Heat Controller Inc Air Conditioner R 22 User Manual

Split SyStem air conditioner  
r-22, 13 Seer  
USer’S manUal / inStallation inStrUctionS  
StartUp & adjUStmentS ............................... 6  
Pre - Start Checklist.............................................. 6  
Start-up Procedures.............................................. 6  
Air Circulation - Indoor Blower .......................... 9  
System Cooling................................................. 7  
System Heating................................................. 7  
refrigerant charging................................. 7  
Charging R-22 Units in AC Mode with  
Outdoor Temperatures Above 55° F...................... 7  
USer information  
important Safety information ................. 2  
operating inStrUctionS............................... 2  
Cooling Operation ................................................. 2  
Heating Operation................................................. 2  
Operating the Air Conditioner for Automatic  
Cooling & Heating................................................. 2  
Operating the Indoor Blower Continuously ........... 2  
Turning the Air Conditioner Off.............................. 2  
air conditioner maintenance.................... 8  
replacement partS........................................ 8  
air conditioner maintenance.................... 2  
troUbleShooting ........................................... 2  
figUreS & tableS ............................................. 9  
Figure 3. Unit Dimensions ................................ 9  
Refrigerant Charging Charts................................. 9  
Figure 4. Charging Chart for 1.5 Ton Units........ 9  
Figure 5. Charging Chart for 2 Ton Units ........ 10  
Figure 6. Charging Chart for 2.5 Ton Units ..... 10  
Figure 7. Charging Chart for 3 Ton Units ........ 11  
Figure 8. Charging Chart for 3.5 Ton Units...... 11  
Figure 9. Charging Chart for 4 Ton Units......... 12  
Figure 10. Charging Chart for 5 Ton Units....... 12  
Refrigerant Charging Tables................................ 13  
Table 4. Charging Table for 1.5 Ton Units........ 13  
Table 5. Charging Table for 2 Ton Units........... 13  
Table 6. Charging Table for 2.5 Ton Units........ 14  
Table 7. Charging Table for 3 Ton Units........... 14  
Table 8. Charging Table for 3.5 Ton Units........ 15  
Table 9. Charging Table for 4 Ton Units........... 15  
Table 10. Charging Table for 5 Ton Units......... 16  
Electrical Information .......................................... 16  
Table 18. Electrical Specs & Physical Data..... 16  
Figure 11. Wiring Diagram............................... 17  
inStaller information  
important Safety information ................. 3  
air conditioner inStallation .................... 4  
General Information .............................................. 4  
Before You Install this Unit..................................... 4  
Locating the Air Conditioner.................................. 4  
Packaging Removal .............................................. 4  
Ground Level......................................................... 4  
Connecting Refrigerant Tubing between the  
Indoor & Outdoor Unit........................................... 5  
electrical Wiring........................................... 5  
Pre - Electrical Checklist ....................................... 5  
Line Voltage........................................................... 5  
Grounding ............................................................. 6  
Thermostat Connections....................................... 6  
Positive Temp. Coefficient Resistor (PTCR) .......... 6  
inStall. / performance checKliSt......... 20  
important  
attention inStallerS:  
it is your responsibility to know this product better than your customer.this includes being able to install the product  
according to strict safety guidelines and instructing the customer on how to operate and maintain the equipment for  
the life of the product. Safety should always be the deciding factor when installing this product and using common  
sense plays an important role as well. pay attention to all safety warnings and any other special notes highlighted  
in the manual. improper installation of the furnace or failure to follow safety warnings could result in serious injury,  
death, or property damage.  
these instructions are primarily intended to assist qualied individuals experienced in the proper installation of  
this appliance. Some local codes require licensed installation/service personnel for this type of equipment. please  
read all instructions carefully before starting the installation. return these instructions to the customer’s package  
for future reference.  
do not deStroy. pleaSe read carefUlly and Keep in a Safe place for fUtUre reference.  
inStaller information  
important Safety information  
caUtion:  
this unit uses r-22 refrigerant. do not use  
any other refrigerant in this unit.Use of another  
refrigerant will damage the unit.  
INSTALLER:Please read all instructions before servicing  
this equipment. Pay attention to all safety warnings and  
any other special notes highlighted in the manual. Safety  
markings are used frequently throughout this manual to  
designateadegreeorlevelofseriousnessandshouldnot  
be ignored. Warning indicates a potentially hazardous  
situation that if not avoided, could result in personal injury  
or death. caUtion indicates a potentially hazardous  
situationthatifnotavoided,mayresultinminorormoderate  
injury or property damage.  
Warning:  
the information listed below must be followed  
during the installation, service, and operation  
of this unit. Unqualied individuals should  
not attempt to interpret these instructions or  
install this equipment. failure to follow safety  
recommendations could result in possible  
damage to the equipment, serious personal  
Warning:  
Shut off all electrical power to the unit before  
performing any maintenance or service on the  
system.failuretocomplymayresultinpersonal  
injury or death.  
injury or death  
.
The installer must comply with all local codes and  
regulations which govern the installation of this type  
of equipment. Local codes and regulations take  
precedence over any recommendations contained in  
these instructions. Consult local building codes and  
the National Electrical Code (ANSI CI) for special  
installation requirements.  
Warning:  
Unless noted otherwise in these instructions,  
only factory authorized parts or accessory  
kits may be used with this product. improper  
installation,service,adjustment,ormaintenance  
may cause explosion, fire, electrical shock or  
other hazardous conditions which may result  
in personal injury or property damage  
All electrical wiring must be completed in accordance  
with local, state and national codes and regulations  
and with the National Electric Code (ANSI/NFPA 70)  
or in Canada the Canadian Electric Code Part 1 CSA  
C.22.1.  
Thisequipmentcontainsliquidandgaseousrefrigerant  
underhighpressure.DONOTUSEANYPORTIONOF  
THE CHARGE FOR PURGING OR LEAK TESTING.  
Installation or servicing should only be performed by  
qualifiedtrainedpersonnelthoroughlyfamiliarwiththis  
type equipment.  
Warning:  
this split system air conditioner left the  
factory with a nitrogen holding charge. follow  
all charging instructions for maximum unit  
performance and efficiency. Some local  
codes require licensed installation/service  
personnel to service this type of equipment.  
refrigerant charging must be done by qualied  
personnelfamiliarwithsafeandenvironmentally  
responsible refrigerant handling procedures.  
Under no circumstances should the owner  
attempttoinstalland/orservicethisequipment.  
failure to comply with this warning could result  
in property damage, personal injury, or death.  
Fully annealed, refrigerant grade copper tubing should  
beusedwheninstallingthesystem.Refrigerantsuction  
line tubing should be fully insulated.  
Installation of equipment may require brazing  
operations. Installer must comply with safety codes  
andwearappropriatesafetyequipment(safetyglasses,  
work gloves, fire extinguisher, etc.) when performing  
brazing operations.  
Follow all precautions in the literature, on tags, and  
on labels provided with the equipment. Read and  
thoroughly understand the instructions provided with  
the equipment prior to performing the installation and  
operational checkout of the equipment.  
3
packaging removal  
air conditioner inStallation  
note: To prevent damage to the tubing connections,  
carefully remove the carton and user’s manual from the  
equipment. Discard the shipping carton.  
general information  
Splitsystemairconditionersaredesignedonlyforoutdoor  
rooftop or ground level installations. This unit has been  
tested for capacity and efficiency in accordance with  
AHRI Standards and will provide many years of safe  
and dependable comfort, providing it is properly installed  
and maintained. Abuse, improper use, and/or improper  
maintenance can shorten the life of the appliance and  
create unsafe hazards.  
ground level  
Ground level installations must be located according to  
localbuildingcodesorordinancesandtheserequirements:  
Clearances must be in accordance with those shown  
in Figure 2.  
Asuitablemountingpadmustbeprovidedandseparate  
from the building foundation. The pad must be level  
and strong enough to support the weight of the unit.  
The slab height must be a minimum of 2(5 cm) above  
grade and with adequate drainage. See Figure 2.  
Toachieveoptimumperformanceandminimizeequipment  
failure, it is recommended that periodic maintenance be  
performed on this unit. The ability to properly perform  
maintenance on this equipment requires certain  
mechanical skills and tools.  
roof mount  
The method of mounting should be designed so that it  
does not overload roof structures or transmit noise to  
theinteriorofthestructure.Theroofmustbestructurally  
capable of handling the weight of the unit.  
Full perimeter support is required under the unit.  
Support must be made of weather resistant materials  
and installed prior to unit installation.  
before you install this Unit  
The cooling load of the area to be conditioned must be  
calculatedandasystemofthepropercapacityselected.  
It is recommended that the area to be conditioned be  
completely insulated and vapor sealed.  
Checktheelectricalsupplyandverifythepowersupply  
isadequateforunitoperation.Thesystemmustbewired  
and provided with circuit protection in accordance with  
localbuildingcodes.Ifthereisanyquestionconcerning  
the power supply, contact the local power company.  
Theindoorsection(airhandler, furnace, etc)shouldbe  
installed before routing the refrigerant tubing. Refer to  
the indoor unit's installation instructions for installation  
details.  
The support must be built to raise the unit 6" above  
the roof.  
6” from Building  
or Structure  
Allunitsaresecurelypackedatthetimeofshipmentand  
upon arrival should be carefully inspected for damage  
prior to installing the equipment at the job site. Verify  
coil fins are straight.If necessary, comb fins to remove  
flattened or bent fins. Claims for damage (apparent or  
concealed)shouldbeledimmediatelywiththecarrier.  
Pleaseconsultyourdealerformaintenanceinformation  
and availability of maintenance contracts.Please read  
all instructions before installing the unit.  
24" for  
Service Access  
12" or 18”  
See Note  
DO NOT  
OBSTRUCT  
TOP OF UNIT  
12" or 18”  
See Note  
locating the air conditioner  
Survey the job site to determine the best location for  
mounting the outdoor unit. See Figure 3 (page 9) for  
unit dimensions.  
NOTE: Units require full perimeter clearances. Installer must maintain  
18” between two units or 12” between single unit and structure.  
Overhead obstructions (Figure 2), poorly ventilated  
areas, and areas subject to accumulation of debris  
should be avoided.  
Sufficientclearanceforunobstructedairflowthroughthe  
outdoorcoilmustbemaintainedinordertoachieverated  
performance.See Figure 2 for minimum clearances to  
obstructions.  
48”  
Consideration should be given to availability of electric  
power, service access, noise, and shade.  
2” Mounting Pad  
figure 2. clearance requirements  
4
connecting refrigerant tubing between the indoor  
& outdoor Unit  
To maintain the unit's warranty, it is required that a  
filter drier be installed when the system is open to  
the atmosphere. This includes, but is not limited to,  
replacingtheevaporatorand/orcondenserofasystem.  
The filter drier must be installed in strict accordance  
with the manufacturer’s installation instructions.  
Optional equipment such as liquid line solenoid  
valves, low ambient, etc., should be installed in  
strict accordance with the manufacturer’s installation  
instructions.  
caUtion:  
this system uses r-22 refrigerant which may  
contain poe oil. When servicing, cover or seal  
openings to minimize the exposure of the  
refrigerantsystemtoairtopreventaccumulation  
of moisture and other contaminants. See page  
8 for additional info.  
electrical Wiring  
After outdoor and indoor unit placement has been  
determined, route refrigerant tubing between the  
equipmentinaccordancewithsoundinstallationpractices.  
Warning:  
to avoid risk of electrical shock, personal  
injury, or death, disconnect all electrical power  
to the unit before performing any maintenance  
or service. the unit may have more than one  
When connecting refrigerant linesets together, it is  
recommended that dry nitrogen be flowing through  
the joints during brazing to prevent internal oxidation  
and scaling.  
Refrigerant tubing should be routed in a manner that electrical supply.  
minimizesthelengthoftubingandthenumberofbends  
label all wires prior to disconnection when  
servicing the unit. Wiring errors can cause  
improper and dangerous operation.  
in the tubing. If precise forming of refrigerant lines is  
required, a copper tubing bender is recommended.  
Avoid sharp bends and contact of the refrigerant lines  
with metal surfaces.  
Refrigerant tubing should be supported in a manner  
that the tubing will not vibrate or abrade during system  
operation.  
All electrical connections must be in compliance with  
all applicable local codes and ordinances, and with  
the current revision of the National Electric Code  
(ANSI/NFPA 70).  
Tubing should be kept clean of foreign debris during  
installation.  
For Canadian installations the electrical connections  
and grounding shall comply with the current Canadian  
Electrical Code (CSA C22.1 and/or local codes).  
Every effort should be made by the installer to ensure  
thattheeldinstalledrefrigerantcontainingcomponents  
of the system have been installed in accordance with  
these instructions and sound installation practices to  
insure reliable system operation and longevity.  
The maximum recommended interconnecting  
refrigerantlinelengthsis75ft.andtheverticalelevation  
difference between the indoor and outdoor sections  
should not exceed 20 ft.  
pre-electrical checklist  
Verify that the voltage, frequency, and phase of the  
supply source match the specifications on the unit  
rating plate. See Table 11 (page 16).  
Verifythattheserviceprovidedbytheutilityissufficient  
tohandletheadditionalloadimposedbythisequipment.  
Refer to the unit wiring label for proper voltage wiring.  
Verify factory wiring is in accordance with the unit  
wiring diagram (Figure 11, page 17). Inspect for loose  
connections.  
copper Wire SiZe — aWg  
(1% Voltage drop)  
line Voltage  
Supply Wire length-feet  
Supply circuit  
ampacity  
A wiring diagram is located on the inside cover of the  
electrical box of the outdoor unit. The installer should  
becomefamiliarwiththewiringdiagrambeforemaking  
any electrical connections to the outdoor unit.  
200  
6
150  
8
100  
10  
8
50  
14  
12  
10  
10  
8
15  
20  
25  
30  
35  
40  
45  
50  
55  
60  
4
6
4
6
8
an electrical disconnect must be located within  
sight of and readily accessible to the unit. This  
switch shall be capable of electrically de-energizing  
the outdoor unit.  
4
4
6
3
4
6
3
4
6
8
2
3
4
6
Line voltage to the unit should be supplied from a  
dedicated branch circuit containing the correct fuse  
or circuit breaker for the unit. Incoming field wiring  
and minimum size of electrical conductors and circuit  
protectionmustbeincompliancewithinformationlisted  
ontheoutdoorunitdatalabel.Anyotherwiringmethods  
must be acceptable to authority having jurisdiction.  
2
3
4
6
2
3
4
6
1
2
3
4
note: Wire Size based on N.E.C. for 60° type copper conductors.  
table 1. copper Wire Size  
5
Theoutdoorunitrequiresbothpowerandcontrolcircuit thermostat connections  
electrical connections. Refer to the wiring diagram /  
schematicforidentificationandlocationofoutdoorunit  
field wiring interfaces (Figure 11, page 17). Make all  
electricalconnectionsinaccordancewithallapplicable  
codes and ordinances.  
Overcurrent protection must be provided at the branch  
circuitdistributionpanelandsizedasshownontheunit  
rating label and according to applicable local codes.  
See the unit rating plate for minimum circuit ampacity  
and maximum overcurrent protection limits.  
Providepowersupplyfortheunitinaccordancewiththe  
unit wiring diagram, and the unit rating plate. Connect  
the line-voltage leads to the terminals on the contactor  
inside the control compartment.  
Use only copper wire for the line voltage power supply  
to this unit as listed in Table 1 (page 5). Use proper  
code agency listed conduit and a conduit connector  
for connecting the supply wires to the unit. Use of rain  
tight conduit is recommended.  
208/230 Volt units are shipped from the factory wired  
for 230 volt operation.For 208V operation, remove the  
lead from the transformer terminal marked 240V and  
connect it to the terminal marked 208V.  
Optional equipment requiring connection to the power  
or control circuits must be wired in strict accordance  
of the NEC (ANSI/NFPA 70), applicable local codes,  
and the instructions provided with the equipment.  
Thermostatconnectionsshouldbemadeinaccordance  
with the instructions supplied with the thermostat and  
the indoor equipment.  
The outdoor unit is designed to operate from a 24 VAC  
Class II control circuit. The control circuit wiring must  
comply with the current provisions of the NEC (ANSI/  
NFPA 70) and with applicable local codes having  
jurisdiction.  
The low voltage wires must be properly connected to  
the units low voltage terminal block. Recommended  
wire gauge and wire lengths for typical thermostat  
connections are listed in Table 2.  
The thermostat should be mounted about 5 feet  
above the floor on an inside wall. DO NOT install the  
thermostat on an outside wall or any other location  
whereitsoperationmaybeadverselyaffectedbyradiant  
heat from fireplaces, sunlight, or lighting fixtures, and  
convective heat from warm air registers or electrical  
appliances. Refer to the thermostat manufacturer’s  
instruction sheet for detailed mounting and installation  
information.  
Start Up & adjUStmentS  
pre-Start check list  
Verify the indoor unit is level and allows proper  
condensate drainage.  
Verify the outdoor coil and top of the unit are free from  
obstructions and debris, and all equipment access/  
control panels are in place.  
grounding  
Verify air filters are cleaned and properly installed.  
Verify duct work is sealed to prevent air leakage.  
Verify line voltage power leads are securely connected  
and the unit is properly grounded.  
Verify low voltage wires are securely connected to the  
correct leads on the low voltage terminal strip.  
Verifypowersupplybranchcircuitovercurrentprotection  
is sized properly.  
Warning:  
the unit cabinet must have an uninterrupted or  
unbroken electrical ground to minimize personal  
injury if an electrical fault should occur. do not  
use gas piping as an electrical ground!  
This unit must be electrically grounded in accordance  
with local codes or, in the absence of local codes, with  
the National Electrical Code (ANSI/NFPA 70) or the CSA  
C22.1 Electrical Code.Use the grounding lug provided in  
the control box for grounding the unit.  
Verify the thermostat is wired correctly.  
Start-Up procedures  
The thermostat's function mode should be set to OFF and  
the fan mode should be set to AUTO. Close all electrical  
disconnects to energize the system.  
Air Circulation - Indoor Blower  
recommended t-Stat Wire  
1. Set the thermostat system mode on OFF and the fan  
mode to ON.  
Unit to t-Stat (length in ft)  
thermostat  
Wire gauge  
2-Wire  
5-Wire  
2. Verify the blower runs continuously. Check the air  
delivery at the supply registers and adjust register  
openings for balanced air distribution.If insufficient air  
isdetected,examineductworkforleaksorobstructions.  
3. Set the thermostat fan mode to AUTO and verify the  
blower stops running.  
(Heating)  
(Heating/Cooling)  
24  
22  
20  
18  
55  
90  
25  
45  
140  
225  
70  
110  
table 2.thermostat Wire gauge  
6
System Cooling  
1. Set the thermostat’s system mode to COOL and the  
3. Leak check and evacuate the whole system using  
proper methods.  
fan mode to AUTO. Gradually lower the thermostat 4. Purge the nitrogen holding charge.  
temperature setpoint below room temperature and 5. Evacuate the unit to 350-500 microns.  
verify the outdoor unit and indoor blower energize.  
2. Verifyblowerwheelisspinningindirectionindicatedby  
6. Allow the unit to remain under vacuum for at least 30  
min.  
arrow.Feeltheairbeingcirculatedbytheindoorblower 7. Weigh-In the proper amount of new (or reclaimed)  
and verify that it is cooler than ambient temperature.  
Listen for any unusual noises. If unusual sounds  
occur, determine the source of the noise and correct  
as necessary.  
R-22 refrigerant. Refer to Table 3 or the units rating  
label to determine the correct amount of charge.  
Refrigerant charging charts are applicable only to  
matched assemblies of this equipment and listed  
airflows for the indoor coil. Refer to Figures 4 - 10  
(Pages 9 - 12) for correct system charging.  
Outdoor units with indoor coils not listed are not  
recommended. Deviations from rated airflows or non-  
listed combinations may require modification to the  
expansiondeviceandrefrigerantchargingprocedures  
for proper and efficient system operation.  
The refrigerant charge can be checked and adjusted  
through the service ports provided external to the  
outdoor unit. Use only gage line sets which have a  
“Schrader” depression device present to actuate the  
valve.  
3. Verify HI and LO refrigerant pressures.  
4. Allow the system to operate for several minutes  
and then set the temperature selector above room  
temperature. Verify the fan and compressor cycle off  
with the thermostat. note: The blower should also  
stop unless fan mode is set to the ON position.  
System Heating (optional)  
1. Set the thermostat's system mode to HEAT and the  
temperature mode above room temperature.  
2. Verify the optional heating equipment (furnace or  
electric heat) and indoor blower energize.Feel the air  
being circulated by the indoor blower and verify that  
it is warmer than ambient temperature. Listen for any  
unusual noises. If unusual sounds occur, determine  
the source of the noise and correct as necessary.  
Charging an R-22 system in AC mode at outdoor tem-  
peratures above 55° F for optimized sub-cooling of 10°  
F - 12° F.  
1. With the system operating at steady-state, measure  
the liquid refrigerant pressure (in psig) at the outdoor  
unit service valve.  
2. Measure the liquid refrigerant temperature (in  
Fahrenheit) at the service valve.  
refrigerant charging  
Warning:  
this split system air conditioner left the factory  
with a nitrogen holding charge. do not  
operate any unit while it contains a nitrogen  
holding charge. doing so may damage the  
units compressor. follow these charging  
instructionsformaximumunitperformanceand  
efciency. Some local codes require licensed  
installation/service personnel to service this  
type of equipment. refrigerant charging must  
bedonebyqualiedpersonnelfamiliarwithsafe  
and environmentally responsible refrigerant  
handling procedures. Under no circumstances  
should the owner attempt to install and/or  
service this equipment. failure to comply with  
this warning could result in property damage,  
personal injury, or death.  
3. Determine the required liquid refrigerant pressure.  
Refer to Tables 4 - 10 (pages 13 - 16) for correct  
system charging.  
If the pressure measured in Step 1 is greater than  
the required liquid refrigerant pressure determined in  
Step 3, then there is too much charge in the system.  
Remove refrigerant and repeat Steps 1 through 3 until  
the system is correctly charged.  
If the pressure measured in Step 1 is less than the  
required liquid refrigerant pressure determined in  
Step 3, there is too little charge in the system. Add  
refrigerant and repeat Steps 1 through 3 until the  
system is correctly charged.  
model  
number  
restrictor bore  
Size (inches)  
System charge  
r-22 (oz.)  
018KA  
024KB  
030KB  
036KB  
042KA  
048KA  
060KA  
0.053  
0.060  
0.065  
0.075  
0.078  
0.089  
0.099  
78  
53  
This unit may contain a compressor with POE oil. If the  
compressor model contains an E before the first hyphen,  
then it is a POE oil compressor. If it does not then it is a  
mineral oil compressor. (Example: ZR42K5E-PFV-130  
is a POE oil compressor, while ZR42K5-PFV-130 is a  
mineral oil compressor).  
56  
68  
122  
126  
160  
table 3. refrigerant metering device  
for 13 Seer Split System air conditioner  
To properly charge these units:  
1. Read all Installation Instructions first.  
2. Complete any brazing operations. (e.g. Split system  
line-sets)  
7
air conditioner maintenance  
caUtion:  
the unit should never be operated without a  
lterinthereturnairsystem.replacedisposable  
lters with the same type and size.  
Warning:  
to prevent electrical shock, personal injury, or  
death,disconnect all electrical power to the unit  
before performing any maintenance or service.  
the unit may have more than one electrical  
supply.  
Do not attempt to add additional oil to motors  
unequipped with oil tubes. The compressor is  
hermeticallysealedatthefactoryanddoesnotrequire  
lubrication.  
Proper maintenance is important to achieve optimum  
performancefromtheairconditioner.Theabilitytoproperly  
perform maintenance on this equipment requires certain  
mechanical skills and tools. If you do not possess these  
skills, contact your dealer for maintenance. Consult your  
localdealerabouttheavailabilityofmaintenancecontracts.  
Routine maintenance should include the following:  
replacement partS  
Replacement parts are available through your distributor.Please  
have the complete model and serial number of the unit when  
ordering replacement parts.  
electrical:  
Capacitors  
Compressors  
Contactors  
Temperature Limit Switches  
Inspect and clean or replace air filters at the beginning  
ofeachheatingandcoolingseason,ormorefrequently  
if required.  
Inspect the condensate drain and outdoor coil at the  
beginningofeachcoolingseason.Removeanydebris.  
Clean the outdoor coil and louvers as necessary using  
amilddetergentandwater.Rinsethoroughlywithwater.  
Inspect the electrical connections for tightness at the  
beginningofeachheatingandcoolingseason.Service  
as necessary.  
Thermostats  
Time Delay Relays  
Transformers  
Pressure Switches  
Relays  
motorS:  
Blower Motor  
Fan Motor  
componentS:  
Blower Assembly  
Cabinet Panels  
Fan Grille  
Filter/Driers  
Expansion Valves  
8
figUreS & tableS  
D
W
H
*picture is representative only, may not be exact match  
Unit Size (ton)  
1.5 Ton  
2 Ton  
height -h-  
23"  
Width -W-  
22 3/4"  
22 3/4"  
22 3/4"  
22 3/4"  
30 3/4"  
30 3/4"  
30 3/4"  
depth -d-  
22 3/4"  
22 3/4"  
22 3/4"  
22 3/4"  
30 3/4"  
30 3/4"  
30 3/4"  
23"  
2.5 Ton  
3 Ton  
27"  
27"  
3.5 Ton  
4 Ton  
31"  
31"  
5 Ton  
43"  
figure 3. Unit dimensions  
tXV cooling charging chartS  
400  
380  
360  
340  
320  
300  
280  
260  
240  
220  
200  
180  
160  
140  
Remove refrigerant when above curve  
Add refrigerant when below curve  
75  
80  
85  
90  
95  
100 105 110 115 120 125 130 135  
Liquid Temperature (F)  
figure 4. charging chart for 1.5 ton Units  
9
400  
380  
360  
340  
320  
300  
280  
260  
240  
220  
200  
180  
160  
140  
Remove refrigerant when above curve  
Add refrigerant when below curve  
75  
80  
85  
90  
95  
100 105 110 115 120 125 130 135  
Liquid Temperature (F)  
figure 5. charging chart for 2 ton Units (with microchannel coil)  
400  
380  
360  
340  
320  
300  
280  
260  
240  
220  
200  
180  
160  
140  
Remove refrigerant when above curve  
Add refrigerant when below curve  
75  
80  
85  
90  
95  
100 105 110 115 120 125 130 135  
Liquid Temperature (F)  
figure 6. charging chart for 2.5 ton Units (with microchannel coil)  
10  
400  
380  
360  
340  
320  
300  
280  
260  
240  
220  
200  
180  
160  
140  
Remove refrigerant when above curve  
Add refrigerant when below curve  
75  
80  
85  
90  
95  
100 105 110 115 120 125 130 135  
Liquid Temperature (F)  
figure 7. charging chart for 3 ton Units (with microchannel coil)  
400  
380  
360  
340  
320  
300  
280  
260  
240  
220  
200  
180  
160  
140  
Remove refrigerant when above curve  
Add refrigerant when below curve  
75  
80  
85  
90  
95  
100 105 110 115 120 125 130 135  
Liquid Temperature (F)  
figure 8. charging chart for 3.5 ton Units  
11  
400  
380  
360  
340  
320  
300  
280  
260  
240  
220  
200  
180  
160  
140  
Remove refrigerant when above curve  
Add refrigerant when below curve  
75  
80  
85  
90  
95  
100 105 110 115 120 125 130 135  
Liquid Temperature (F)  
figure 9. charging chart for 4 ton Units  
400  
380  
360  
340  
320  
300  
280  
260  
240  
220  
200  
180  
160  
140  
Remove refrigerant when above curve  
Add refrigerant when below curve  
75  
80  
85  
90  
95  
100 105 110 115 120 125 130 135  
Liquid Temperature (F)  
figure 10. charging chart for 5 ton Units  
12  
figUreS & tableS  
refrigerant charging tableS  
Shaded boxes indicate flooded conditions.  
Rated design values. The suction pressure will vary from design value if indoor air flow, entering dry bulb,  
or entering wet bulb temperatures are lower than design.  
1. All pressures are listed in psig and all temperatures in ° F  
2. Discharge temperatures greater than charted values indicate an undercharged system.  
oUtdoor temperatUre (° f)  
70  
75  
80  
85  
90  
95  
100  
105  
Suct.  
press.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp.  
74  
76  
78  
80  
82  
84  
86  
88  
90  
92  
94  
96  
98  
100  
156  
159  
161  
161  
165  
119  
124  
130  
139  
142  
173  
175  
177  
178  
182  
126  
131  
136  
143  
146  
190  
192  
194  
195  
199  
133  
138  
142  
148  
151  
206  
208  
211  
213  
216  
220  
139  
144  
148  
153  
157  
160  
223  
225  
227  
230  
233  
237  
145  
150  
154  
158  
162  
166  
239  
241  
243  
247  
250  
254  
151  
156  
160  
164  
168  
172  
256  
258  
260  
264  
267  
271  
157  
161  
165  
169  
174  
178  
272  
274  
276  
281  
284  
288  
163  
166  
170  
175  
180  
184  
table 4. charging table for 1.5 ton Units  
oUtdoor temperatUre (° f)  
70  
75  
80  
85  
90  
95  
100  
105  
Suct.  
press.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp.  
71  
73  
75  
77  
79  
81  
83  
85  
87  
89  
91  
93  
95  
97  
149  
152  
154  
154  
157  
103  
109  
114  
124  
126  
167  
170  
172  
172  
176  
115  
120  
125  
132  
135  
185  
187  
190  
191  
194  
126  
131  
135  
141  
145  
203  
205  
207  
209  
213  
216  
137  
141  
146  
150  
154  
158  
221  
223  
225  
228  
231  
235  
147  
151  
156  
160  
164  
168  
239  
241  
243  
246  
250  
253  
157  
162  
166  
170  
174  
178  
257  
259  
261  
265  
268  
272  
167  
171  
175  
180  
184  
188  
274  
276  
278  
283  
287  
290  
177  
181  
185  
190  
194  
199  
table 5. charging table for 2 ton Units (with microchannel coil)  
13  
refrigerant charging tableS  
Shaded boxes indicate flooded conditions.  
Rated design values. The suction pressure will vary from design value if indoor air flow, entering dry bulb,  
or entering wet bulb temperatures are lower than design.  
1. All pressures are listed in psig and all temperatures in ° F  
2. Discharge temperatures greater than charted values indicate an undercharged system.  
oUtdoor temperatUre (° f)  
70  
75  
80  
85  
90  
95  
100  
105  
Suct.  
press.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp.  
68  
70  
72  
74  
76  
78  
80  
82  
84  
86  
88  
90  
92  
94  
139  
142  
144  
142  
145  
94  
100  
105  
118  
121  
158  
160  
162  
161  
165  
108  
113  
118  
127  
130  
176  
178  
180  
180  
184  
120  
125  
130  
137  
140  
194  
196  
198  
199  
203  
206  
133  
137  
142  
147  
151  
154  
212  
214  
216  
218  
222  
225  
144  
149  
153  
158  
161  
165  
230  
232  
234  
237  
241  
244  
156  
160  
164  
168  
173  
177  
248  
250  
252  
256  
260  
263  
167  
171  
175  
180  
184  
188  
266  
268  
270  
275  
279  
282  
178  
182  
186  
191  
196  
200  
table 6. charging table for 2.5 ton Units (with microchannel coil)  
oUtdoor temperatUre (° f)  
70  
75  
80  
85  
90  
95  
100  
105  
Suct.  
press.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp.  
69  
71  
73  
75  
77  
79  
81  
83  
85  
87  
89  
91  
93  
95  
147  
150  
152  
150  
153  
99  
105  
110  
124  
126  
167  
169  
171  
170  
174  
113  
118  
123  
133  
136  
186  
188  
190  
190  
194  
126  
131  
136  
143  
146  
205  
207  
209  
210  
214  
217  
139  
144  
148  
153  
157  
161  
224  
226  
228  
230  
234  
237  
151  
156  
160  
164  
168  
172  
243  
245  
247  
251  
254  
257  
163  
168  
172  
176  
180  
184  
262  
264  
266  
271  
274  
277  
175  
179  
183  
187  
192  
196  
281  
283  
285  
291  
294  
297  
186  
190  
194  
199  
204  
208  
table 7. charging table for 3 ton Units (with microchannel coil)  
14  
refrigerant charging tableS  
Shaded boxes indicate flooded conditions.  
Rated design values. The suction pressure will vary from design value if indoor air flow, entering dry bulb,  
or entering wet bulb temperatures are lower than design.  
1. All pressures are listed in psig and all temperatures in ° F  
2. Discharge temperatures greater than charted values indicate an undercharged system.  
oUtdoor temperatUre (° f)  
70  
75  
80  
85  
90  
95  
100  
105  
Suct.  
press.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp.  
73  
75  
77  
79  
81  
83  
85  
87  
89  
91  
93  
95  
97  
99  
174  
176  
178  
181  
185  
138  
143  
149  
153  
156  
186  
188  
190  
193  
197  
142  
147  
152  
156  
159  
198  
200  
202  
205  
209  
146  
151  
156  
160  
163  
210  
212  
214  
217  
221  
224  
150  
155  
159  
163  
167  
170  
222  
224  
226  
229  
233  
236  
154  
158  
163  
167  
171  
174  
234  
236  
238  
242  
245  
248  
158  
162  
166  
170  
174  
178  
246  
248  
250  
254  
257  
260  
162  
166  
170  
174  
178  
182  
258  
260  
262  
266  
269  
272  
165  
169  
173  
177  
182  
186  
table 8. charging table for 3.5 ton Units  
oUtdoor temperatUre (° f)  
70  
75  
80  
85  
90  
95  
100  
105  
Suct.  
press.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp.  
72  
74  
76  
78  
80  
82  
84  
86  
88  
90  
92  
94  
96  
98  
150  
153  
155  
155  
159  
125  
130  
135  
144  
147  
167  
169  
171  
172  
176  
131  
136  
141  
148  
151  
184  
186  
188  
190  
193  
138  
143  
148  
153  
156  
200  
202  
204  
207  
210  
213  
144  
149  
154  
158  
162  
165  
217  
219  
221  
224  
227  
230  
151  
155  
159  
164  
167  
171  
233  
235  
237  
241  
244  
247  
157  
161  
165  
169  
173  
177  
249  
251  
253  
257  
261  
264  
162  
166  
170  
175  
179  
183  
266  
268  
270  
274  
278  
281  
168  
172  
176  
181  
185  
190  
table 9. charging table for 4 ton Units  
15  
oUtdoor temperatUre (° f)  
85 90  
70  
75  
80  
95  
100  
105  
Suct.  
press.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
liq.  
dis.  
press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp. press. temp.  
68  
70  
72  
74  
76  
78  
80  
82  
84  
86  
88  
90  
92  
94  
149  
151  
154  
154  
158  
141  
146  
151  
160  
163  
166  
168  
171  
172  
175  
146  
151  
156  
163  
166  
183  
185  
187  
189  
193  
151  
156  
161  
166  
169  
200  
202  
204  
207  
210  
213  
156  
160  
165  
170  
173  
177  
217  
219  
221  
224  
227  
231  
160  
165  
169  
173  
177  
181  
234  
236  
238  
241  
245  
248  
165  
169  
173  
177  
181  
185  
251  
253  
255  
259  
262  
265  
169  
173  
177  
181  
186  
190  
267  
269  
271  
276  
279  
283  
173  
177  
180  
185  
190  
194  
table 10. charging table for 5 ton Units  
electrical diagramS & tableS  
Units Size (tons)  
1.5 ton  
2 ton  
2.5 ton  
3 ton  
3.5 ton  
4 ton  
5 ton  
Volts-Cycles-Phase (1)  
Total Amps  
208/230-60-1  
16.8  
8.7  
15  
11.5  
20  
14.1  
30  
16.2  
30  
21.3  
45  
26.7  
50  
electrica  
data  
Delay Fuse Max. (2)  
Min. Circuit Ampacity  
35  
10.8  
14.1  
9.9  
17.5  
9.9  
20.6  
19.9  
26.3  
33.1  
Area  
Rows-FPI  
Tube Dia  
Type  
8.2  
9.9  
17.7  
17.7  
25.4  
Coil  
1 - 22  
3/8” O.D.  
1 - 18  
MC  
1 - 18  
MC  
1 - 18  
MC  
1 - 22  
3/8” O.D.  
1 - 22  
3/8” O.D.  
1 - 22  
3/8” O.D.  
PSC  
1.20  
Fan Motor  
Amps  
0.3  
0.7  
0.7  
1.40  
1/4  
1.40  
1/4  
1.40  
1/4  
component  
data  
HP  
1/20  
1/10  
1/10  
1/4  
Dia -  
Blades  
18” - 3  
18” - 3  
18” - 3  
18” - 3  
24” - 3  
24” - 3  
24” - 3  
Fan Blade  
SCFM  
RLA  
1410  
8.3  
1985  
10.8  
56.0  
3/4”  
3/4”  
3/4”  
3000  
13.4  
3000  
15.4  
4000  
14.7  
4000  
19.8  
4000  
25.3  
146.0  
7/8”  
Compressor Data  
LRA  
40.3  
3/4”  
3/4”  
3/4”  
68.0  
87.0  
77.0  
104.0  
7/8”  
0-24 ft.  
25-39 ft.  
40-75 ft.  
3/4”  
3/4”  
7/8”  
refrigerant suction line: Length/O.D.  
liquid line: All lengths - 3/8” O.D.  
7/8” (3)  
7/8” (3)  
7/8” (3)  
7/8” (3)  
7/8”  
7/8”  
1-1/8” (4)  
1-1/8” (4)  
1-1/8” (4)  
1-1/8” (4)  
r-22 refrigerant charge (in ounces):  
(Outdoor unit, Indoor Unit 15’ Line Set)  
78  
53  
56  
68  
122  
126  
160  
Net  
103  
107  
112  
117  
105  
109  
105  
109  
176  
183  
176  
183  
229  
238  
approximate Weight (lbs.)  
Ship  
table 11. electrical Specications & physical data  
16  
WIRING DIAGRAM  
Split System Air Conditioner (Outdoor Section)  
Single Phase  
NOTES:  
Optional Hard Start Kit  
1. Couper le courant avant de faire letretien.  
2. Employez uniquement des conducteurs  
en cuivre.  
3. Ne convient pas aux installations  
de plus de 150 volt a la terre.  
1. Disconnect all power before servicing.  
2. For supply connections use copper conductors only.  
to “H” on capacitor  
RED  
3. Not suitable on systems that exceed 150 volts to ground.  
4. For replacement wires use conductors suitable for 105 deg C.  
5. For ampacities and overcurrent protection, see unit rating plate.  
6. Connect to 24 vac/40ca/class 2 circuit. See furnace/airhandler installation  
instructions for control circuit and optional relay/transformer kits.  
7. Anti-Short Cycle Timer (ASCT) may or may not be installed in the unit. If desired,  
ASCT is factory installed on select models only or may be field installed as shown using  
manufacturer’s approved kit. If not present, connect Yellow and Black wires per Note 6.  
8. DO NOT use a Hard Start Kit on a model with a PTCR installed.  
to T2 on  
contactor  
2
1
3
BLACK  
R
START  
RELAY  
BLACK  
C
YELLOW  
START  
CAPAC  
S
OUTDOOR  
FAN MOTOR  
PTCR  
(if equip)  
BLUE  
ORANGE  
208/230V  
YELLOW  
YELLOW  
F
L2  
L1  
DUAL  
CAPACITOR  
PTCR  
to “C” on  
capacitor  
C
CCH  
(OPTIONAL)  
COMPRESSOR  
CONTACTS  
H
T2  
YELLOW  
YELLOW  
T1  
R
S
RED OR  
RED BLACK  
PTCR (If equipped)  
C
T2  
L2  
T1  
L1  
H
F
RED OR  
YELLOW  
ASCT  
(SEE  
NOTE 7)  
COMPRESSOR  
C
BLACK  
CONTACTOR  
YELLOW  
OR  
YELLOW  
BLACK  
S
RED OR  
RED BLACK  
T2  
C
OUTDOOR FAN  
MOTOR  
R
T1  
T3  
BLACK OR  
BLK WHT  
ASCT  
(SEE NOTE 7)  
R
CC  
C
YELLOW BLACK  
ASCT  
S
GROUNDING  
SCREW  
L1 L2  
GND  
24 VOLT FIELD  
CONNECTIONS  
CRANKCASE  
HEATER  
(OPTIONAL)  
SEE NOTE 6  
LEGEND:  
FIELD WIRING  
LOW VOLTAGE  
HIGH VOLTAGE  
CC - Contactor Coil  
CCH - Crankcase Heater  
HPS - High Pressure Switch  
710570B  
¢710570|¤ (Replaces 710570A)  
0109  
figure 11. Wiring diagram  
17  
18  
19  
inStallation / performance checK liSt  
inStallation addreSS:  
electrical SyStem  
Electrical connections tight?  
Line voltage polarity correct?  
YES  
YES  
NO  
NO  
CITY ________________________ STATE ________________  
UNIT MODEL # ________________________________________  
Rated Voltage: ___________________________________ VOLTS  
L1-L2 Volts: _____________________________________ VOLTS  
L1-L3 Volts: _____________________________________ VOLTS  
L2-L3 Volts: _____________________________________ VOLTS  
Avg. Volts: ______________________________________ VOLTS  
UNIT SERIAL # _______________________________________  
UnitInstalledMinimumclearancesper  
YES  
NO  
Figure 1 (page 5)?  
inStaller name:  
CITY _______________________  
STATE ________________  
Max. deviation of voltage  
from avg. volts:___________________________________ VOLTS  
Has the owner’s information been  
reviewed with the customer?  
YES  
YES  
NO  
NO  
Has the Literature Package been left  
with the unit?  
% Volt imbalance: ________________________________ VOLTS  
Blower Motor HP:________ Sheave Setting ___________# Turns  
refrigeration SyStem  
Has the thermostat been calibrated?  
Is the thermostat level?  
YES  
YES  
NO  
NO  
Was unit given 24 hr warm up period  
for crankcase heaters?  
YES  
NO  
Is the heat anticipator setting correct?  
(If Applicable)  
YES  
NO  
Stage-1 Liquid Pressure (high side) ________________________  
Stage-1 Suction Pressure (low side) ________________________  
Warranty information  
A warranty certificate with full details is included with the  
airconditioner.Carefullyreviewtheseresponsibilitieswith  
your dealer or service company.The manufacturer will not  
be responsible for any costs found necessary to correct  
problems due to improper setup, improper installation,  
adjustments, improper operating procedure on the part  
of the user, etc. Some specific examples of service calls  
which are not included in the limited warranty are:  
Correcting wiring problems in the electrical circuit  
supplying the air conditioner.  
Resetting circuit breakers or other switches.  
Adjusting or calibrating of thermostat.  
Specifications & illustrations subject to change without notice or incurring obligations.  
Jackson, MI | Printed in U.S.A. (11/12)  
709480a (Replaces 7094800)  

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