341

361

381

408

435

461

153

228

243

259

275

296

318

339

359

379

406

433

459

149

226

241

257

273

294

316

337

357

377

404

431

457

145

234

239

255

271

292

314

335

355

375

402

429

455

141

209

223

237

253

269

290

312

333

353

373

400

427

453

137

207

221

235

251

267

288

310

331

351

371

398

425

451

133

205

219

233

249

265

286

308

329

349

369

396

423

449

129

203

217

231

247

263

284

306

327

347

367

394

421

447

125

201

215

229

245

261

282

304

325

345

365

392

419

445

121

197

212

227

243

259

280

302

323

343

363

390

417

443

117

194

210

225

241

257

278

300

321

341

361

388

415

441

113

190

207

223

239

255

277

298

320

340

360

387

414

439

109

188

205

221

237

253

275

296

318

338

358

385

412

437

105

186

203

219

235

251

273

294

316

336

356

383

410

435

Suction Pressure at Large Service Valve(psig)

16 SEER R410A HP Charge Chart 5 TON(Cooling mode)

Cooling Mode

Outdoor Ambient Temperature( oF )

100

105

110

115

Liquid Pressrue at Small Service Value(psig)

165

254

274

291

309

329

350

370

398

421

447

472

161

252

271

289

306

327

348

368

396

419

445

470

157

250

268

287

304

325

346

366

394

417

443

468

153

229

248

266

285

302

323

344

364

392

415

441

466

149

227

246

264

283

300

321

342

362

390

413

439

464

145

225

244

262

281

298

319

340

360

388

411

437

462

141

205

224

242

260

279

296

317

338

358

386

409

435

460

137

202

222

240

258

277

294

315

336

356

384

407

433

458

133

199

220

238

256

275

292

313

334

354

382

405

431

456

129

197

218

236

254

273

290

311

332

352

380

403

429

454

125

195

216

234

252

271

288

310

330

350

378

401

427

452

121

193

214

232

250

269

286

308

328

348

376

399

425

450

117

191

212

230

248

267

284

306

326

346

374

397

423

448

113

189

210

228

246

265

282

304

324

344

372

395

421

446

109

187

208

226

244

263

280

302

322

342

370

393

419

444

105

185

206

224

242

261

278

300

320

340

368

391

417

442

5. Adjust refrigerant level to attain proper gage pressure.
Add refrigerant if the design liquid line pressure is lower than the chart value. Connect gages to refrigerant bottle and unit as illustrated (Figure 40). Purge all hoses. Open bottle. Stop adding refrigerant when liquid line pressure matches the Refrigerant Charging Chart.

6. Stabilize the system. Wait 20 minutes for the system condition to stabilize between adjustments.
When the liquid line pressure match the chart, the system is properly charged. Remove gages. Replace service port caps to prevent leaks. Tighten finger tight plus an additional 1/6 turn.
20 MIN.

Recover refrigerant if the design liquid line pressure is lower than the chart value.
Figure 41

Figure 42

7. Record system Information for reference (Table 8). Record system pressures and temperatures after charging is complete.

Description

Value

Outdoor model number

Measured Outdoor Ambient

°F

Measured Indoor Ambient

°F

Liquid Gage Pressure

PSIG

Suction Gage Pressure Table 8

PSIG

15. System operation and troubleshooting
15.1 Compressor crankcase heater (CCH) (Heat pump only)
The crankcase heating start must meet two conditions: A. Outdoor temperature41°F B. At power up or if the compressor has been off for more than 3 hours
The crankcase heating stop must meet the following condition: Outdoor temperature44.6°F or compressor starts.
15.2 Reversing valve (Heat pump only)
Reversing valve energizes at the heating conditions, and cuts off at the cooling condition.
15.3 Protection function (Heat pump only)
T3 = Outdoor Coil Temperature T3143.6°F, compressor stops working T3125.6°F, compressor restarts working
T4 = Out Ambient Temperature T4 < 5°F, compressor stops working T4 > 10.4°F, compressor restarts working ,I ) 7 ) XQLW FDQ RSHUDWH LQ FRROLQJ ,I ) 7 F, unit can operate in heating
When T4< 5°F, the outdoor unit would provide a signal to drive up the heater installed in the indoor unit.
Discharge temperature protection
Discharge temperature > 275°F, compressor stops working. Discharge temperature < 194°F, compressor restarts working.
High pressure protection
High pressure > 638 PSIG, compressor and outdoor fan motor stop working. High pressure < 464 PSIG, compressor and outdoor fan motor restart working (3 minutes delay necessary).
Low pressure protection
Low pressure < 21 PSIG, compressor and outdoor fan motor stop working. Low pressure > 44 PSIG, compressor and outdoor fan motor restart working (3 minutes delay necessary).

15.5 Defrost mode (Heat pump only)
Manual defrost mode When the switch SW3-1 is set to “ON”, the system turns to the defrost mode. The defrost mode exits by the logic of shut-down conditions of defrost mode.
Once the manual defrost mode is finished, please turn the switch SW3-1 back to “off “.
Start-up conditions of defrost mode When SW3-3 switch is set to “ON” (Figure 43), the mode will start up in any of the following conditions: Compressor operates and T3 < 32°F for a period of 30 minutes. T3 < 28.4°F and compressor operates for the first time after connected to the power source. When T3 < 28.4°F and the system is on standby for two hours continuously. When SW3-3 switch is set to “OFF”(Figure 43), the mode will start up in any of the following conditions: Compressor operates and T3 < 32 °F for a period of 60 minutes. T3 < 28.4 °F and compressor operates for the first time after connected to the power source. When T3 < 28.4 °F and the system is on standby for two hours. Shut-down conditions of defrost mode: The mode will shut down in any of the following conditions:
The defrosted time lasts 10 minutes
7 °F DQG 7 °F
Compressor stops operating
7 °F lasts 60 seconds when T4 < 28.4°F
SW3 Switch

In stand-by status, the compressor will not start in low pressure protection. Within 30 minutes, if 4 protection cycles occur. The system will be locked. It will be restore after power cycle.
15.4 Protection function (Air conditioner only)
High pressure protection
High pressure > 638 PSIG, compressor and outdoor fan motor stop working. High pressure < 464 PSIG, compressor and outdoor fan motor restart working (3 minutes delay necessary).

SW3 Switch

Figure 43

The location of SW3 Switch in the PCB Board

15.6 Temperature sensor resistance table

Temperature °F Resistance k Temperature °F Resistance k Temperature °F Resistance k Temperature °F Resistance k

-4

106.73

29.87

10.00

119

3.69

-3

103.25

29.22

9.50

120

3.61

-2

99.89

28.19

9.26

121

3.53

-1

96.65

27.39

9.03

122

3.45

93.53

26.61

8.81

123

3.38

90.53

25.85

8.59

124

3.30

87.62

25.12

8.38

125

3.23

84.83

24.42

8.17

126

3.16

82.13

23.73

7.97

127

3.10

79.52

23.07

7.78

128

3.03

77.01

22.42

7.59

129

2.96

74.58

21.80

7.40

130

2.90

72.24

21.20

7.22

131

2.84

69.98

20.61

7.05

132

2.78

67.80

20.04

6.88

133

2.72

65.69

19.49

6.72

134

2.67

63.65

18.96

6.56

135

2.61

61.68

18.44

6.40

136

2.56

59.78

17.94

6.25

137

2.50

57.95

17.45

6.10

138

2.45

56.17

16.98

5.96

139

2.40

54.46

16.52

5.82

140

2.35

52.80

16.08

100

5.68

141

2.30

51.20

15.65

101

5.55

142

2.25

49.65

15.23

102

5.42

143

2.21

48.16

14.83

103

5.30

144

2.16

46.71

14.43

104

5.18

145

2.12

45.31

14.05

105

5.06

146

2.08

43.95

13.68

106

4.94

147

2.03

42.64

13.32

107

4.83

148

1.99

41.38

12.97

108

4.72

149

1.95

40.15

12.64

109

4.61

150

1.91

38.97

12.31

110

4.51

151

1.88

37.82

11.99

111

4.41

152

1.84

36.71

11.68

112

4.31

153

1.80

35.64

11.38

113

4.21

154

1.77

34.60

11.09

114

4.12

155

1.73

33.59

10.80

115

4.03

156

1.70

32.61

10.53

116

3.94

157

1.66

31.67

10.00

117

3.85

158

1.63

30.76

10.00

118

3.77

159

1.60

Table 9

15.7 Electrical data table
Model
Minimum circuit ampacity(A) Maximum circuit protecetor(A)
Table 10

18 24 30 36 42 48 60 18 24 30 36 42 48 60

10.4 13.7 16.5 19.4 22.5 23.8 29.9 10.4 13.4 16.5 19.4 21.6 22.9 28.8

15 20 25 30 35 40 50 15 20 25 30 35 35 45

15.8 Troubleshooting table

CDORTCOTHWEE.C4ECI3DONHP.XFOLDFHSHS.MTTCTI.RCO.GNNTORAEAELEROP/OBCEWTUIHTROVCHEORILMRNMO.LIRRSIASDC.PEGFKCRNTWEOETDEPLSCPEVVT.C.KSCXOO.CFSS.WFR.PIFOO.SVTUO.T.VVSVORNFCAEOCSOA.ECSLLSNROIECSROOSIENTNSTLTOCOLEWTRRCIEOEDAVEAHOAA..VLSTDHSINNNDDNIENTMNECREEDCCCGGNEVEEUTCUE..ETASTVSRSASRRCETAAPCSNEERCRNGRROPAOAAOLLPOFOCCFPPUROKTIKOEOSPMIIENEECSWRAWAAOERRRRHHRLE.RLRAALAUCTCCTOCCMARFFOAASIIDLFADBHRRDKKIITPIIDCOSTDLLMTORSROODTTPUCELEEIIIIIEPOOIOTEOEMNNOONOONGGNEAEDEVESFTFAALFFFWWRIGGGGNNRRDRRPFSE.SSEEEEYTTL……

SYSTEM FAULTS

REFRIGERANT CIRCUIT

Head Pressure Too High

P P S P S P P S

S P S

Head Pressure Too Low

S P S P

S S S S

SS P S S S P

Suction Pressure Too High

S PP S

P P

Suction Pressure Too Low

S P S

SS S S S

Liquid Refrig. Floodback

(TXV)

I.D. Coil Frosting

C H

S S

Compressor Runs Inadequate or C

No Cooling/Heating

S P S P

S S S

SPSS S S P S S S S

ELECTRICAL

Compressor & O.D. Fan Won’t Start C P P H P P

S SPSPP SPS P

S S S SS

Compressor Will Not Start But C P P

O.D. Fan Runs

H P P

P P P

S S

O.D. Fan Won’t Start

C P

H P

Compressor Hums But Won’t Start

C H

P P

I.D. Blower Won’t Start

C P PS H P PS

P SPS S P SPS S

DEFROST

Unit Won’t Initiate Defrost

P S

Defrost Terminates on Time

P S

Unit Icing Up

C H

S S

C- Cooling H – Heating P – Primary Causes S – Secondary Causes

16. Warranty
Assist owner with processing Warranty cards and/or online registration.
16.1 Maintenance
Dirt should not be allowed to accumulate on the indoor or outdoor coils or other parts in the air circuit. Clean as often as necessary to keep the unit clean. Use a brush, vacuum cleaner attachment or other suitable means.
The outdoor fan motor is permanently lubricated and does not require periodic oiling.
Refer to the furnace or air handler instructions for filter and blower motor maintenance.
The indoor coil and drain pan should be inspected and cleaned regularly to assure proper drainage.

It is unlawful to knowingly vent, release or discharge refrigerant into the open air during repair, service, maintenance or the final disposal of this unit. When the system is functioning properly and the owner has been fully instructed, secure the owner’s approval.
16.2 Changing motor
When motor requires changing, follow the steps below:
STEP 1 – Go into electrical panel, disconnect motor power lines.
Note: Disconnect main power to unit. Severe burns and electrical shock will occur if you do not disconnect main power.
STEP 2 – Remove cover (be careful of motor wires).
STEP 3 – Be sure to place fan cover unit on the ground (Figure 43 ).
Note: Do not place or lean fan blades on ground or against surface.

STEP 4 – Remove fan motor by removing 5/16″ nuts from cover.
STEP 5 – Remove fan blade from motor by removing 1/2″ nut and place fan on the ground.
STEP 6 – Reverse removal process to reinstall the fan and motor.
Note: When connecting motor wires be sure to check motor direction.

Damage will occur to condenser unit if you remove 5/16” nuts prior to cover removal.

1/2″nut

Figure 44

5/16″nuts

17. Wiring diagrams

17.1 For 18K-48K HP System

GROUND PLUG PLATE

T1 L1

WHITE

T2 L2

BLACK

RC 3

A1 CC

BLACK A2 YELLOW

JACINTH CCH

L1
POWER
L2

C Yout Heat
TO THERMOSTAT

RC 1

YELLOW

COMP

YELLOW OR WHITE R
RED

ORANGE

XS1

GREEN

XP1

ORANGE

HPC

RC 2

HGS

BROWN

BLACK

OFM

CN17

WHITE BLACK
XP2 XP2

FAN DFC

CN11

SW3

CN15 C RV

JACINTH

R C W1
Y B CN16

RED BLACK PURPLE YELLOW BLUE

GREEN

LPC T4

RED = 24V POWER BLACK = 24V COM BLUE = REVERSING VALVE PURPLE = AUX HEAT IN DEFROST YELLOW = COMPRESSOR CONTACTOR

COMPRESSOR CONTACTOR

CCH CRANKCASE HEATER

COMP COMPRESSOR

DFC DEFROST CONTROL

AMBIENT TEMPERATURE

PIPE TEMPERATURE

HPC HIGH PRESSURE CUT-OUT CONTROL

LPC LOW PRESSURE CUT-OUT CONTROL

OFM OUTDOOR FAN MOTOR

RC 1 RUN CAPACITOR 1

RC 2 RUN CAPACITOR 2

RC 3 RUN CAPACITOR 3

REVERSING VALVE

GND GROUND CHASSIS

HGS HOT GAS SENSOR

LINE VOLTAGE FACTORY STANDARD FIELD INSTALLED FACTORY OPTIONAL

LOW VOLTAGE FACTORY STANDARD FIELD INSTALLED FACTORY OPTIONAL USE COPPER CONDUCTORS ONLY
0$18$/ ‘()5267 $8720$7,& ‘()5267 5(6(59(‘ 1250$/ ‘()5267 ‘()5267,1* &<&/(0,1 ‘()5267,1* &<&/(0,1

0 STEADY ON = NORMAL OPERATION OFF = DFC FAILURE
1 1 FLASH = T3 SENSOR FAILURE 2 2 FLASH = T4 SENSOR FAILURE OR HGS OPEN 3 3 FLASH = LPC OPEN

WARNING: CABINET MUST BE PERMANMENTLY GOUNDED AND ALL WIRING TO CONFORM TO I.E.C,N.E.C,C.E.C,C.L.C,AND LOCAL CODES AS APPLICABLE REPLACEMENT WIRE MUST BE THE SAME GAUGE AND INSULATION TYPE AS ORIGINAL WIRE
Figure 45

17.2 For 60K HP System

GROUND PLUG PLATE

RC 1
Y/G RED

T1 L1

WHITE

T2 L2

BLACK CC
A1

A2 YELLOW

BLACK

RED JACINTH

C S

YELLOW OFM

COMP

XS1

GREEN

XP1

CN11

WHITE

T4 DFC

BLACK

T3 CN9

SW3
XP2

XP2 CN10

RV C

LPC

GND
W Y B C
CN8

L1 POWER
L2
CCH JACINTH

Y/G

WHITE YELLOW BLUE BLACK

YELLOW HPC

YOUT L2 L1
HEAT TO THERMOSTAT

&&&2035(6625&217$&725 &203&2035(6625 ‘)&'()5267&21752/ 7$0%,(177(03(5$785( 73,3(7(03(5$785( +3&+,*+35(6685(&87287&21752/ +*6+27*$66(1625 /3&/2:35(6685(&87287&21752/ 2)0287’225)$102725 5&581&$3$&,725 595(9(56,1*9$/9( *1’*5281’&+$66,6 /,1(92/7$*( )$&725<67$1’$5′ ),(/’,167$//(‘ )$&725<237,21$/ /2:92/7$*( )$&725<67$1’$5′ ),(/’,167$//(‘ )$&725<237,21$/ 86(&233(5&21’8&725621/<
0$18$/ ‘()5267 $8720$7,& ‘()5267 5(6(59(‘ 1250$/ ‘()5267 ‘()5267,1* &<&/(0,1 ‘()5267,1* &<&/(0,1

HGS

LPC

RV
WHITE = AUX HEAT IN DEFROST YELLOW = COMPRESSOR CONTACTOR BLUE = REVERSING VALVE BLACK = 24V COM

67($'<21 1251$/23(5$7,21 2)) ‘)&)$,/85(
)/$6+ 76(1625)$,/85( )/$6+ 76(1625)$,/85(25+*623(1 )/$6+ /3&23(1 )/$6+ 2)0)$,/85(

Figure 46

17.3 For 18K-36K AC System

PLUG PLATE

T1
BLACK
T2 CC
A1 YELLOW

L1 RED

BLACK L2

BLACK

HPC

GROUND
L1 L2

YELLOW

GREEN

BLACK C

&203

RC 1

BLACK

WHITE OR YELLOW BLACK

RED
RC 3

BLACK

BLACK ORANGE
)$1
RC 2
BROWN

GREEN

POWER TO THERM OSTAT

LINE VOLTAGE FACTORY STANDARD FIELD INSTALLED FACTORY OPTIONAL

LOW VOLTAGE FACTORY STANDARD FIELD INSTALLED FACTORY OPTIONAL USE COPPER CONDUCTORS ONLY

HPS CC COMP RC 1 RC 2 RC 3

HIGH PRESSURE CUT-OUT CONTROL COMPRESSOR CONTACTOR COMPRESSOR RUN CAPACITOR 1 RUN CAPACITOR 2 RUN CAPACITOR 3

Figure 47 21

17.4 For 42K-60K AC System

GROUND PLUG PLATE

T1 L1

WHITE

T2 L2

RED

BLACK CC
A1

BLACK A2 YELLOW

L1 POWER
L2

C RC 1
S

COMP Y/G

RED

GREEN

YELLOW

OFM Y/G

CN11

GND

WHITE

BLACK

T3 CN9

DFC
21

SW3

YELLOW

XS1 XP1

XP2
XP2 CN10

RV C

B C
CN8

BLACK

T4 T3

LPC

YELLOW HPC

YELLOW = COMPRESSOR CONTACTOR BLACK = 24V COM

YOUT L2 L1
HEAT TO THERMOSTAT

&&&2035(6625&217$&725 &203&2035(6625 ‘)&'()5267&21752/ 7$0%,(177(03(5$785( 73,3(7(03(5$785( +3&+,*+35(6685(&87287&21752/ /3&/2:35(6685(&87287&21752/ 2)0287’225)$102725 5&581&$3$&,725 595(9(56,1*9$/9( *1’*5281’&+$66,6
/,1(92/7$*( )$&725<67$1’$5′ ),(/’,167$//(‘ )$&725<237,21$/ /2:92/7$*( )$&725<67$1’$5′ ),(/’,167$//(‘ )$&725<237,21$/ 86(&233(5&21’8&725621/<
0$18$/ ‘()5267 $8720$7,& ‘()5267 5(6(59(‘ 1250$/ ‘()5267 ‘()5267,1* &<&/(0,1 ‘()5267,1* &<&/(0,1
67($'<21 1251$/23(5$7,21
2)) ‘)&)$,/85(
)/$6+ 76(1625)$,/85(
)/$6+ 76(1625)$,/85(
)/$6+ /3&23(1
)/$6+ 2)0)$,/85(

Figure 48

18. Matching table and Checkout Procedures

18.1 Matching table
Condensing Unit
J4AC6018A1000AA J4AC6024A1000AA J4AC6030A1000AA J4AC6036A1000AA J4AC6042A1000AA J4AC6048A1000AA J4AC6060A1000AA

Air Handle/A-Coil
J4AH4E36A1B00AA J4AH4E36A1B00AA J4AH4E36A1B00AA J4AH4E60A1C00AA J4AH4E60A1C00AA J4AH4E60A1C00AA J4AH4E60A1C00AA

Piston Size/TXV Valve Model 052 058 065 073 075 080
4AYTXVH3G6000A

SEER
16 16 16 16 16 16 15

If Preinstalled Piston Replace Required YES YES YES YES YES YES YES

J4HP6018A1000AA J4AH4E36A1B00AA

052

YES

J4HP6024A1000AA J4AH4E36A1B00AA

058

YES

J4HP6030A1000AA J4AH4E36A1B00AA 4AYTXVH3G2436A 16

YES

J4HP6036A1000AA J4AH4E60A1C00AA

070

YES

J4HP6042A1000AA J4AH4E60A1C00AA 4AYTXVH3G4248A 16

YES

J4HP6048A1000AA J4AH4E60A1C00AA 4AYTXVH3G6000A 16

YES

J4HP6060A1000AA J4AH6E60A1C00AA 4AYTXVH3G6000A 15

YES

Note: Since the manufacturer has a policy of continuous product and product data improvement, if the system combination you are looking for is not listed, check for the latest version of this document at www.oxboxhvac.com.

18.2 Operational and Checkout Procedures

Final phases of this installation are the unit Operational and Checkout Procedures. To obtain proper performance, all units must be operated and charge adjustments made in accordance with procedures found in the Service Facts of the Outdoor Unit.
After installation has been completed, it is recommended that the entire system be checked against the following list:

1. Be sure unit suspension(if used) is secure and that there are no tools or loose debris in or around or on top of the unit………………………………………………[ ] 2. Properly insulate suction lines and fittings………[ ] 3. Properly secure and isolate all refrigerant lines… [ ] 4. Verify that all electrical connections are tight. …..[ ]

5.Check all duct outlets; they must be open and unrestricted. [ ] 6.Check drain lines and be sure all joints are tight…………… [ ] 7.Be sure that a return air filter is installed……………………… [ ] 8.Operate complete system in each mode to verify proper
performance. Verify operation of supplementary electric heater. ……………………………………………………………………. [ ]

BX-SVN-J4ACHP6-1A-EN