Installation Instructions€¦ · Installation Instructions to the expe_ NOTE: Read the entire...

Installation Instructions

to the expe_

NOTE: Read the entire instruction manual before starting theinstallation.

NOTE: Installer: Make sure the Owner's Manual and Service

Instructions are left with the unit after installation.

TABLE OF CONTENTS

PAGE

SAFETY CONSIDERATIONS ....................... 1-2

INTRODUCTION ................................... 2

RECEIVING AND INSTALLATION ................. 2-10

Check Equipment .................................. 2

Identify Unit .................................... 2

Inspect Shipment ................................. 2

Provide Unit Support ............................... 2Roof Curb ...................................... 2

Slab Mount ..................................... 2

Provide Clearances ................................. 7

Field Fabricate Ductwork ............................ 7

Rig and Place Unit ................................. 7

Inspection ...................................... 7

Rigging/Lifting of Unit ............................ 7Connect Condensate Drain ........................... 8

Install Duct Connections ............................. 8

Configuring Units for Downflow (Vertical) Discharge .... 8Install Electrical Connections ......................... 9

High-Voltage Connections ......................... 9

Special Procedures for 208v Operation ............... 10

Control Voltage Connections ....................... 10Standard Connection ............................. 10

Transformer Protection ........................... 10

PRE-START-UP ................................... 12

START-UP ..................................... 12-14

Check for Refrigerant Leaks ......................... 12

Start-Up Adjustments .............................. 12

Checking Cooling Control Operation ................ 12

Checking and Adjusting Refrigerant Charge ........... 12

Indoor Airflow and Airflow Adjustments ............. 13

Continuous Fan Operation ........................ 14

Cooling Sequence of Operation ..................... 14MAINTENANCE ................................ 24-26

Air Filter ...................................... 24

Indoor Blower and Motor ......................... 24

Outdoor Coil, Indoor Coil, and Condensate Drain Pan ... 25Outdoor Fan ................................... 25

Electrical Controls and Wiring ..................... 25

Refrigerant Circuit ............................... 26

Evaporator Airflow .............................. 26Puron Items .................................... 26

TROUBLESHOOTING .............................. 27

START-UP CHECKLIST ............................ 27

A09033

Fig. 1 - Unit 50VL-A

SAFETY CONSIDERATIONSImproper installation adjustment, alteration, service, maintenance,

or use can cause explosion, fire, electrical shock, or other

conditions which may cause death, personal iniury, or property

damage. Consult a qualified installer, service agency, or your

distributor or branch for information or assistance. The qualified

installer or agency must use factory-authorized kits or accessories

when modifying this product Refer to the individual instructions

packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,

and work gloves. Use quenching cloth for brazing operations.

Have a fire extinguisher available. Read these instructions

thoroughly and follow all warnings or cautions included in

literature and attached to the unit. Consult local building codes, the

current editions of the National Electrical Code (NEC) NFPA 70.In Canada refer to the current editions of the Canadian electrical

Code CSA C22.1.

Recognize safety information. This is the safety-alert symbol Z_

When you see this symbol on the unit and in instructions or

manuals, be alert to the potential for personal injury. Understand

these signal words; DANGER, WARNING, and CAUTION. These

words are used with the safety-alert symbol. DANGER identifies

the most serious hazards which will result in severe personal injury

or death. WARNING signifies hazards which could result in

personal injury or death. CAUTION is used to identify unsafe

practices which may result in minor personal iniury or product and

property damage. NOTE is used to highlight suggestions which

will result in enhanced installation, reliability, or operation.

g

ELECTRICALSHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.

Before installing or servicing system, always turn off main

power to system and install lockout tag. There may be

more than one disconnect switch. Turn off accessory heater

power switch if @plicable.

PERSONAL INJURY AND ENVIRONMENTALHAZARD

Failure to relieve system pressure could result in personal

injury and/or death.

1. Relieve pressure and recover all refrigerant before

servicing existing equipment, and before final unit disposal.

Use all service ports and open all flow-control devices,

including solenoid valves.

2. Federal regulations require that you do not vent

refrigerant into the atmosphere. Recover during system

repair or final unit disposal.

CUT HAZARD

Failure to follow this caution may result in personal injury.

When removing access panels (see Fig. 17) or performingmaintenance functions inside your unit, be aware of sharpsheet metal parts and screws. Although special care is takento reduce sharp edges to a minimum, be extremely carefulwhen handling parts or reaching into the unit.

INTRODUCTION

The 50VL-A packaged air conditioner is fully self-contained and

designed for outdoor installation (See Fig.l ). See Fig. 2 and 3 for

unit dimensions. All unit sizes have discharge openings for both

horizontal and downflow configurations, and are factory shipped

with all downflow duct openings covered. The unit may be

installed either on a rooftop or on a ground-level cement slab. (See

Fig. 4 for roof curb dimensions.)

RECEIVING AND INSTALLATION

Step 1 -- Check Equipment

IDENTIFY UNIT

The unit model number and serial number are printed on the unitinformative plate. Check this information against shipping papers.INSPECT SHIPMENT

Inspect for shipping damage before removing packaging materials.If unit @pears to be damaged or is torn loose from its anchorage,have it examined by transportation inspectors before removal.Forward claim papers directly to transportation company.Manufacturer is not responsible for any damage incurred in transit.Check all items against shipping list. Immediately notify thenearest equipment distribution office if any item is missing. Toprevent loss or damage, leave all parts in original packages untilinstallation.

If the unit is to be mounted on a curb in a downflow @plication,review Step 7 to determine which method is to be used to removethe downflow panels before rigging and lifting into place. Thepanel removal process may require the unit to be on the ground.

Step 2 -- Provide Unit Support

IMPORTANT: The unit must be secured to the curb by installing

screws through the bottom of the curb flange and into the unit base

rails. When installing large base units onto the common curb, the

screws must be installed before allowing the full weight of the unit

to rest on the curb. A minimum of six screws are required for large

base units. Failure to secure unit properly could result in an

unstable unit. See Warning near Rigging/Lifting information and

accessory curb instructions for more details.

For hurricane tie downs, contact distributor for details and PE

(Professional Engineering) Certificate if required.

ROOF CURB

Install accessory roof curb in accordance with instructions shipped

with curb (See Fig. 4). Install insulation, cant strips, roofing, and

flashing. Ductwork must be attached to curb.

IMPORTANT: The gasketing of the unit to the roof curb is

critical for a water tight seal. Install gasketing material supplied

with the roof curb. Improperly applied gasketing also can result in

air leaks and poor unit performance.

Curb should be level to within 1/4 in. (6.35 mm) (See Fig 6). This

is necessary for unit drain to function properly. Refer to accessoryroof curb installation instructions for additional information as

required.

Installation on older "G" series roof curbs.

Two accessory kits are available to aid in installing a new "G"

series unit on an old "G" roof curb.

1. Accessory kit number CPADCURB001A00, (small chassis)

and accessory kit number CPADCURB002A00, (large

chassis) includes roof curb adapter and gaskets for the

perimeter seal and duct openings. No additional

modifications to the curb are required when using this kit.

2. An alternative to the adapter curb is to modify the existing

curb by removing the outer horizontal flange and use

accessory kit number CPGSKTKIT001A00 which includes

spacer blocks (for easy alignment to existing curb) and

gaskets for the perimeter seal and duct openings. This kit is

used when existing curb is modified by removing outer

horizontal flange.

UNIT/STRUCTURAL DAMAGE HAZARD

Failure to follow this caution may result in property

damage.

Ensure there is sufficient clearance for saw blade when

cutting the outer horizontal flange of the roof curb so there

is no damage to the roof or flashing.

SLAB MOUNT

Place the unit on a solid, level concrete pad that is a minimum of 4

in. (102 mm) thick with 2 in. (51 mm) above grade. The slab

should extend @proximately 2 in. (51 mm) beyond the casing on

all 4 sides of the unit (See Fig. 7). Do not secure the unit to the slab

except when required by local codes.

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DUCT SIDE _F UNIT ......................................... [SO B]

ELE:TRICAL 'ANEL ......................... 56 ['_14 4]

GROUhDEDSURFACES, POWE/' ENT,_v SIDE 42 [/066 8]

REOL1REOCLEARANCE FOR OPERATIONAND SERVICING

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SIDE 0 POSITE DUCTS.............................. 56 [9_0]OUDTPANEL [504 8]_

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ROOF CURB DETAIL

LARGE CURB

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A09415

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Dashed I_nes show cross support

Iocalion for large basepan units

SMALL/COMMON CURB A09413

SMALL

BASEUNIT

LARGE

BASE

UNIT

-aUNIT PLACEMENT ON

COMMON CURB

SMALL OR LARGE BASE UNIT

A09094

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A09414

BUNIT CATALOG A (small/commonSIZE NUMBER IN. base)

(mm) IN, (mm)*

11Small CPRFCURB01OAOO (279)

or 14 10 (254)Large CPRFCURB011AOO (356)

11CPRFCURB012AOO (279)

Large 14 (356)14

CPRFCURB013AOO (356)

B C D E F(large base) IN. IN. IN. IN.

IN. (mm)* (mm) (mm) (mm) (mm)

32.4

(822)

16 47.8 2.714 (356) (406) (1214) (69)

43.9(1116)

G H

IN. (mm) IN. (mm)

30.6 (778)

46.1 (1170)

42.2 (1072)

* Part Numbers CPRCURB010A00 and CPRCURB011A00 can be used on both small and large basepan units. The cross supports must be located based onwhether the unit is a small basepan or a large basepan.NOTES:

1. Roof curb must be set up for unit being installed.

2. Seal strip must be applied, as required, to unit being installed.

3. Roof curb is made of 1d-gauge steel.

4. Attach ductwork to curb (flanges of duct rest on curb).

5. Insulated panels: 1-in. (25.4 mm) thick fiberglass 1 lb. density.

Fig. 4 - Roof Curb Dimensions

CAUTION - NOTICE TO RIGGERSPRUDENCE - AViS AUX MANIPULATEUR

ACCESS PANELS MUST BE iN PLACE WHEN RIGGING.PANNEAUX D'ACCES DOlT ETRE EN PLACE POUR MANIPULATION.

Use top skid as spreader bar. / Utiliser la palette du haut comme barre de r6partition

jJ ..... MiNiMUM HEIGHT: 36" (9!4.4 ram)J HAUTEUR MINIMUM

DUCTS

SEE DETAIL AVOIR DETAIL A

UNIT HEIGHT

HAUTEUR D'UNITIEJ" _

DETAIL AVOiR DIETAIL A

SEAL STRIP MUST BE IN BANDE SCELLANT BOIT ETRE

PLACE BEFORE PLACING EN PLACE AVANT DE PLACERUNIT ON ROOF CURB L:U NtTE SUR LA BASE DE TOtT

50CY502286 2,0

SMALL CABINET

24 30 36Unit* Unit*

Ib kg Ib kg Ib kg

Rigging 295 134 307 139 365 166 RiggingWeight Weight

LARGE CABINET

42 48

Ib kg Ib kg Ib

421 191 439 199 467

For 460 volt units, add 14 Ib (6.35 kg) to the rigging weight.

NOTE: See dimensional drawing for corner weighs.

Fig. 5 - 50VL-A Unit Suggested Rigging

6o

A09051

kg

212

Step 3 -- Provide ClearancesThe required minimum service clearances are shown in Fig. 2 and

3. Adequate ventilation and outdoor air must be provided. The

outdoor fan draws air through the outdoor coil and discharges it

through the top fan grille. Be sure that the fan discharge does notrecirculate to the outdoor coil. Do not locate the unit in either a

corner or under an overhead obstruction. The minimum clearance

under a partial overhang (such as a normal house overhang) is 48

in. (1219 mm) above the unit top. The maximum horizontal

extension of a partial overhang must not exceed 48 in. (1219 mm)IMPORTANT: Do not restrict outdoor airflow. An air restriction

at either the outdoor-air inlet or the fan discharge may be

detrimental to compressor life.

Do not place the unit where water, ice, or snow from an overhang

or roof will damage or flood the unit. Do not install the unit on

carpeting or other combustible materials. Slab-mounted units

should be at least 4 in. (102 mm) above the highest expected waterand runoff levels. Do not use unit if it has been under water.

Step 4 -- Field-Fabricate DuctworkSecure all ducts to roof curb and building structure on verticaldischarge units. Do not connect ductwork to unit. For horizontal

applications, unit is provided with flanges on the horizontal

openings. All ductwork should be secured to the flanges. Insulate

and weatherproof all external ductwork, joints, and roof openings

with counter flashing and mastic in accordance with applicablecodes.

Ducts passing through an unconditioned space must be insulated

and covered with a vapor barrier. If a plenum return is used on a

vertical unit, the return should be ducted through the roof deck to

comply with applicable fire codes. See unit rating plate for any

required clearances around ductwork. Cabinet return-air staticshall not exceed -.25 IN. W.C.

Step 5 -- Rig and Place UnitRigging and handling of this equipment can be hazardous for

many reasons due to the installation location (roofs, elevated

structures, etc.).

Only trained, qualified crane operators and ground support staff

should handle and install this equipment.

When working with this equipment, observe precautions in the

literature, on tags, stickers, and labels attached to the equipment,

and any other safety precautions that might apply.

Training for operators of the lifting equipment should include, but

not be limited to, the following:

1. Application of the lifter to the load, and adjustment of the

lifts to adapt to various sizes or kinds of loads.

2. Instruction in any special operation or precaution.

3. Condition of the load as it relates to operation of the lifting

kit, such as balance, temperature, etc.

Follow all applicable safety codes. Wear safety shoes and work

gloves.

3

MAXIMUM ALLOWABLEB DIFFERENCE in. (mm)

A-B B-C A-C

1/4 (6.35) 1/4 (6.35) 1/4 (6.35)

Fig. 6 - Unit Leveling Tolerances

A07925

INSPECTION

Prior to initial use, and at monthly intervals, all rigging shackles,

clevis pins, and straps should be visually inspected for any damage,

evidence of wear, structural deformation, or cracks. Particular

attention should be paid to excessive wear at hoist hooking points

and load support areas. Materials showing any kind of wear inthese areas must not be used and should be discarded.

UNIT FALLING HAZARD


iniury or death.

Never stand beneath rigged units or lift over people.

1. Leave top shipping skid on the unit for use as a spreader bar 1to prevent the rigging straps from damaging the unit. If the

skid is not available, use a spreader bar of sufficient length nto protect the unit from damage.

PROPERTY DAMAGE HAZARD


When straps are taut, the clevis should be a minimum of 36in, (914 mm) above the unit top cover.

Ri_in_/Liftin_ of Unit (See Fire 5)

UNIT FALLING HAZARD


injury or death.

Large base units must be secured to common curb before

allowing full weight of unit to rest on curb. Install screws

through curb into unit base rails while rigging crane is still

supporting unit.

Lifting holes are provided in base rails as shown.

1. Attach shackles, clevis pins, and straps to the base rails of

the unit. Be sure materials are rated to hold the weight of the

unit (See Fig. 5).

2. Attach a clevis of sufficient strength in the middle of the

straps. Adjust the clevis location to ensure unit is lifted level

with the ground.

After the unit is placed on the roof curb or mounting pad, remove

the top skid.

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A07926

Fig. 7 - Slab Mounting Detail

Step 6 -- Connect Condensate Drain

NOTE: When installing condensate drain connection be sure to

comply with local codes and restrictions.

Model 50VL-A disposes of condensate water through a 3/4 in.

NPT fitting which exits through the base on the evaporator coilaccess side. See Fig. 2 and 3 for location.

Condensate water can be drained directly onto the roof in rooftop

installations (where permitted) or onto a gravel apron in ground

level installations. Install a field-supplied 2-in. (51 mm)

condensate trap at end of condensate connection to ensure proper

drainage. Make sure that the outlet of the trap is at least 1 in. (25

mm) lower than the drain pan condensate connection to prevent the

pan from overflowing (See Fig. 8). When using a gravel apron,make sure it slopes away from the unit.

Connect a drain tube using a minimum of 3/4 -in. PVC or 3/4 -in.

copper pipe (all field-supplied) at the outlet end of the 2-in. (51

mm) trap. Do not undersize the tube. Pitch the drain tube

downward at a slope of at least 1-in. (25 mm) for every 10 fl (3.1

m) of horizontal run. Be sure to check the drain tube for leaks.

Prime trap at the beginning of the cooling season start-up.

1-in. (25

____ TRAP

OUTLET

--mm,m,l ,......_S 2-m.(5_......_mm.

A09052

Fig. 8 - Condensate Trap

Step 7 -- Install Duct Connections

The design and installation of the duct system must be inaccordance with the standards of the NFPA for installation of

non-residence type air conditioning and ventilating systems,

NFPA 90A or residence type, NFPA 90B and/or local codes andordinances.

Select and size ductwork, supply-air registers, and return air grilles

according to ASHRAE (American Society of Heating,

Refrigeration, and Air Conditioning Engineers) recommendations.

The unit has duct flanges on the supply- and return-air openingson the side of the unit.

When designing and installing ductwork, consider the following:

1. All units should have field-supplied filters or accessoryfilter rack installed in the return-air side of the unit.

Recommended sizes for filters are shown in Table 1.

2. Avoid abrupt duct size increases and reductions. Abrupt

change in duct size adversely affects air performance.

IMPORTANT: Use flexible connectors between ductwork and

unit to prevent transmission of vibration. Use suitable gaskets to

ensure weather-tight and airtight seal. When electric heat is

installed, use fireproof canvas (or similar heat resistant material)

connector between ductwork and unit discharge connection. If

flexible duct is used, insert a sheet metal sleeve inside duct. Heat

resistant duct connector (or sheet metal sleeve) must extend 24-in.

(610 mm) from electric heater element.

3. Size ductwork for cooling air quantity (cfm). The minimum

air quantity for proper electric heater operation is listed in

Table 2. Heater limit switches may trip at air quantitiesbelow those recommended.

4. Seal, insulate, and weatherproof all external ductwork. Seal,

insulate and cover with a vapor barrier all ductwork passing

through conditioned spaces. Follow latest Sheet Metal and

Air Conditioning Contractors National Association(SMACNA) and Air Conditioning Contractors Association(ACCA) minimum installation standards for residentialheating and air conditioning systems.

5. Secure all ducts to building structure. Flash, weatherproof,and vibration-isolate duct openings in wall or roofaccording to good construction practices.

CONFIGURING UNITS FOR DOWNFLOW

(VERTICAL) DISCHARGE

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personalinjury or death.

Before performing service or maintenance operations on thesystem, turn off main power to unit and install lockout tag.

1. Open all electrical disconnects and install lockout tag before

starting any service work.

2. Remove horizontal (metal) ductcovers to access vertical

(downflow) discharge duct knockouts in unit basepan. (See

Fig. 9.)

To remove downflow return and supply knockout covers, break

front and right side connecting tabs with a screwdriver andhammer. Push cover down to break rear and left side tabs.

NOTE: These panels are held in place with tabs similar to an

electrical knockout. Reinstall horizontal duct covers (Fig. 9)

shipped on unit from factory. Insure openings are air and

watertight.

NOTE: The design and installation of the duct system must be inaccordance with the standards of the NFPA for installation of

nonresidence-type air conditioning and ventilating systems, NFPA

90A or residence-type, NFPA 90B; and/or local codes andordinances.

Adhere to the following criteria when selecting, sizing, and

installing the duct system:

1. Units are shipped for side shot installation.

2. Select and size ductwork, supply-air registers, and

return-air grilles according to American Society of Heating,

Refrigeration and Air Conditioning Engineers (ASHRAE)recommendations.

3. Use flexible transition between rigid ductwork and unit to

prevent transmission of vibration. The transition may be

screwed or bolted to duct flanges. Use suitable gaskets to

ensure weather-tight and airtight seal.

4. All units must have field-supplied filters or accessory filterrack installed in the return-air side of the unit.

Recommended sizes for filters are shown in Table 1.

5. Size all ductwork for maximum required airflow (either

heating or cooling) for unit being installed. Avoid abrupt

duct size increases or decreases or performance may beaffected.

6. Adequately insulate and weatherproof all ductwork located

outdoors. Insulate ducts passing through unconditioned

space, and use vapor barrier in accordance with latest issue

of Sheet Metal and Air Conditioning Contractors National

Association (SMACNA) and Air Conditioning Contractors

of America (ACCA) minimum installation standards for

heating and air conditioning systems. Secure all ducts to

building structure.

7. Flash, weatherproof, and vibration-isolate all openings in

building structure in accordance with local codes and good

building practices.

BasepanDownflow

(Vertical)

Supply _.Knockout

Horizontal Duct CoversA09076

BasepanDownflow

J (Vertical)Return

Knockout

Fig. 9 - Supply and Return Duct Opening

Step 8 -- Install Electrical Connections

A09093


Failure to follow this warning could result an personal

iniury or death.

The unit cabinet must have an uninterrupted, unbroken

electrical ground to minimize the possibility of personal

iniury if an electrical fault should occur. This ground may

consist of an electrical wire connected to the unit ground

screw in the control compartment, or conduit approved for

electrical ground when installed in accordance with NFPA

70 (NEC) (latest edition) (in Canada, Canadian Electrical

Code CSA C22.1) and local electrical codes.

[]NIT COMPONENT DAMAGE HAZARD

Failure to follow this caution may result in damage to theunit being installed.

1. Make all electrical connections in accordance with

NFPA 70 (NEC) (latest edition) and local electrical codes

governing such wiring. In Canada, all electricalconnections must be in accordance with CSA standard

C22.1 Canadian Electrical Code Part 1 and applicable

local codes. Refer to unit wiring diagram.

2. Use only copper conductor for connections between

field-supplied electrical disconnect switch and unit. DONOT USE ALUMINUM WIRE.

3. Be sure that high-voltage power to unit is within

operating voltage range indicated on unit rating plate. On

3-phase units, ensure phases are balanced within 2

percent. Consult local power company for correction of

improper voltage and/or phase imbalance.

4. Do not damage internal components when drilling

through any panel to mount electrical hardware, conduit,

etc.

HIGH-VOLTAGE CONNECTIONS

The unit must have a separate electrical service with a

field-supplied, waterproof disconnect switch mounted at, or within

sight from the unit. Refer to the unit rating plate, NEC and localcodes for maximum fuse/circuit breaker size and minimum circuit

amps (ampacity) for wire sizing.

The field-supplied disconnect may be mounted on the unit over

the high-voltage inlet hole when the standard power and

low-voltage entry points are used. See Fig. 2 and 3 for acceptablelocation.

See unit wiring label (Fig. 12, 13 and 14) and Fig. 10 for reference

when making high voltage connections. Proceed as follows to

complete the high-voltage connections to the unit.

Single phase units:

1. Run the high-voltage (L1, L2) and ground lead into thecontrol box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the line sideof the contactor.

4. Connect field LI to black wire on connection 11 of the

compressor contactor.

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FIELD-SUPPLIEDFUSED DISCONNECT

VVHT(VVl)___ ]

ve @@YELLYL_ _)

GRN(G) _. @

._RED(R)_. @

BRN(C) _, @

BLU (DH)__

Q J3 Phase

Only

__1 POWER

SUPPLY

A09066

Fig. lO - High- and Control-Voltage Connections

THERMOSTAT

(TYPICAL)

5. Connect field wire L2 to yellow wire on connection 23 of

the compressor contactor.

Three-phase units:

1. Run the high-voltage (L1, L2, L3) and ground lead into thecontrol box.

2. Connect ground lead to chassis ground connection.

3. Locate the black and yellow wires connected to the line sideof the contactor.

4. Connect field LI to black wire on connection 11 of the

compressor contactor.

5. Connect field wire L3 to yellow wire on connection 13 of

the compressor contactor.

6. Connect field wire L2 to blue wire from compressor.

SPECIAL PROCEDURES FOR 208-V OPERATION



injury or death.

Before installing or servicing system, always turn off main

power to system and install lockout tag. With disconnect

switch open, move black wire from transformer (3/16

in.)(4.8 mm) terminal marked 230 to terminal marked 208.

This retaps transformer to primary voltage of 208 vac.

CONTROL VOLTAGE CONNECTIONS

NOTE: Do not use any type of power-stealing thermostat. Unit

control problems may result.

Use no. 18 American Wire Gage (AWG) color-coded, insulated

(35°C minimum) wires to make the control voltage connectionsbetween the thermostat and the unit. If the thermostat is located

more than 100 ft (30.5 m) from the unit (as measured along the

control voltage wires), use no. 16 AWG color-coded, insulated

(35 ° C minimum) wires.

STANDARD CONNECTION

Locate the seven (eight for 3-phase) low voltage thermostat leadsin 24 volt splice box. A gray wire is standard on 3-phase units for

connection to an economizer. See Fig. 10 for connection diagram.

Run the low-voltage leads from the thermostat, through the control

wiring inlet hole grommet (Fig. 2 and 3), and into the low-voltage

splice box. Provide a drip loop before running wires through panel.

Secure and strain relief all wires so that they do not interfere with

operation of unit.

If an accessory electric heater is installed, low voltage leads from

heater must be connected to factory supplied control leads from

Indoor Fan Board P4 connector. Factory wires are provided for

electric heat staging WI and W2 (W2 and W3 on IFB). If room

thermostat has only one stage of supplemental heat, connect white

and violet wires shown in Fig. 10 to second stage heat field wire.

Some electric heaters have four control wires (plus common wire).

Consult unit wiring diagram and electric heater wiring diagram foradditional details.

TRANSFORMER PROTECTION

The transformer is of the energy-limiting type, however a direct

short will likely blow a secondary fuse. If an overload or short is

present, correct overload condition and check for blower fuse on

Indoor Fan Board. Replace fuse as required with correct size and

rating.

10

UNIT SIZE

NOMINAL CAPACITY (ton)SHIPPING WEIGHT* lb.

SHIPPING WEIGHT* (kg)

COMPRESSORS

Quantity

REFRIGERANT (R-410A)Quantity IbQuantity (kg)

REFRIGERANT METERING DEVICE

OUTDOOR COIL

Rows...Fins/in,Face Area (sq ft)

OUTDOOR FANNominal CfmDiameter in.

Diameter (mm)Motor Hp (Rpm)

INDOOR COILRows...Fins/in,

Face Area (sq ft)

INDOOR SLOWER

Nominal Cooling Airflow (Cfm)Size in.

Size (mm.)Motor HP (RPM)

HIGH-PRESSURE SWITCH

(peig) Cut-out Reset (Auto)

LOSS-OF-CHARGE / LOW-PRES-

SURE SWITCH (Liquid Line) (peig)cut-out Reset (auto)

RETURN-AIR FILTERSt_

24 48 60

2 4 5

295 439 467134 199 212

Table 1 - Physical Data-Unit 50VL-A

30 36 42

2-1/2 3 3-1/2

307 365 421

139 166 191

Scroll

1

6.0 5.6 9.5 8.8 9.4 12.52.7 2.5 4.3 4.0 4.3 5.7

TXV

1...21 1...21 2...21 2...21 2...21 2...2111.9 13.6 15.4 13.6 17.5 21.4

2500 2700 2800 3000 3200 360024 24 24 26 26 26

609.6 609.6 609.6 660.4 660.4 660.4

1/10 (810) 1/10 (810) 1/5 (810) 1/5 (810) 1/5 (810) 1/5 (810)

3...17 3...17 3...17 3...17 3...17 3...173.7 3.7 3.7 4.7 4.7 5.7

800 1000 1200 1400 1600 1750

10x10 10x10 1lx10 1lx10 1lx10 1lx10254x254 254x254 279.4x254 279.4x254 279.4x254 279.4x254

1/2 (1050) 1/2 (1050) 3/4 (1000) 3/4 (1075) 1.0 (1075) 1.0 (1040)

650 +/- 15420 +/- 25

20 +/- 545 +/- 10

Throwaway Size in. 20x20x1 20x24x1 24x30x1 24x36x1Throwaway Size (mm) 508x508x25 508x610x25 610x762x25 610x914x25

*For 460 volt units add 14 Ib (6.35 kg) to the shipping weight.

1- Required filter sizes shown are based on the larger of the AHRI (Air Conditioning Heating and Refrigeration Institute) rated cooling airflow or the heating air-flow velocity of 300 if/minute for throwaway type or 450 if/minute for high-capacity type. Air filter pressure drop for non-standard filters must not exceed 0.08in. W.C,

$ If using accessory filter rack refer to the filter rack installation instructionsfor correct filter sizes and quantity.

I!

Table 2 - Minimum Airflow for Safe Electric Heater Operation (CFM)

SIZE 24 30 36 42 48 60

Cfm 800 1000 1200 1400 1600 1750

11

PRE-START-UP

ENVIRONMENTAL, FIRE,ELECTRICAL SHOCK HAZARD

EXPLOSION,

Failure to follow this warning could result in personaliniury or death and/or property damage.

1, Follow recognized safety practices and wear protectivegoggles when checking or servicing refrigerant system.

2, Relieve and recover all refrigerant from system beforetouching or disturbing compressor plug if refrigerantleak is suspected around compressor terminals.

3, Never attempt to repair soldered connection whilerefrigerant system is under pressure.

4. Do not use torch to remove any component. Systemcontains oil and refrigerant under pressure.

5. To remove a component, wear protective goggles andproceed as follows:

a. Shut off electrical power to unit and installlockout tag.

b. Relieve and reclaim all refrigerant from systemusing both high- and low-pressure ports.

c. Cut component connecting tubing with tubingcutter and remove component from unit.

d. Carefully unsweat remaining tubing stubs whennecessary. Oil can ignite when exposed to torchflame.

Proceed as follows to inspect and prepare the unit for initial

start-up:

1. Remove all access panels (see Fig. 17).

2. Read and follow instructions on all DANGER, WARNING,

CAUTION, and INFORMATION labels attached to, or

shipped with unit.

3. Make the following inspections:

a. Inspect for shipping and handling damages, such as

broken lines, loose parts, disconnected wires, etc.

b. Inspect for oil at all refrigerant tubing connections and

on unit base. Detecting oil generally indicates a

refrigerant leak. Leak test all refrigerant tubing

connections using electronic leak detector, or

liquid-soap solution. If a refrigerant leak is detected, see

following Check for Refrigerant Leaks section.

c, Inspect all field- and factory-wiring connections, Be

sure that connections are completed and tight,

d, Ensure wires do not touch refrigerant tubing or sharp

sheet metal edges,

e. Inspect coil fins. If damaged during shipping and

handling, carefully straighten fins with a fin comb.

4. Verify the following conditions:

a. Make sure that condensate drain pan and trap are filled

with water to ensure proper drainage.

b. Make sure that all tools and miscellaneous loose partshave been removed.

START-UP

Step 1 -- Check for Refrigerant Leaks

Proceed as follows to locate and repair a refrigerant leak and to

charge the unit:

1. Locate leak and make sure that refrigerant system pressure

has been relieved and reclaimed from both high- and

low-pressure ports.

2. Repair leak following accepted practices.

NOTE: Install a filter drier whenever the system has been opened

for repair.

3. Add a small charge of Puron (R-410A) refrigerant vapor to

system and leak-test unit.

4. Recover refrigerant from system and evacuate to 500microns if no additional leaks are found.

5. Charge unit with Puron (R-410A) refrigerant, using an

accurate scale. Refer to unit rating plate for required charge.

Step 2 -- Start-Up Cooling Section And Make

Adjustments

Complete the required procedures given in the Pre-Start-Upsection before starting the unit. Do not jumper any safety devices

when operating the unit. Do not operate the unit when the outdoor

temperature is below 40°F (4°C) (unless accessory low-ambient

kit is installed). Do not rapid cycle the compressor. Allow 5

minutes between "on" cycles to prevent compressor damage.

CHECKING COOLING CONTROL OPERATION

Start and check the unit for proper cooling control operation asfollows:

1. Place room thermostat SYSTEM switch in OFF position.Observe that blower motor starts when FAN switch is

placed in ON position and shuts down when FAN switch is

placed in AUTO position.

2. Place SYSTEM switch in COOL position and FAN switch

in AUTO position. Set cooling control below room

temperature. Observe that compressor, condenser fan, and

evaporator blower motors start. Observe that compressor

and outdoor fan shut down when control setting is satisfiedand that indoor blower shuts down after 90 second fan time

delay expires.

IMPORTANT: Three-phase, scroll compressors are direction

oriented. Unit must be checked to ensure proper compressor

3-phase power lead orientation. If not corrected within 5 minutes,

the internal protector will shut off the compressor. The 3-phase

power leads to the unit must be reversed to correct rotation. When

turning backwards, the difference between compressor suction and

discharge pressures may be minimal.

CHECKING AND ADJUSTING REFRIGERANT

CHARGE

The refrigerant system is fully charged with Puron (R-410A)

refrigerant and is tested and factory sealed.

NOTE: Adjustment of the refrigerant charge is not required

unless the unit is suspected of not having the proper Puron

(R-410A) charge.

A subcooling charging chart is attached to the inside of the

compressor access panel (see Fig. 17). The chart includes therequired liquid line temperature at given discharge line pressures

and outdoor ambient temperatures.

An accurate thermocouple- or thermistor-type thermometer, and a

gauge manifold are required when using the subcooling charging

method for evaluating the unit charge. Do not use mercury or small

dial-type thermometers because they are not adequate for this typeof measurement.

NOTE: Allow system to operate for a minimum of 15 minutes

before checking or adjusting refrigerant charge.

IMPORTANT: When evaluating the refrigerant charge, an

indicated adjustment to the specified factory charge must always be

very minimal. If a substantial adjustment is indicated, an abnormal

condition exists somewhere in the cooling system, such asinsufficient airflow across either coil or both coils.

12

Proceedasfollows:1.Removecapsfromlow-andhigh-pressureservicefittings.2.Usinghoseswithvalvecoredepressors,attachlow-and

high-pressuregaugehosesto low- andhigh-pressureservicefittings,respectively.

3.Startunitandletrununtilsystempressuresstabilize.4.Measureandrecordthefollowing:

a.Outdoorambient-airtemperature(°F[°C]db).b.Liquidlinetemperature(°F[°C])atTXV.c.Discharge(high-side)pressure(psig).d.Suction(low-side)pressure(psig)(forreferenceonly).

5.UsingCoolingChargingChartscompareoutdoor-airtemperature(°F [°C]db)withthedischargelinepressure(psig)to determinedesiredsystemoperatingliquidlinetemperature(SeeFig.15).

6.Compareactualliquidlinetemperaturewithdesiredliquidlinetemperature.Usingatoleranceof-2°F(-I.I°C),addrefrigerantif actualtemperatureismorethan2°F(I.I°C)higherthanproperliquidlinetemperature,or removerefrigerantif actualtemperatureismorethan2°F(I.I°C)lowerthanrequiredliquidlinetemperature.

NOTE: If theproblemcausingtheinaccuratereadingsis arefrigerantleak,refertoCheckforRefrigerantLeakssection.INDOOR AIRFLOW AND AIRFLOW ADJUST-

MENTS

UNIT OPERATION HAZARD

Failure to follow this caution may result in unit damage.

For cooling operation, the recommended airflow is 350 to

450 cfm for each 12,000 Btuh of rated cooling capacity. For

heating operation, the airflow must produce a temperature

rise that falls within the range stamped on the unit rating

plate.

NOTE: Be sure that all supply-and return-air grilles are open,

free from obstructions, and adjusted properly.



injury or death.

Disconnect electrical power to the unit and install lockout

tag before changing blower speed.

This unit is factory-set up for use with a single cooling fan speed.

In addition, this unit has the field-selectable capability to run two

different cooling fan speeds: The rated cooling fan speed (350~400

CFM/Ton) and an enhanced dehumidification fan speed (As low as

320 CFM/Ton) for use with either a dehumidistat or a thermostat

that supports dehumidification.

The cooling speed is marked "LOW" on the interface fan board

(IFB) (See Fig. 11) . The factory-shipped settings are noted in

Table 4. There are 4 additional speed tap wires available for use in

either electric heating or cooling (For color coding on the indoor

fan motor leads, see Table 3). The additional 4 speed tap wires are

shipped loose with vinyl caps and are located in the control box,

near the interface fan board (IFB) (See Fig. 11).

SINGLE COOLING FAN SPEED SET-UP (Dehumidi-fication feature not used)

To change cooling speed:

1. Remove the vinyl cap off of the desired speed tap wire

(Refer to Table 3 for color coding). Add the wet coil

pressure drop in Table 6 to the system static to determine the

correct cooling airflow speed in Table 4 that will deliver the

nominal cooling airflow as listed in Table 1 for each size.

2. Remove the current speed tap wire from the "LOW"

terminal on the interface fan board (IFB) (See Fig. 11) andplace vinyl cap over the connector on the wire.

3. Connect the desired speed tap wire to the "LOW" terminal

on the interface fan board (IFB).

NOTE: If accessory electric heat is installed, and the electric heat

fan speed is chosen to be the same as the normal cooling fan speed,

the dry airflow must meet or exceed the minimum airflow speed

specified in Table 2 for the specific size unit.

TWO COOLING FAN SPEEDS SET-UP (Dehumidi-

fication feature used)

IMPORTANT: Dehumidification control must open control

circuit on humidity rise above set point.

Use of the dehumidification cooling fan speed requires use ofeither a 24 VAC dehumidistat or a thermostat which includes

control of a 24 VAC dehumidistat connection. In either case, the

dehumidification control must open the control circuit on humidity

rise above the dehumidification set point.

1. Using Fig. 11, move the two pin DEHUM jumper from the

"STD" position to the "DEHUM" position.

2. Remove fan speed tap wire from the "LOW" terminal on

the interface fan board (IFB) (See Fig. 11).

3. Determine correct normal cooling fan speed for unit and

application. Add the wet coil pressure drop in Table 6 to

the system static to determine the correct cooling airflow

speed in Table 4 that will deliver the nominal coolingairflow as listed in Table 1 for each size.

NOTE: If accessory electric heat is installed, the dry

airflow must meet or exceed the minimum airflow speed

specified in Table 2 for the specific size unit. The electric

heat fan speed will be the same as the normal cooling fan

speed.


(Refer to Table 3 for color coding) for the normal cooling

fan speed and place desired speed tap wire on "HIGH" onthe interface board.

5. Refer to airflow tables (Table 4) to determine allowable

speeds for the dehumidification cooling fan speed. In Table

4, speeds that are not allowed for dehumidification coolingare shaded.


(Refer to Table 3 for color coding) for the dehumidification

cooling fan speed and place desired speed tap wire on the

"LOW" connection on the interface board (IFB). Verify

that static pressure is in the acceptable range for the speed

tap to be used for dehumidification cooling.

7. Use any spare vinyl plugs to cap any unused speed tapwires.

g

13

gFig. 11 - Interface Fan Board (IFB)

A09059

SINGLE SPEED COOLING WITH HIGHERELECTRIC HEAT SPEED

This unit can also be configured to operate with single speed

cooling and a higher speed for an accessory electric heater.

1. Using Fig. 11, move the two pin DEHUM jumper from the

"STD" position to the "DEHUM" position.

2. See Table 2 for minimum airflow for electric heat operation.

Add electric heater and filter pressure drop to duct system

static pressure to determine total external static pressure.

3. Select speed tap from Table 4 that will achieve requiredairflow from Table 2.


(Refer to Table 3 for color coding).

5. Connect the desired speed tap wire to the "HIGH" terminal

on the interface fan board (IFB).

[]NIT OPERATION HAZARD

Failure to follow this caution may result in unit componentdamage or improper operation,

To use this mode, a speed connection must be made on the"HIGH" terminal that meets or exceeds the minimumairflow found in Table 2.

Table 3 - Color Coding for Indoor Fan Motor Leads

Black = High Speed

Orange = Med-High Speed

Red = Med Speed

Pink = Med-Low Speed

Blue = Low Speed



iniury or death.

Disconnect electrical power to the unit and install lockout

tag before changing blower speed.

CONTINUOUS FAN OPERATION

When the DEHUM feature is not used, the continuous fan speed

will be the same as cooling fan speed. When the DEHUM feature

is used, the continuous fan will operate on IFB "LOW" speed

when the DH control lead is not energized, or IFB "HIGH" speed

when the DH lead is energized (see Fig. 11).

COOLING SEQUENCE OF OPERATION

With the room thermostat SYSTEM switch in the COOL position

and the FAN switch in the AUTO position, the cooling sequence of

operation is as follows:

When the room temperature rises to a point that is slightly above

the cooling control setting of the thermostat, the thermostat

completes the circuit between thermostat terminal R to terminals Y

and G. These completed circuits through the thermostat connect

contactor coil (C) (through unit wire Y) and time delay relay

(TDR) (through unit wire G) across the 24-V secondary of

transformer (TRAN).

The normally open contacts of energized contactor (C) close and

complete the circuit through compressor motor (COMP) to

condenser (outdoor) fan motor (OFM). Both motors start instantly.

A set of normally open contacts on the interface fan board (IFB)

are closed which energizes a circuit to the indoor fan motor (IFB).

NOTE: Once the compressor has started and then has stopped, it

should not be started again until 5 minutes have elapsed.

The cooling cycle remains on until the room temperature drops to a

point that is slightly below the cooling control setting of the room

thermostat. At this point, the thermostat breaks the circuit between

thermostat terminal R to terminals Y and G. These open circuits

deenergize contactor coil C and IFB. The condenser and

compressor motors stop. After a 90-second delay, the blower

motor stops. The unit is in a standby condition, waiting for the next

call for cooling from the room thermostat.

14

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UNIT

SIZE

24

30

36

42

48

60

600

0.030

7OO

0.037

80O

0.044

Table 6 - 50VL-A Horizontal and Downflow Discharge Wet Coil Pressure Drop (IN. W.C.)

STANDARD CFM (SCFM)900 1000 11O0 1200 1300 1400 1500 1600 1700 1800 1900

0.053 0.063

0.053 0.063 0.072 0.081 0.105

0.055 0.060 0.090 0.100 0.110 0.140

0.045 0.050 0.060 0.065 0.075 0.080 0.090 0.094 O.110

0.041 0.063 0.085 0.100 0.104 0.110 0.120 0.130

0.060 0.065 0.007 0.077 0.085

2000

0.140

0.100

2100

0.115

2200

0.125

DOWNFLOWECONOMIZER +

INCLUDED FILTERS600-t 400 cfm

(12x20xt+t2x20xl)1200-t800 cfm

(16x24xt+t4x24xt)1500-2200 cfm

(16x24xt+t8x24xt)

FILTER SIZE in.

(mm)

600=1400cfm

(12x20x1 +12x20x1)

1200=1800cfm

(16x24x1 +14x24x1)1500=2200cfm

(16x24x1 +18x24x1)

COOLINGTONS

2.0, 2.5,30

35, 40

5.0

Table 7 - Horizontal and Downflow Economizer with 1-in. Filter Pressure Drop (IN. W.C.)

STANDARD CFM (SCFM)

690 700 800 900 1000 1100 1200 1300 1400 1500 1690 1700 1800

0.07 0.08 0.10 0.14 0.17 0.21 0.25 0.3t 0.35

0.10 0.12 0.13 0.15 0.17 0.19 0.22

0.10 0.12 0.13 0.15

1900

0.17

COOLING

TONS

2.0,

2.5,3.0

3.5,4.0

5.0

Table 8 - Horizontal and Downflow Filter Pressure Drop Table (IN. W.C.)

STANDARD CFM (SCFM)600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900

0.05 0.07 0.08 0.09 0.10 0.11 0.13 0.14 0.15

0.07 0.08 0.09 0.10 0.11 0.11 0.12

0.08 0.10 0.10 0.11 0.12

2000

0.18

2000

21oo

0.20

2100

2200

0.23

2200

Table 9 - Electric Heat Pressure Drop Tables (IN. W.C.)

Small Cabinet: 24-36

STATIC STANDARD CFM (SCFM)500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600

5 kW 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.02 0.04 0.06 0.07

10 kW 0.00 0.00 0.00 0.00 0.00 0.02 0.04 0.06 0.07 0.09 0.10 0.11

16 kW 0.00 0.00 0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18

20 kW 0.00 0.00 0.02 0.04 0.06 0.08 0.09 0.11 0.13 0.15 0.17 0.19

Large Cabinet: 42-60

STATIC STANDARD CFM (SCFM)1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500

5 kW 0.00 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12

10 kW 0.00 0.00 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13

16 kW 0.00 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15

20 kW 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 0.11 0.12 0.13 0.14 0.15 0.16

0.13 0.14 0.15

CONNECTION WIRING DIAGRAM

DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING

BLK

YEL

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ii i

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GRN/YEL

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TSTAT RED-------_ o

G--GRH --

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YEL

BRN

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SCHEMATIC250-1-60

UNIT COMPONENT ARRANGEMENT

OUTDOOR FANSECTION

COMPRESSOR INDOORFANSECTIOR SECTION

r_

CAP

CONP

csBR

/--SEE NOTE 8

/

IFB

CONTROL BOX AREA

SINGLE PT, _

CONNECTIONFORE_ECT.HEAT

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ACCESSSORY ELECTRIC HEAT_'_-.____

- - - I -_ - HRN

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-- -- _l -- -HRN

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HPS LPS

--BLO_BLK----O-I."_3_BLK---e---BLU---O_-Z)--BLU _

LEGEND/-_ FIELD SPLICE C COHTACIOR

TERMINAL {MARKED) ENERGIZED CAP CAPACITORo TERMINAL (UNMARKED) CCH CRANK CASE HEATER

• SPLICE (IF USED} COMP COMPRESSOR MOTOR

0 SPLICE (MARKED} DEHUM DEHUMIDIFICATION MODE-- FACTORY WIRING GMD GROUND

HPS HIGH PRESSURE SWITCH-- --FIELD CONTROL WIRING HR HEATER RELAY---FIELD POWER WIRING---- ACCESSORY OR OPTIONAL IFB INTERFACE FAN BOARD

WIRING IFM INDOOR FAR _OTOR

--TO INDICATE COMMON LPS LOW PRESSURE SWITCHPOTENTIAL ONLY: OFM OUTDOOR FAN MOTORHOT TO REPRESENT WIRING STD STANDARD

TRAN TRANSFORMER

NOTES:

lr IF ANY OP THE ORIGINAL WIRES PDRNISHED ARE REPLACED,IT MUST HE REPLACED WITH TYPE 9U DEGREE C WIRE ORIT'S EQUIVALENT,

2. SEE PRICE PAGES FOR THERMOSTAT AND SUHBASES.3. DS[ 75 DEGREE COPPER CONDUCTORS FOR FIELD INSTALLATION,4. REFER TO INSTALLATION INSTRUCTIOHS

POR CORRECT SPEED SZLZCFION OF IFM.5. RELOCATION OF SPEED TAPS MAY BE REOUIREU

WHEN USIHG FIELD INSTALLED ELECTRIC HEATERS,CONSULT INSTALLATION INSTRUCTIONS TODETERMINE CORRECT SPEED TAP SETTIHG.

G, *UO NOT UISCONNECT PLUG UNDER LOAU,"7, THIS FUSE IS MANUFACTURED BY LITTELFUSE, PIN 257003.8. UNIT FACTORY'SHIPPED IN STD MODE.

A10205

Fig. 12 - Connection Wiring Diagram 208/230-1-60

g

17

LADDER WIRING DIAGRAM

DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE SERVICING

SEE NOTE 7_

R O-RED

CO-BRN

Y O_YEL

G _RN--DHO--BL

W20--WHT

W30-V[O

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L2

YEL

23

23

23

C,TRAN

50VL500269

Fig. 12 Cont. - Ladder Wiring Diagram 208/230-1-60

DA10205

18



GCN/--1'UREO SCHEMAT ICBL[} _ _,IELO 2so s 60

SUPPLY BLK l

UNIT ONLY- - '_ I ...... , I

MAXIMUM WIRE L3 . y WITH ELECTRIC I;Z]_ i iSIZE 2AWG - -- ._-_-YEL _-ll-_}---_ EL- \--EL--II-YE {{EATERS SEE-q'_'_." --_----d I

• _'/ _ \_At_._BRI,Htt_BRN....._.___j/nL ? S_It_:_ _ _1_-- Z 1<__:' 11

i _ f---_O_P,ESSORPLUG ACCESSORY, _ - -- _< I Ii I _ i ,<TIC I I_,

EOUPGND TEL i --YEL'"(_'_--'_ IICOMP --I_I__.jzDL_I . II

_k i -- -- - -I_t - - J= -_YEL-- i I:_ I L_r- -Cbr- -I - I

,__<_ ___i L-J-J / / / GRNIYEL RN I "_C"_'_Ji I_L2 2_L° _ , °

--/ >,-X_ EO_----- 8_,\ ----

BLU _ / z __ -- ----BRN---- I "-----+---BRR---

YELl ,/1 _.._1 _--i _ S ) --5 RED--

L

Y2_RY-- \ / r --

T_AT SEE,O','E"-"m \1 _ - :_o-- \ 11 J ,_7 Ac_,Rso,,ELECT"IR,EAT--.. I

_ z-_-_<=p!==__ _=p "_ IC BRN < _ u I_ I _ _ _ = KR1 {5 IIW) I--.........-- --4 _=_ = _ / .... I

_. II _------ -----__ ___Io .... ±_o-- _ I

II III ; I " _:_ _ I _ I _-_ Z I .... I I_RR_ _[}N i _ _L-_--_--_--i--S-_--_--_--_.'I

w,--v:o ]_-i '_"z°_: I'-'_":! t"_[--'L_. ....................

' NPS LPS BLU_-- -- BLI(===_i-BLR'K:_-'(_ BLR -_BLU

UNITCOMPONENTARRANGEMENT LEOEND-- -- -- C CORTACTOROUTDOOR FAR _ _ FIELD SPLICE CAP CAPACITORSECTION _ ur,_

I I COLOR CODE _ TERMINAL (NAR_ED} ENERGIZED CCN CRANK CASE NEATERBLIl BLACR o TERNIRAL {UNMARRED) COMP COMPRESSOR MOTOR_i li _i u_" It _p/lel" (IF n_rnl [}H UERtltlIDIFICATION ItODE

COMPRESSOR INDOOR FAN CONTROL BOX AREA GRY GRAY rAeTnRy W_R_ ECO ECO 0 IZE

SECYION SECTION _ GRN GREEN -----_FIELOCO;TRGi'_WIRIN6 G_7 6x_O_N_RESSURE SWITCH

I" e "1 _K _ _N ANG` ---FIELD POllER WIRING MR HEATER RELAY

I, o_I SINGLE PT, | RED RED -- -_VCR_ORY OR OPTIONAL I_BIB! I_(_R_ACEANFA(i_TBORARDI _' _ I CONNECTION VIO VIOLET LPS LOW PRESSURE SWITCH

FOR WIIT WIllie --TO INDICATE COMMON OFI_ OUTDOOR FAR MOTORELECT>IIEAT TEL YELLOW POIENTIAL ONLY: STD STANDARD 140DE

NOT TO REPRESENT WIRING TRAN TRANSFORMER

IFN NOTES:

IFB 2, SEE PRICE PAGES FOR THERMOSTATS,EOUIP 3. USE 75 DEGREE COPPER CONDUCTORS FOR FIELD INSTALLATION./ • 4. REFER YO INSTALLATION INSTRUCTIONSGND FOR CORRECT SPEED SELECTION OF IFM.

SEE HEATER i 5. RELOCATION OF SPEED TAPS MAY BE REQUIREDSCHEIIATIC / -- WHEN USING FIELD INSTALLED ELECTRIC HEATERS,FOR WIRING _ I ........... i CONSULT INSTALLATION INSTRUCTIONS TO

C Ui_LV_mtt|-- _ I I DETER_INE CORRECT SPEED TAP SETTING.S r_ I _t_ --_ ..... I PER NEC I R, "DO NOT DISCONNECT PLUG UNDER LOAD, "

R _M i = _ ---- ' 7, THIS rUSE IS MANUFACTURED BY LITTELFUSE, PiN 257003_J ...... 8, DEHUM FEATURE CANNOT BE USED WHEN ECONOMIZER IS INSTALLED,

124V SPLICE UNIT FACTORY-SHIPPED IN ST[}IlODE.

I BOX ------24V POWER ENTRY

A10202

Fig. 13 - Connection Wiring Diagram 208/230-3-60

19

!!



R O-RED

C O'-B RN

YIO--YEL

G O-GRN

DHO'-BL b_

W20-WHT

W30-VlO

Y2 J GRY-

L2 L1

BLK

11 iBLK

11 ------__----_

II ----BLI_

--BLK-

RED_24VAC

:USE_IFB

Pl - 2(_,C ,,

P1-3_,ylIY"P1-4©%.)1. --_'Y21DH"

_I - 60,,w2,,

P1- 70,,W3,,

P2-2("_--d

P2-g(p-;- At

P4-10--_

P4-20----

P4- 30--J-J

P4- 40--JJ

P4- 50...._

LVVV

sfDI--O-O-O-O-O-O-O-O_

DEHUMIO I

_GH

IGIY..L

21 lr USED_CH J 2S C

xx _ LGRN-'Jl l

i BLKJJ'---9_--BL_YEL_ _I

j Eb......,_

BLU _L

i DLK_ J

RED

L3

YEL

'13

230 "mAN COM

-O...L_k.,k..k _,k..O-- YEb

T BLK

BLI_

PS LPS C1 C

,,--_Lu-o--Zo-BLu------Ct_ACCESSORY_...__

ELECTRIC HEAT _--_-_--

__ _ I I I

JVJO_J_ if@ I 'I

.....__G Ry_______...GRy- q I"i i

I i

YEL-

--B RN------Z_----,BRN

_----._=SEENOTE 8

i_L F_u

LBLK

2)-BRN-

.13

C,IFB

)C, TRAN

C, IFB

___BRN--

RED

BRN

_PNK+BLU-- SA_

GRY

YEL

GRY.

Fig. 13 Cont. - Ladder Wiring Diagram 208/230-3-60

50VL500270 DAI0202

2O



YR--GRY --

TSTATSEE HOT[ 7--

e --RED --

C-- BRR--

YI--YEL --

G--GRN --

DH--BLU --

WS--WHT --

UNIT COMPONENT ARRANGEMENT

OUTDOOR FANSECTION

INDOOR FANSECTION

COMPRESSOR

SECTION

COMP

R

CONTROL BOX AREA

SINGLE PI. _

CONNECTIONFORELECT.HEAT

IFB

SEE HEATER J

SCHEMATICFOR WIRING

[]-___ _

h PLtCL

/EOUIP.GNU

DISCONNECT

PER IPOWEHEN'NY

o

I ISEE NOTE 4

HPS LPS

BLK-----O-I'_:)--BLK_BLU_BLU _

LEGEND/-"FIELD SPLICE _AP CAPACIToRCONTACTOR

COLOR CODE _'TERMIRAL (MARKED}ENERGIZED CCH CRANK CASE HEATER

BLB BLACB o TERMINAL (UNMARKED} COMP COMPRESSOR MOTORDH DEHUMIDIFICATION MODE

BLU BLUE • SPLICE (IF USED) DEHUM DEHUMIDIFICATION MODEBRN BROWN O SPLICE (MAR_ED) [CON ECONOMIZERGRY GRAY --FACTORY WIRING GHD GROUNDGRN GREEN ----FIELD CONTROL WIRING HPS HIGH PRESSURE SWITCH

ORB ORANGE ---FIELD POWER WIRING BR HEATER RELAYPNK PINK - -.ACCESSORY OR OPTIONAL IFB INTERFACE FAN BOARD

_!_ _8_et WIRING IFM IHDOORFANMOTORLPS LOW PRESSURE SWITCH

W_ --TO ,NDICATECOMMOH OFM OUTDOOR FAN MOTORYEL L W POTENTIAL ONLY; STD STANDARD MODENOT TO REPRESENT WIRING TRAH TRANSFORMER

NOTES;

t, IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED,IT MUST BE REPLACED WITH TYPE 90 DEGREE C WIRE ORIT'S EOUIVALENT.

?, SEE PRICE PAGES FOR THERMOSTAT AHD SUBBASES,3. USE 75 _EGREE COPPER CONDUCTORS FOR FIELD INSTALLATIOH,4. REFER TO INSTALLATION INSTRUCTIONS

For CORRECT SPEED SELECTION OF IFM,5, RELOCATION OF SPEED TAPS MAY BE REOUIRED

WHEN USING FIELD INSTALLED ELECTRIC HEATERS,CONSULT INSTALLATIOH INSTRUCTIONS TODEYERMIH[ CORRECT SPEED TAP SETTING,

6, "DO NOT DISCONNECT PLUG UNDER LOAD,"7, THIS FUSE IS MANUFACTURED BY LITTELFUSE, PIN ?570038, THESE FUSES ARE MANUFACTURED BY COOPER BUSSMAR, PIN FRO-R-59, DEHUM FEATURE CARROT BE USED WHEN [COHOMIZEN IS INSTALLED.

UNIT FACTORY-SHIPPED IN STD MODE,

A10204C

Fig. 14 - Connection Wiring Diagram 460-3-60

21

II


DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWERBEFORE SERVICING

SEEfiOTE7"_

R O-RED

C OIBRN

YIO--YEL

O O-GRNDHO-BLU

W20-WHT

W30-vlO

Y2 i VIO-

L2 I

G/Y_L YEL

--BLK21 Ir USED_ CCH I c

__E_BLK F_/_II 23

BLU _k K_ _YILJ

L1

BLK

ll(

11(

ll( _BLK

_BLK

P1120 "CI'

P1_OIIyI IY"

P1-4 0 "G"PI - 5(_),y21DII,

P11@0 "W2"

P1 - 70 ,,W3,,

p211_

P2-2(_ IP2- 30-- IP2-4_

_o

P4-1_

p412_

P4-3_L

P4140"_

STD_

DEHUMLO_J

G/Y

RED

460V _ 460V__YEb

G/Y

HPS LPS C1 (2

ACCESSORYELECTRIC HEAT

, ,-_ ....... BRN-

--WHT_-_-_HT - _ , BRH-

--VlO _Io1 ' O_ '

--PN_IPN_ - ' _, ' BRH-

--GRyII_I_RyI ' _ '

--BRN_-BR_ ..........

w/_SEE NOTE 9

I BLU--

pNK I

SEE NOTE 4 RED --ORN--

@ BLK--

L3

YEL'_ 3

C,TRAN

BRN

BRN--

BRN

RED

9b

ECON BLK

HAR}ESS

4_---BRN--IICOM C

5 @

6---PNK_BLU_

7---PNK--t_BLU_---8

Fig. 14 Cont. - Ladder Wiring Diagram 460-3-60

50VL500271 DA10204

22

_ Required Subcooling °F(°C) __

Outdoor Ambient Temperature °F(°C) Required Subcoolin_/°F)Model Size Pressure

_- 75(24) _ 85(29) , 95(35) _-105(41) _ 115(46) (psig) 5 10 15 20 25189 81 56 51 46 41

024 16(9.1) 16(9.1) 16(g.1) 17(9.5) 18(9.9/030 10 (5.6} 10 (5.6} 10 (5.6) 10 (5.6)

036 15 (8.4) 15 (8.2) 14 (8) 14 (7.7) 13 (7.5}

042 14 _7.8) 14_7.8} 14_7,8_ 12 (6.9} 11 _6.4}

048 _ 17(9.4) 16p[ 15 _8.6) 15(8.1) 14_7.5_

060 L 18(9.9} 17(9.5) 17_9.3_ 15 (8.6_ 14_8}

1- Measure Discharge line pressure by attaching a gauge to the service port.

--._" 2- Measure the Liquid line temperature by attaching a temperature sensing

device to it.

3- insulate the temperature sensing device so that the Outdoor Ambientdoesn't affect the reading.

4- Refer to the required Subcooling in the table based on the model size and

= the Outdoor Ambient temperature,_r_5- Interpolate if the Outdoor ambient temperature lies in between the table

=" values.=;

"_ 6- Find the Pressure Value in the table corresponding to the the measured_..= Pressure of the Compressor Discharge line.

_r_7= Read across from the Pressure reading to obtain the Liquid line

_' temperature for a required Subcooling=8- Add Charge if the measured temperature is higher than the table value.

g - Remove charge if the measured temperature is lower than the table value.

50VL50(}323 REV 2.0 ]

Required Liquid Line Temperature for a Specific_

Required Subcoolin 9 (°C)

196 63 58 53 48 43

203 66 61 58 51 46

210 68 63 58 53 48

2t7 70 65 56 55 50

224 72 67 62 57 52

23I 74 69 64 59 54

238 76 71 66 61 56

245 77 72 67 62 57

252 79 74 69 64 59

260 81 76 71 66 61

268 83 78 73 68 63

276 85 80 75 70 65

284 87 82 77 72 67

292 89 84 79 74 69

300 91 86 81 76 71

309 93 88 63 78 73

318 95 90 85 80 75

327 97 92 87 82 77

336 99 94 89 84 79

345 101 96 91 86 81

354 103 98 93 88 83

364 105 106 95 g0 85

374 107 102 97 92 87

384 108 183 98 93 88

394 110 105 160 95 90

404 112 107 102 97 92414 114 109 104 99 94

424 116 11t 166 161 96

434 116 113 108 183 96

444 119 114 109 104 99

454 121 116 1tl 106 101

464 123 118 1t3 108 183

474 124 119 1t4 109 104

484 126 121 116 111 106

494 127 122 117 112 107

504 129 124 119 114 109

5f4 131 126 121 116 111

524 132 127 122 117 112

534 134 129 124 119 t14

Pressure

(kPa) 3 6 8 11 14

1303 16 13 11 8 5

1351 17 15 12 9 6

1399 19 16 13 10 8

1448 20 17 14 11 9

t496 21 16 t5 13 10

t544 22 19 16 14 11

1593 23 20 18 15 12

1641 24 21 19 16 13

1689 25 22 20 17 14

1737 26 23 21 18 15

t792 27 25 22 19 t6

f848 29 26 23 20 17

1903 30 27 24 21 19

1958 31 28 25 22 20

2013 32 29 26 23 21

2068 33 30 27 24 22

2130 34 3t 26 26 23

2192 35 32 29 27 24

2254 36 33 31 28 25

2316 37 34 32 29 26

2378 38 35 33 36 27

2440 39 36 34 31 28

2509 40 38 35 32 29

2578 41 39 36 33 30

2647 42 40 37 34 31

2716 44 41 38 35 32

2785 45 42 39 36 332854 46 43 40 37 34

2923 47 44 41 38 35

2992 48 45 42 39 36

3061 48 46 43 46 37

3130 49 47 44 41 38

3199 50 48 45 42 39

3268 51 48 46 43 40

3337 52 49 47 44 41

3406 53 50 47 45 42

3475 54 5f 48 46 43

3544 55 52 49 46 44

3612 56 53 50 47 45

3681 56 54 51 48 45

o>o_

g

MAINTENANCE

To ensure continuing high performance, and to minimize thepossibility of premature equipment failure, periodic maintenancemust be performed on this equipment. This cooling unit should beinspected at least once each year by a qualified service person. Totroubleshoot unit, refer to Table 8, Troubleshooting Chart.

NOTE TO EQUIPMENT OWNER: Consult your local dealerabout the availability of a maintenance contract.

PERSONAL INJURY AND UNIT DAMAGEHAZARD

Failure to follow this warning could result in personalinjury or death and possible unit component damage.

The ability to properly perform maintenance on thisequipment requires certain expertise, mechanical skills,tools and equipment. If you do not possess these, do notattempt to perform any maintenance on this equipment,other than those procedures recommended in the Owner'sManual.

ELECTRICAL SHOCK AND FIRE HAZARD

Failure to follow these warnings could result in personalinjury or death:

1. Turn off electrical power to the unit and install lockouttag before performing any maintenance or service on thisunit.

2. Use extreme caution when removing panels and parts.

3. Never place anything combustible either on or in contactwith the unit.

[]NIT OPERATION HAZARD

Failure to follow this caution may result in equipmentdamage or improper operation.

Errors made when reconnecting wires may cause improperand dangerous operation. Label all wires prior todisconnecting when servicing.

The minimum maintenance requirements for this equipment are asfollows:

1. Inspect air filter(s) each month. Clean or replace whennecessary.

2. Inspect indoor coil, drain pan, and condensate drain eachcooling season for cleanliness. Clean when necessary.

3. Inspect blower motor and wheel for cleanliness eachcooling season. Clean when necessary.

4. Check electrical connections for tightness and controls forproper operation each cooling season. Service whennecessary.

5. Ensure electric wires are not in contact with refrigeranttubing or sharp metal edges.

Air Filter

IMPORTANT: Never operate the unit without a suitable air filterin the return-air duct system. Always replace the filter with thesame dimensional size and type as originally installed. See Table 1for recommended filter sizes.

Inspect air filter(s) at least once each month and replace(throwaway-type) or clean (cleanable-type) at least twice duringeach cooling season and twice during the heating season, orwhenever the filter becomes clogged with dust and lint.

Indoor Blower and Motor

NOTE: All motors are pre-lubricated. Do not attempt to lubricatethese motors.

For longer life, operating economy, and continuing efficiency,clean accumulated dirt and grease from the blower wheel andmotor annually.


Failure to follow this warning could result in personaliniury or death.

Disconnect and tag electrical power to the unit beforecleaning the blower motor and wheel.

To clean the blower motor and wheel:

1. Remove and disassemble blower assembly as follows:

a. Remove blower access panel (see Fig. 17).

b. Disconnect 5 pin plug and 4 pin plug from indoorblower motor. Remove capacitor if required.

c. On all units remove blower assembly from unit.Remove screws securing blower to blower partition andslide assembly out. Be careful not to tear insulation inblower compartment.

d. Ensure proper reassembly by marking blower wheel andmotor in relation to blower housing before disassembly.

e. Loosen setscrew(s) that secures wheel to motor shaft,remove screws that secure motor mount brackets to

housing, and slide motor and motor mount out ofhousing.

2. Remove and clean blower wheel as follows:

a. Ensure proper reassembly by marking wheel orientation.

b. Lift wheel from housing. When handling and/orcleaning blower wheel, be sure not to disturb balance

weights (clips) on blower wheel vanes.

c. Remove caked-on dirt from wheel and housing with abrush. Remove lint and/or dirt accumulations from

wheel and housing with vacuum cleaner, using softbrush attachment. Remove grease and oil with mildsolvent.

d. Reassemble wheel into housing.

e. Reassemble motor into housing. Be sure setscrews aretightened on motor shaft fiats and not on round part ofshaft. Reinstall blower into unit.

f. Connect 5 pin plug and 4 pin plug to indoor blowermotor. Reinstall capacitor if required.

g. Reinstall blower access panel (see Fig. 17).

3. Restore electrical power to unit. Start unit and check forproper blower rotation and motor speeds during coolingcycles.

24

1A

MOTOR

X_

FAN GRILLE

MOTOR SHAFT

MAX DISTANCE BETWEEN TOP OF FAN GRILLE AND BOTTOM OF FAN BLADE

SIZE "A"

24

3O

36

42

48

6O

IN,

6.3

6.3

7.3

7.6

7.6

7.6

Fig. 16 - Fan Blade Position

MM

160

160

185

193

193

193

A08505

air filter(s). If the drain trough is restricted, clear it with a

"plumbers snake" or similar probe device.

OUTDOOR FAN

I!

Control

Blower Access

Access PanelCompressor PanelAccess Panel

A09214

Fig. 17 - Unit Access Panels

Outdoor Coil, Indoor Coil, and Condensate Drain Pan

Inspect the condenser coil, evaporator coil, and condensate drainpan at least once each year.

The coils are easily cleaned when dry; therefore, inspect and cleanthe coils either before or after each cooling season. Remove allobstructions, including weeds and shrubs, that interfere with theairflow through the condenser coil.

Straighten bent fins with a fin comb. If coated with dirt or lint,clean the coils with a vacuum cleaner, using the soft brushattachment. Be careful not to bend the fins. If coated with oil or

grease, clean the coils with a mild detergent and water solution.Rinse coils with clear water, using a garden hose. Be careful not tosplash water on motors, insulation, wiring, or air filter(s). For bestresults, spray condenser coil fins from inside to outside the unit. Onunits with an outer and inner condenser coil, be sure to cleanbetween the coils. Be sure to flush all dirt and debris from the unitbase.

Inspect the drain pan and condensate drain line when inspectingthe coils. Clean the drain pan and condensate drain by removing allforeign matter from the pan. Flush the pan and drain trough withclear water. Do not splash water on the insulation, motor, wiring, or

UNIT OPERATION HAZARD

Failure to follow this caution may result in damage to unitcomponents.

Keep the condenser fan free from all obstructions to ensureproper cooling operation. Never place articles on top of theunit.

1. Remove 6 screws holding condenser grille and motor to topcover.

2. Turn motor/grille assembly upside down on top cover toexpose the fan blade.

3. Inspect the fan blades for cracks or bends.

4. If fan needs to be removed, loosen the setscrew and slide thefan off the motor shaft.

5. When replacing fan blade, position blade as shown in Fig.16.

6. Ensure that setscrew engages the flat area on the motor shaftwhen tightening

7. Replace grille.

Electrical Controls and Wiring

Inspect and check the electrical controls and wiring annually. Besure to turn off the electrical power to the unit.

Remove access panels (see Fig. 17) to locate all the electricalcontrols and wiring. Check all electrical connections for tightness.Tighten all screw connections. If any smoky or burned connectionsare noticed, disassemble the connection, clean all the parts, restripthe wire end and reassemble the connection properly and securely.

After inspecting the electrical controls and wiring, replace theaccess panels (see Fig. 17). Start the unit, and observe at least onecomplete heating cycle and one complete cooling cycle to ensureproper operation. If discrepancies are observed in either or bothoperating cycles, or if a suspected malfunction has occurred, check

25

each electrical component with the proper electricalinstrumentation. Refer to the unit wiring label when making thesecheckouts.

NOTE: Refer to the heating and/or cooling sequence of operationin this publication as an aid in determining proper controloperation

Refrigerant Circuit

Inspect all refrigerant tubing connections and the unit base for oilaccumulations annually. Detecting oil generally indicates arefrigerant leak.

EXPLOSION, SAFETY AND ENVIRONMENTALHAZARD

Failure to follow this warning could result in personalinjury, death or equipment damage.

This system uses Puron (R-410A) refrigerant which hashigher operating pressures than R-22 and other refrigerants.No other refrigerant may be used in this system. Gauge set,hoses, and recovery system must be designed to handlePuron. If you are unsure, consult the equipmentmanufacturer.

If oil is detected or if low cooling performance is suspected,

leak-test all refrigerant tubing using an electronic leak-detector,

halide torch, or liquid-soap solution. If a refrigerant leak is

detected, refer to Check for Refrigerant Leaks section.

If no refrigerant leaks are found and low cooling performance is

suspected, refer to Checking and Adjusting Refrigerant Chargesection.

Evaporator Airflow

The heating and/or cooling air-flow does not require checkingunless improper performance is suspected. If a problem exists, be

sure that all supply- and return-air grilles are open and free from

obstructions, and that the air filter is clean. When necessary, refer to

Indoor Airflow and Airflow Adjustments section to check the

system airflow.

Puron Items

The indoor metering device is a TXV type device.

Pressure Switches

Pressure switches are protective devices wired into the control

circuit (low voltage). They shut off compressor if abnormally high

or low pressures are present in the refrigeration circuit. These

pressure switches are specifically designed to operate with Puron

(R-410A) systems. R-22 pressure switches must not be used as

replacements for the Puron (R-410A) air conditioner.

Loss of Charge/Low-Pressure Switch (Air ConditionerOnly)This switch is located on the liquid line and protects against low

suction pressures caused by such events as loss of charge, low

airflow across indoor coil, dirty filters, etc. It opens on a pressure

drop at about 20 psig (957 Pa). If system pressure is above this,switch should be closed.

To check switch:

1. Turn off all power to unit.

2. Disconnect leads on switch.

3. Apply ohmmeter leads across switch. You should have

continuity on a good switch.

NOTE: Because these switches are attached to refrigeration

system under pressure, it is not advisable to remove this device for

troubleshooting unless you are reasonably certain that a problem

exists. If switch must be removed, remove and recover all system

charge so that pressure gauges read 0 psi (0 Pa). Never open system

without breaking vacuum with dry nitrogen.

High-Pressure Switch

The high-pressure switch is located in the discharge line andprotects against excessive condenser coil pressure. It opens at 650

psig (31.1 kPa). High pressure may be caused by a dirty condensercoil, failed fan motor, or condenser air recirculation.

To check switch:

1. Turn off all power to unit.

2. Disconnect leads on switch.

3. Apply ohmmeter leads across switch. You should have

continuity on a good switch.

Copeland Scroll Compressor (Puron Refrigerant)

The compressor used in this product is specifically designed to

operate with Puron (R-410A) refrigerant and cannot be

interchanged.

The compressor is an electrical (as well as mechanical) device.

Exercise extreme caution when working near compressors. Power

should be shut off, if possible, for most troubleshooting techniques.

Refrigerants present additional safety hazards.

FIRE/EXPLOSION HAZARD

Failure to follow this warning could result in personalinjury or death and/or property damage.

Wear safety glasses and gloves when handling refrigerants.Keep torches and other ignition sources away fromrefrigerants and oils.

The scroll compressor pumps refrigerant throughout the system by

the interaction of a stationary and an orbiting scroll. The scroll

compressor has no dynamic suction or discharge valves, and it is

more tolerant of stresses caused by debris, liquid slugging, and

flooded starts. The compressor is equipped with a noise reducing

shutdown device and an internal pressure relief port. The pressure

relief port is a safety device, designed to protect against extreme

high pressure. The relief port has an operating range between 550

(26.3 kPa) and 625 (29.9 kPa) psig differential pressure.

Refrigerant

EXPLOSION, ENVIRONMENTAL HAZARD

Failure to follow this warning could result in personalinjury, death or equipment damage.

This system uses Puron (R-410A) refrigerant which hashigher operating pressures than R-22 and other refrigerants.No other refrigerant may be used in this system. Gauge set,hoses, and recovery system must be designed to handlePuron. If you are unsure, consult the equipmentmanufacturer.

This system uses Puron (R-410A) refrigerant which has higher

operating pressures than R-22 and other refrigerants. No other

refrigerant may be used in this system. Gage set, hoses, and

recovery system must be designed to handle Puron. If you are

unsure, consult the equipment manufacturer. Failure to use Puron

compatible servicing equipment or replacement components may

result in property damage or injury.

Compressor Oil

The Copeland scroll compressor uses 3MAF POE oil. If additional

oil is needed, use Uniqema RL32-3MAF. If this oil is not

available, use Copeland Ultra 32 CC or Mobil Arctic EAL22 CC.

This oil is extremely hygroscopic, meaning it absorbs water

26

readily.POEoilscanabsorb15timesasmuchwaterasotheroilsdesignedforHCFCandCFCrefrigerants.Takeallnecessaryprecautionstoavoidexposureoftheoiltotheatmosphere.

Servicing Systems on Roofs with Synthetic Materials

POE (polyolester) compressor lubricants are known to cause long

term damage to some synthetic roofing materials. Exposure, even if

immediately cleaned up, may cause embrittlement (leading to

cracking) to occur in one year or more. When performing any

service that may risk exposure of compressor oil to the roof, take

appropriate precautions to protect roofing. Procedures which risk

oil leakage include, but are not limited to, compressor replacement,

repairing refrigerant leaks, replacing refrigerant components such

as filter drier, pressure switch, metering device, coil, accumulator,

or reversing valve.

Synthetic Roof Precautionary Procedure

1. Cover extended roof working area with an impermeable

polyethylene (plastic) drip cloth or tarp. Cover an

approximate 10 x 10 ft (3 x 3 m) area.

2. Cover area in front of the unit service panel with a terry

cloth shop towel to absorb lubricant spills, prevent run-offs,

and protect drop cloth from tears caused by tools or

components.

3. Place terry cloth shop towel inside unit immediately under

component(s) to be serviced and prevent lubricant run-offs

through the louvered openings in the unit base.

4. Perform required service.

5. Remove and dispose of any oil contaminated material perlocal codes.

Liquid Line Filter Drier

The filter drier is specifically designed to operate with Puron. Use

only factory-authorized components. Filter drier must be replaced

whenever the refrigerant system is opened. When removing a filter

drier, use a tubing cutter to cut the drier from the system. Do not

unsweat a filter drier from the system. Heat from unsweating will

release moisture and contaminants from drier into system.

Puron (R-410A} Refrigerant Char_in_

Refer to unit information plate and charging chart. Some R-410A

refrigerant cylinders contain a dip tube to allow liquid refrigerant toflow from cylinder in upright position. For cylinders equipped

with a dip tube, charge Puron units with cylinder in upright

position and a commercial metering device in manifold hose.

Charge refrigerant into suction-line.

TROUBLESHOOTING

Refer to the Troubleshooting Chart (Table 10) for troubleshootinginformation.

START-UP CHECKLIST

Use the Start-Up Checklist at the back of this manual.I!

27

Table 10 - Troubleshooting Chart

SYMPTOM

Compressor and outdoor fan will not start

Compressor will not start but condenser fanruns

Three-phase scroll compressor (size 30-

60 unit) has a low pressure differential

Compressor cycles (other than normallysatisfying) cooling/heating calls

Compressor operates continuously

Excessive head pressure

Head pressure too low

Excessive suction pressure

Suction pressure too low

CAUSE

Power failure

Fuse blown or circuit breaker tripped

Defective contactor, transformer, control relay, or high-pressure, loss-of-charge or low-pressure switch

Insufficient line voltage

Incorrect or faulty wiring

Thermostat setting too low/too high

Faulty wiring or circuitLoose connections in compressor

Compressor motor burned out, seized, or

internal overload open

Defective run capacitor, overload, or PTC (positivetemperature coefficient) thermistor

REMEDY

Call power company

Replace fuse or reset circuit breaker

Replace component

Determine cause and correct

Check wiring diagram and rewire correctly

Reset thermostat setting

Check wiring and repair or replace

Determine cause

Replace compressor

Determine cause and replace

One leg of 3-phase power dead

Low input voltage

Scroll compressor is rotating in the wrong direction

Refrigerant overcharge or undercharge

Defective compressor

Insufficient line voltageBlocked outdoor coil

Defective run/start capacitor, overload or start relay

Faulty outdoor fan motor or capacitor

Restriction in refrigerant system

Dirty air filterUnit undersized for load

Thermostat temperature set too low

Low refrigerant charge

Air in system

Outdoor coil dirty or restricted

Dirty air filter

Dirty indoor or outdoor coil

Refrigerant overcharged

Air in system

Indoor or outdoor air restricted or air short-cycling


Restriction in liquid tube

Refrigerant overcharged

Dirty air filter


Metering device or low side restrictedInsufficient coil airflow

Temperature too low in conditioned area

Outdoor ambient below 55°F (13°C)Filter drier restricted

Replace fuse or reset circuit breakerDetermine cause


Correct the direction of rotation by reversing the

3-phase power leads to the unit

Recover refrigerant, evacuate system, and re-charge to capacities shown on rating plate

Replace and determine causeDetermine cause and correct


Determine cause and replace

Replace

Locate restriction and remove

Replace filterDecrease load or increase unit size

Reset thermostat setting

Locate leak, repair, and recharge

Recover refrigerant, evacuate system, and re-charge

Clean coil or remove restriction

Replace filterClean coil

Recover excess refrigerant

Recover refrigerant, evacuate system, and re-charge


Check for leaks, repair and rechargeRemove restriction

Recover excess refrigerant

Replace filter

Check for leaks, repair and recharge

Remove source of restriction

Check filter-replace if necessary

Reset thermostat settingInstall low-ambient kit

Replace

28

AIR CONDITIONER WITH PURON (R-410A) QUICK REFERENCE GUIDE

Puron refrigerant operates at 50-70 percent higher pressures than R-22. Be sure that servicing equipment and replacement components aredesigned to operate with Puron. Puron refrigerant cylinders are rose colored.

• Puron refrigerant cylinders manufactured prior to March 1, 1999, have a dip tube that allows liquid to flow out of cylinder in upright

position.

Cylinders manufactured March 1, 1999 and later DO NOT have a dip tube and MUST be positioned upside down to allow liquid to flow.

• Recovery cylinder service pressure rating must be 400 psig. DOT 4BA400 or DOT BW400.

• Puron systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose.

• Manifold sets should be minimum 700 psig high-side and 180 psig low-side with 550 psig low-side retard.

• Use hoses with nfinimum 700 psig service pressure rating.

• Leak detectors should be designed to detect HFC refrigerant.

• Puron, as with other HFCs, is only compatible with POE oils.

• Vacuum pumps will not remove moisture from oil.

• Only use factory specified liquid-line filter driers with rated working pressures no less than 600 psig.

• Do not install a suction-line filter drier in liquid line.

• POE oils absorb moisture rapidly. Do not expose oil to atmosphere.

• POE oils may cause damage to certain plastics and roofing materials.

• Wrap all filter driers and service valves with wet cloth when brazing.

• A Puron liquid-line filter drier is required on every unit.

• Do not use an R-22 TXV.

• Never open system to atmosphere while it is under a vacuum.

• When system must be opened for service, break vacuum with dry nitrogen and replace filter driers.

• Always replace filter drier after opening system for service.

• Do not vent Puron into the atmosphere.

• Observe all warnings, cautions, and bold text.

• Do not leave Puron suction line driers in place for more than 72 hrs.

29

I.PRELIMINARYINFORMATIONMODELNO.:SERIALNO.:DATE:TECHNICIAN:

START-UP CHECKLIST

(Remove and Store in Job Files)

II. PRESTART-UP (Insert check mark in box as each item is completed)

( ) VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT

( ) REMOVE ALL SHIPPING HOLD DOWN BOLTS AND BRACKETS PER INSTALLATION INSTRUCTIONS

( ) CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS

( ) CHECK THAT INDOOR (EVAPORATOR) AIR FILTER IS CLEAN AND IN PLACE

( ) VERIFY THAT UNIT INSTALLATION IS LEVEL

( ) CHECK FAN WHEEL, AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW TIGHTNESS

III. START-UP

ELECTRICAL

SUPPLY VOLTAGE

COMPRESSOR AMPS

INDOOR (EVAPORATOR) FAN AMPSTEMPERATURES

OUTDOOR (CONDENSER) AIR TEMPERATURE

RETURN-AIR TEMPERATURE DB

COOLING SUPPLY AIR DB

PRESSURES

REFRIGERANT SUCTION

REFRIGERANT DISCHARGE

( ) VERIFY REFRIGERANT CHARGE USING CHARGING CHARTS* Measured at suction inlet to compressor1- Measured at liquid line leaving condenser.

DB

WB

WB

PSIG, SUCTION LINE TEMP*

PSIG, LIQUID TEMPi-

Copyright 2010 Carrier Corp. • 7310 W. Morris St. • Indianapolis, IN 46231 Edition Date: 09/10

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

Catalog No:5OVL-07SI

Replaces: 50VL- 06Sl

3O

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