Lennox 10ACC Installation Instructions PDF

Page 1

504,787M

04/04

2003 Lennox Industries Inc.

Dallas, Texas, USA

10ACC Outdoor Units

Lennox Merit 10ACC outdoor units are designed for use in

either fixed orifice or expansion valve (TXV) systems. The

TXV may require a fieldinstalled hard start kit. Refer to the

Lennox Engineering Handbook for expansion valve kits

which must be ordered separately.

Shipping & Packing List

1 Assembled outdoor unit

1 Fixed orifice refrigerant metering device

1 Coupling, 5/16 x 3/8" (018)

Check the unit for shipping damage. Consult last carrier im-

mediately if damage is found.

WARNING installation, adjustment, alteration, service or main- tenance can cause property damage, personal injury or loss of life. Installation and service must be per- formed by a qualified installer or service agency.

IMPORTANT The Clean Air Act of 1990 bans the intentional vent- ing of refrigerant (CFCs and HCFCs) as of July 1, 1992. Approved methods of recovery, recycling or reclaiming must be followed. Fines and/or incarcera- tion may be levied for noncompliance.

INSTALLATION INSTRUCTIONS

Merit Series 10ACC Units

CONDENSING UNITS 504,787M 04/04

Supersedes 02/04

Table of Contents 10ACC Outdoor Units 1. . . . . . . . . . . . . . . . . . . . . . . . . . . Shipping & Packing List 1. . . . . . . . . . . . . . . . . . . . . . . . . General Information 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Dimensions 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the Unit 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Piping 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Metering Devices 9. . . . . . . . . . . . . . . . . . . . Manifold Gauge Set 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Valves 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leak Testing 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evacuation 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . StartUp 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional Accessories 16. . . . . . . . . . . . . . . . . . . . . . . . . . StartUp & Performance Check List 16. . . . . . . . . . . . . .

RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE

General Information

These instructions are intended as a general guide and do

not supersede national or local codes in any way. Authori-

ties having jurisdiction should be consulted before installa-

tion.

WARNING This product and/or the indoor unit it is matched with may contain fiberglass wool.

Disturbing the insulation during installation, mainte- nance, or repair will expose you to fiberglass wool dust. Breathing this may cause lung cancer. (Fiber- glass wool is known to the State of California to cause cancer.)

Fiberglass wool may also cause respiratory, skin, and eye irritation.

To reduce exposure to this substance or for further information, consult material safety data sheets available from address shown below, or contact your supervisor.

Lennox Industries Inc.

P.O. Box 799900 Dallas, TX 753799900

Litho U.S.A.

Page 2

Unit Dimensions inches (mm)

SIDE VIEW

VAPOR & LIQUID LINE

CONNECTION

INLET

AIR

INLET

AIR

DISCHARGE AIR

SIDE VIEW

TOP VIEW

A

OUTDOOR COIL FAN

COMPRESSOR

INLET AIR

INLET AIR

B

23/4 (70)

ELECTRICAL INLETS

OPTIONAL UNIT STANDOFF KIT (4)

(Field Installed)

43/8 (111)

63/8 (162)

63/8 (162)

TOP VIEW BASE SECTION

2 (51)

3/4 (19)

43/8 (111)

43/8 (111)

43/8 (111)

43/8 (111)

43/8 (111)

COMPRESSOR

COIL DRAIN OUTLETS (Around perimeter of base)

OPTIONAL UNIT STANDOFF KIT (4)

(Field Installed)

LIQUID LINE CONNECTION

VAPOR LINE CONNECTION

C

C

Model No. A B C

10ACC018 10ACC024 030 in. 25 241/4 221/4

, , mm 635 616 565

10ACC 036 in. 25 241/4 241/4

mm 635 616 616

10ACC036 (Canada only) 10ACC 042

in. 29 281/4 241/4 mm 737 718 616

10ACC 048 in. 33 321/4 241/4

mm 838 819 616

10ACC 060 in. 37 361/4 281/4

mm 940 921 718

Page 3

Setting the Unit

CAUTION In order to avoid injury, take proper precaution when lifting heavy objects.

CAUTION Sharp sheet metal edges can cause injury. When installing the unit, avoid accidental contact with sharp edges.

Refer to unit dimensions for sizing mounting slab, plat-

forms or supports. Refer to figure 1 for installation clear-

ances.

36 (914 mm)

Installation Clearances

36* (914 mm)

*NOTE A service clearance of 30" (762 mm) must be main-

tained on one of the sides adjacent to the control box. Clear-

ance to one of the other three sides must be 36" (914 mm).

Clearance to one of the remaining two sides may be 12" (304

mm) and the final side may be 6" (152 mm).

36* (914 mm)

NOTE A clearance of 24" (610 mm) must be maintained between two units. NOTE 48" (1219 mm) clearance required on top of unit. Maximum soffit overhang is 36" (914 mm).

36 (914 mm)

Figure 1

Slab Mounting

When installing unit at grade level, install on a level slab

high enough above grade to allow adequate drainage of

water. Top of slab should be located so runoff water from

higher ground will not collect around unit.

Roof Mounting

Install the unit at a minimum of 4 inches (102 mm) above

the surface of the roof. Ensure the weight of the unit is prop-

erly distributed over roof joists and rafters. Redwood or

steel supports are recommended.

Electrical

In the U.S.A., wiring must conform with current local codes

and the current National Electric Code (NEC). In Canada,

wiring must conform with current local codes and the current

Canadian Electrical Code (CEC).

Refer to the furnace or blower coil installation instructions

for additional wiring application diagrams and refer to unit

nameplate for minimum circuit ampacity and maximum

overcurrent protection size.

WARNING Unit must be grounded in accordance with national and local codes. Electric Shock Hazard. Can cause injury or death.

1 Install line voltage power supply to unit from a properly

sized disconnect switch.

2 Ground unit at unit disconnect switch or to an earth

ground.

NOTE To facilitate conduit, a hole is in the bottom of

the control box. Connect conduit to the control box us

ing a proper conduit fitting.

NOTE Units are approved for use only with copper

conductors.

24V, Class II circuit connections are made in the low

voltage junction box. Refer to figure 2 for field wiring

diagram.

NOTE A complete unit wiring diagram is located in

side the unit control box cover.

3 Install room thermostat (ordered separately) on an in-

side wall approximately in the center of the conditioned

area and 5 feet (1.5 m) from the floor. It should not be

installed on an outside wall or where it can be effected

by sunlight, drafts or vibrations.

4 Install low voltage wiring from outdoor to indoor unit

and from thermostat to indoor unit. See figure 3.

Page 4

Typical Wiring Field Wiring Diagram

*

* *

*May be optional

Figure 2

Figure 3

Thermostat Designations

R

W1

Y

G

C

R

W

Y

G

C

Thermostat Indoor Unit

Outdoor Unit

Y1 Outdoor Unit

C Outdoor Unit

power

heat

cooling

indoor blower

common

NOTE see unit wiring diagram for power supply connections.

NOTE If the indoor unit is not equipped with blower relay. It must be fieldprovided and installed (P83251 or equivalent).

Page 5

Refrigerant Piping

Field refrigerant piping consists of liquid and vapor lines

from the outdoor unit (sweat connections) to the indoor coil

(flare or sweat connections). Use Lennox L15 (sweat, non-

flare) series line sets as shown in table 1 or use field-fabri-

cated refrigerant lines. Refer to Refrigerant Piping Guide

(Corp. 9351L9) for proper size, type, and application of

fieldfabricated lines. Valve sizes are also listed in table 1.

Table 1 Refrigerant Line Kits

Model

Valve Field Size Connections

Recommended Line Set

Name Liquid Line

Vapor Line

Liquid Line

Vapor Line

L15 Line Sets

018 3/8 in

(10 mm)

5/8 in

(16 mm) 5/16 in*

(8 mm)

5/8 in

(16 mm)

L1521

15 ft. 50 ft. (4.6m 15m)

024

030 036

3/8 in

(10 mm)

3/4 in.

(19 mm) 3/8 in

(10 mm)

3/4 in.

(19 mm)

L1541

15 ft. 50 ft. (4.6 m 15m)

042

048

3/8 in

(10 mm)

7/8 in.

(22 mm)

3/8 in

(10 mm)

7/8 in.

(22 mm)

L1565

15 ft. 50 ft. (4.6 m 15m)

060 3/8 in (10 mm)

11/8 in. (29 mm)

3/8 in (10 mm)

11/8 in. (29 mm)

Field Fabricated

NOTE Units are designed for line sets of up to 50 feet (15

m). For applications longer than 50 feet, consult the Len-

nox Refrigerant Piping Guide (Corp. 9351L9). Select line

set diameters from table 1 to ensure that oil returns to the

compressor.

*Use reducer from bag assembly.

Installing Refrigerant Line

During the installation of any heat pump or a/c system, it is

important to properly isolate the refrigerant lines to prevent

unnecessary vibration. Line set contact with the structure

(wall, ceiling or floor) causes some objectionable noise

when vibration is translated into sound. As a result, more

energy or vibration can be expected. Closer attention to

line set isolation must be observed.

Following are some points to consider when placing and

installing a highefficiency outdoor unit:

1- Placement Be aware some localities are adopting

sound ordinances based on how noisy the unit is from

the adjacent property not at the original installation.

Install the unit as far as possible from the property line.

When possible, do not install the unit directly outside a

window. Glass has a very high level of sound transmis-

sion.

2- Line Set Isolation The following illustrations demon-

strate procedures which ensure proper refrigerant line

set isolation. Figure 4 shows how to install line sets on

vertical runs. Figure 5 shows how to install line sets on

horizontal runs. Figure 6 shows how to make a transition

from horizontal to vertical. Finally, figure 7 shows how to

place the outdoor unit and line set.

Page 6

Refrigerant Line Sets How To Install Vertical Runs

(new construction shown)

PVC Pipe Fiberglass Insulation

Caulk

Outside Wall

Vapor Line (wrapped with Armaflex)

Liquid Line

IMPORTANT - Refrigerant lines must not contact

structure.

Outside Wall

Inside Wall

Liquid LineVapor Line IMPORTANT - Refrigerant lines must not contact wall.

Wood Block Between Studs

Strap

Sleeve

Wood Block

Strap

Sleeve

Wire Tie

Wire Tie

Wire Tie

NOTE - Similar installation practices should be used if line set is to be installed on exterior of outside wall.

Figure 4

Page 7

Refrigerant Line Sets: Installing Horizontal Runs

8 feet

8 feet

Metal Sleeve

Strapping Material (around vapor line only)

Tape or Wire Tie

Wire Tie (around vapor line only)

Floor Joist or Roof Rafter

Tape or Wire Tie

Strap the vapor line to the joist or rafter at 8 ft. intervals then strap the liquid line to the vapor line.

To hang line set from joist or rafter, use either metal strapping material or anchored heavy nylon wire ties.

Floor Joist or Roof Rafter

Figure 5

Page 8

Refrigerant Line Sets: Transition From Vertical To Horizontal

Liquid Line

Vapor Line Wrapped in

Armaflex

Strap Liquid Line To Vapor Line

Metal Sleeve

Anchored Heavy Nylon Wire Tie

Automotive Muffler-Type

Hanger

Wall Stud

Wall Stud

Liquid Line

Vapor Line Wrapped in

Armaflex

Strap Liquid Line To Vapor Line

Metal Sleeve

Figure 6

Outside Unit Placement and Installation

Install unit away from windows.

Two 90 elbows installed in line set will reduce line set vibration.

Figure 7

Page 9

Brazing Connection Procedure

1 Cut ends of the refrigerant lines square (free from nicks

or dents). Debur the ends. The pipe must remain

round, do not pinch end of the line.

2 Before making line set connections, use dry nitrogen to

purge the refrigerant piping. This will help to prevent

oxidation and the introduction of moisture into the sys-

tem.

3 Use silver alloy brazing rods (5 or 6 percent minimum

silver alloy for coppertocopper brazing or 45 percent

silver alloy for coppertobrass or coppertosteel braz-

ing) which are rated for use with HCFC2 refrigerant.

Wrap a wet cloth around the valve body and the copper

tube stub. Braze the line set to the service valve.

4 Wrap a wet cloth around the valve body and copper

tube stub to protect it from heat damage during braz-

ing. Wrap another wet cloth underneath the valve body

to protect the base paint.

NOTE The tube end must stay bottomed in the fitting

during final assembly to ensure proper seating, sealing

and rigidity.

5 Install a fieldprovided thermal expansion valve (ap-

proved for use with HCFC2 refrigerant) in the liquid line

at the indoor coil.

Refrigerant Metering Devices

Use 10ACC units in either TXV systems or fixed orifice sys-

tems. See the Lennox Engineering Handbook for approved

TXV and fixed orifice match-ups and application informa-

tion. Table 1 lists the unit liquid and vapor line sizes and cor-

responding line sets.

Fixed Orifice Systems

10ACC units are shipped with a fixed orifice refrigerant me-

tering device. Replace the existing indoor unit fixed orifice

with the orifice supplied with the outdoor unit. Place the

supplied fixed orifice sticker on the indoor cabinet after

installation. See table 2 for the fixed orifice size for each

unit. In nonstandard applications, the provided fixed orifice

may not be appropriately sized. Refer to the Engineering

Handbook for specific orifice information.

Table 2 Fixed Orifice Drill Sizes

Unit Fixed Orifice Catalog #

Fixed Orifice Drill Size

10ACC018 42J38 .053

10ACC024 60M29 .061

10ACC030 42J44 .065

10ACC036 42J50 .077

10ACC042 42J52 .080

10ACC048 42J55 .086

10ACC060 42J61 .098

Install the fixed orifice as shown in figure 8. Do not twist the

cap tubes when loosening the seal nut from the orifice

housing.

Metering Device Installation

valve OR orifice

orifice (factoryinstalled)

expansion valve (opt.)

oring

oring

strainer

liquid line stub

distributor

Figure 8

Expansion Valve Systems

Expansion valves equipped with Chatleff fittings are avail-

able from Lennox. Refer to the Engineering Handbook for

expansion valves for use with specific matchups.

If you install a expansion valve with an indoor coil that

includes a fixed orifice, remove the orifice before the

expansion valve is installed.

IMPORTANT Failure to remove the fixed orifice when installing an expansion valve on the indoor coil will result in im- proper operation and damage to the system.

Manifold Gauge Set

When checking the unit charge, use a manifold gauge set

that is equipped with low loss" hoses. Do not use a man-

ifold gauge set with anything other than a low loss" hose.

Page 10

Service Valves

The liquid line and vapor line service valves (figures 9 and

10) and gauge ports are used for leak testing, evacuating,

charging and checking charge. See table 3 for torque re-

quirements

Each valve is equipped with a service port which has a fac-

toryinstalled Schrader valve. A service port cap protects

the Schrader valve from contamination and serves as the

primary leak seal.

Table 3 Torque Requirements

Part Recommended Torque

Service valve cap 8 ft. lb. 11 NM

Sheet metal screws 16 in. lb. 2 NM

Machine screws #10 28 in. lb. 3 NM

Compressor bolts 90 in. lb. 10 NM

Gauge port seal cap 8 ft. lb. 11 NM

To Access Schrader Port:

1 Remove service port cap with an adjustable wrench.

2 Connect gauge to the service port.

3 When testing is completed, replace service port cap. Tighten finger tight, then an additional 1/6 turn.

To Open Service Valve:

1 Remove the stem cap with an adjustable wrench.

2 Use a service wrench with a hexhead extension to back the stem out counterclockwise as far as it will go.

NOTE Use a 3/16" hex head extension for liquid line sizes or a 5/16" extension for vapor line sizes.

3 Replace the stem cap. Tighten finger tight, then tighten an additional 1/6 turn.

Liquid Service Valve (Valve Closed)

Schrader valve open to line set when valve is

closed (front seated)

service port

service port cap

stem cap

insert hex wrench here

(valve front seated)

to outdoor coil

to indoor coil

Liquid Service Valve (Valve Open)

Schrader valve

service port

service port cap

insert hex wrench here

to indoor coil

to outdoor coil

stem cap

Figure 9

Page 11

To Close Service Valve:

1 Remove the stem cap with an adjustable wrench.

2 Use a service wrench with a hexhead extension to turn the stem clockwise to seat the valve. Tighten the stem firmly.

NOTE Use a 3/16" hex head extension for liquid line sizes or a 5/16" extension for vapor line sizes.

3 Replace the stem cap. Tighten finger tight, then tighten an additional 1/6 turn.

Vapor Line Ball Valve

Vapor line service valves function the same way as the oth-

er valves, the difference is in the construction. These

valves are not rebuildable. If a valve has failed, you must

replace it. A ball valve is illustrated in figure 10.

The ball valve is equipped with a service port with a factory

installed Schrader valve. A service port cap protects the

Schrader valve from contamination and assures a leak

free seal.

Vapor Line Ball Valve (Valve Open)

Schrader valve

service port

service port cap

stem cap

stem

Use Adjustable Wrench To open: rotate stem counter-clockwise90.

To close: rotate stem clockwise 90.

ball (shown open)

to outdoor coil

to indoor coil

Figure 10

Leak Testing

After the line set has been connected to the indoor and

outdoor units, check the line set connections and indoor

unit for leaks.

WARNING Danger of fire. Bleeding the refrigerant charge from only the high side may result in the low side shell and suc- tion tubing being pressurized. App- plication of a brazing torch while pres- surized may result in ignition of the refrigerant and oil mixture check the high and low pressures before unbra- zing.

WARNING Refrigerant can be harmful if it is inhaled. Refrigerant must be used and recovered responsibly.

Failure to follow this warning may result in personal injury or death.

WARNING Danger of explosion: Can cause equipment damage, injury or death. Never use oxygen to pressurize a re- frigeration or air conditioning system. Oxygen will explode on contact with oil and could cause personal injury.

WARNING Danger of explosion: Can cause equipment damage, injury or death. When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioning system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa).

Using an Electronic Leak Detector or Halide

1 Connect a cylinder of HCFC-22 to the center port of the

manifold gauge set.

2 With both manifold valves closed, open the valve on

the HCFC-22 cylinder (vapor only).

3 Open the high pressure side of the manifold to allow

the HCFC-22 into the line set and indoor unit. Weigh in

a trace amount of HCFC-22. [A trace amount is a maxi-

mum of 2 ounces (57 g) or 3 pounds (31 kPa) pres-

sure.] Close the valve on the HCFC-22 cylinder and the

valve on the high pressure side of the manifold gauge

set. Disconnect the HCFC-22 cylinder.

4 Connect a cylinder of nitrogen with a pressure regulat-

ing valve to the center port of the manifold gauge set.

Page 12

5 Connect the manifold gauge set high pressure hose to

the vapor valve service port. (Normally, the high pres-

sure hose is connected to the liquid line port; however,

connecting it to the vapor port better protects the man-

ifold gauge set from high pressure damage.)

6 Adjust the nitrogen pressure to 150 psig (1034 kPa).

Open the valve on the high side of the manifold gauge

set which will pressurize line set and indoor unit.

7 After a few minutes, open a refrigerant port to ensure

the refrigerant you added is adequate to be detected.

(Amounts of refrigerant will vary with line lengths.)

Check all joints for leaks. Purge nitrogen and HCFC-22

mixture. Correct any leaks and recheck.

Evacuation

Evacuating the system of noncondensables is critical for

proper operation of the unit. Noncondensables are defined

as any gas that will not condense under temperatures and

pressures present during operation of an air conditioning

system. Noncondensables and water vapor combine with

refrigerant to produce substances that corrode copper pip-

ing and compressor parts.

IMPORTANT Use a thermocouple or thermistor electronic vacuum gauge that is calibrated in microns. Use an instrument that reads from 50 microns to at least 10,000 microns.

1 Connect manifold gauge set to the service valve ports

as follows:

low pressure gauge to vapor line service valve high pressure gauge to liquid line service valve

2 Connect micron gauge.

3 Connect the vacuum pump (with vacuum gauge) to the

center port of the manifold gauge set.

4 Open both manifold valves and start the vacuum

pump.

5 Evacuate the line set and indoor unit to an absolute

pressure of 23,000 microns (29.01 inches of mercu-

ry). During the early stages of evacuation, it is desir-

able to close the manifold gauge valve at least once to

determine if there is a rapid rise in absolute pressure.

A rapid rise in pressure indicates a relatively large leak.

If this occurs, repeat the leak testing procedure.

NOTE The term absolute pressure means the total

actual pressure within a given volume or system,

above the absolute zero of pressure. Absolute pres-

sure in a vacuum is equal to atmospheric pressure mi-

nus vacuum pressure.

6 When the absolute pressure reaches 23,000 microns

(29.01 inches of mercury), close the manifold gauge

valves, turn off the vacuum pump and disconnect the

manifold gauge center port hose from vacuum pump.

Attach the manifold center port hose to a nitrogen cylin-

der with pressure regulator set to 150 psig (1034 kPa)

and purge the hose. Open the manifold gauge valves

to break the vacuum in the line set and indoor unit.

Close the manifold gauge valves.

CAUTION Danger of Equipment Damage. Avoid deep vacuum operation. Do not use compres- sors to evacuate a system. Extremely low vacuums can cause internal arcing and compressor failure. Damage caused by deep vacuum operation will void warranty.

7 Shut off the nitrogen cylinder and remove the manifold

gauge hose from the cylinder. Open the manifold

gauge valves to release the nitrogen from the line set

and indoor unit.

8 Reconnect the manifold gauge to the vacuum pump,

turn the pump on, and continue to evacuate the line set

and indoor unit until the absolute pressure does not

rise above 500 microns (29.9 inches of mercury) within

a 20minute period after shutting off the vacuum pump

and closing the manifold gauge valves.

9 When the absolute pressure requirement above has

been met, disconnect the manifold hose from the vacu-

um pump and connect it to an upright cylinder of

HCFC-22 refrigerant. Open the manifold gauge valves

to break the vacuum from 1 to 2 psig positive pressure in

the line set and indoor unit. Close manifold gauge

valves and shut off the HCFC-22 cylinder and remove

the manifold gauge set.

StartUp

IMPORTANT If unit is equipped with crankcase heater, it should be energized 24 hours before unit startup to prevent compressor damage as a result of slugging.

1 Rotate the fan to check for frozen bearings or binding.

2 Inspect all factory and field-installed wiring for loose

connections.

3 After evacuation is complete, open the liquid line and

vapor line service valves to release refrigerant charge

(contained in outdoor unit) into the system.

4 Replace the stem caps and secure finger tight, then

tighten an additional one-sixth (1/6) of a turn.

5 Check voltage supply at the disconnect switch. The

voltage must be within the range listed on the units

nameplate. If not, do not start the equipment until you

Page 13

have consulted the power company and the voltage

condition has been corrected.

6 Set the thermostat for a cooling demand. Turn on pow-

er to the indoor blower and close the outdoor unit dis-

connect switch to start the unit.

7 Recheck voltage while the unit is running. Power must

be within range shown on the nameplate.

Charging

Units are factory charged with the amount of HCFC-22 re-

frigerant indicated on the unit nameplate. This charge is

based on a matching indoor coil and outdoor coil with a 15 ft.

(4.6 m) line set. For varying lengths of line set, refer to table 4

for refrigerant charge adjustment check.

Table 4

Liquid Line Set Diameter

Oz. per 5 ft. (g per 1.5 m) adjust from 15 ft. (4.6 m) line set*

5/16 in. (8 mm) 2 ounce per 5 ft. (57g per 1.5 m)

3/8 in. (10 mm) 3 ounce per 5 ft. (85g per 1.5 m)

*If line length is greater than 15 ft. (4.6 m), add this amount. If line length is less than 15 ft. (4.6 m), subtract this amount.

The outdoor unit should be charged during warm weather.

However, applications arise in which charging must occur

in the colder months. The method of charging is deter-

mined by the units refrigerant metering device and the

outdoor ambient temperature.

Measure the liquid line temperature and the outdoor ambi-

ent temperature as outlined below:

1 Close manifold gauge set valves. Connect the man-

ifold gauge set to the service valve.

low pressure gauge to vapor valve service port high pressure gauge to liquid valve service port

Connect the center manifold hose to an upright cylin-

der of HCFC22.

2 Set the room thermostat to call for heat. This will create

the necessary load for properly charging the system in

the cooling cycle.

3 Use a digital thermometer to record the outdoor ambi-

ent temperature.

4 When the heating demand has been satisfied, switch

the thermostat to cooling mode with a set point of 68F

(20C). When pressures have stabilized, use a digital

thermometer to record the liquid line temperature.

5 The outdoor temperature will determine which charg-

ing method to use. Proceed with the appropriate charg-

ing procedure.

Weighing in the Charge Fixed Orifice or

TXV Systems Outdoor Temp. < 65F (18C)

If the system is void of refrigerant, or if the outdoor ambient

temperature is cool, the refrigerant charge should be

weighed into the unit. Do this after any leaks have been re-

paired.

1 Recover the refrigerant from the unit.

2 Conduct a leak check, then evacuate as previously

outlined.

3 Weigh in the unit nameplate charge.

If weighing facilities are not available or if you are charging

the unit during warm weather, follow one of the other proce-

dures outlined below.

Charging Using the Subcooling Method

Fixed Orifice Systems Outdoor Temp.

> 65F (18C)

If you charge a fixed orifice system when the outdoor ambi-

ent is 65F (18C) or above, use the subcooling method to

charge the unit.

1 With the manifold gauge hose still on the liquid service

port and the unit operating stably, use a digital ther-

mometer to record the liquid line temperature.

2 At the same time, record the liquid line pressure reading.

3 Use a temperature/pressure chart for HCFC-22 to de-

termine the saturation temperature for the liquid line

pressure reading.

4 Subtract the liquid line temperature from the saturation

temperature (according to the chart) to determine sub-

cooling. (Saturation temperature Liquid line tem-

perature = Subcooling)

5 Compare the subcooling value with those in table 5. If

subcooling is greater than shown, recover some refrig-

erant. If subcooling is less than shown, add some re-

frigerant.

Page 14

Table 5 10ACC Subcooling Values

(Fixed Orifice Systems Only)

OUTDOOR TEMP

LIQUID SUBCOOLING [+ 1F (.6C)] .

F (C) 18 24 30 36 42 48 60

65 (18)

14 (8)

10 (5.6)

16 (9)

17 (9.5)

17 (9.5)

15 (8.3)

14 (8)

70 (21)

13 (7)

9 (5)

15 (8.3)

17 (9.5)

17 (9.5)

14 (8)

15 (8.3)

75 (24)

14 (8)

8 (4.5)

15 (8.3)

16 (9)

16 (9)

13 (7)

15 (8.3)

80 (27)

13 (7)

7 (3.9)

15 (8.3)

15 (8.3)

15 (8.3)

13 (7)

14 (8)

85 (29)

13 (7)

6 (3.3)

14 (8)

14 (8)

14 (8)

12 (6.7)

14 (8)

90 (32)

12 (6.7)

5 (2.8)

14 (8)

14 (8)

14 (8)

12 (6.7)

13 (7)

95 (35)

11 (6)

4 (2.2)

13 (7)

12 (6.7)

14 (8)

12 (6.7)

13 (7)

100 (38)

11 (6)

4 (2.2)

13 (7)

11 (6)

13 (7)

11 (6)

12 (6.7)

105 (41)

10 (5.6)

3 (1.7)

12 (6.7)

10 (5.6)

12 (6.7)

10 (5.6)

12 (6.7)

110 (43)

9 (5)

3 (1.7)

11 (6)

9 (5)

11 (6)

9 (5)

11 (6)

115 (45)

8 (4.5)

2 (1.1)

11 (6)

8 (4.5)

11 (6)

8 (4.5)

10 (5.6)

Charging Using Normal Operating Pressures

and the Approach Method

TXV Systems Outdoor Temp. > 65F (18C)

The following procedure is intended as a general guide and

is for use on expansion valve systems only. For best results,

indoor temperature should be 70F (21C) to 80F (26C).

Monitor system pressures while charging.

1 Record outdoor ambient temperature using a digital

thermometer.

2 Attach high pressure gauge set and operate unit for

several minutes to allow system pressures to stabilize.

3 Compare stabilized pressures with those provided in

table 7, Normal Operating Pressures." Minor varia-

tions in these pressures may be expected due to differ-

ences in installations. Significant differences could

mean that the system is not properly charged or that a

problem exists with some component in the system.

Pressures higher than those listed indicate that the

system is overcharged. Pressures lower than those

listed indicate that the system is undercharged. Verify

adjusted charge using the approach method.

4 Use the same digital thermometer you used to check

the outdoor ambient temperature to check the liquid

line temperature. The difference between the ambient

and liquid temperatures should match values given in

table 6. Loss of charge results in low capacity and effi-

ciency.

5 If the values dont agree with the those in table 6, add

refrigerant to lower the approach temperature, or re-

cover refrigerant from the system to increase the ap-

proach temperature.

Table 6 Approach Method

Model No. Approach Temperature

Liquid Line Outdoor Ambient F (C)

10ACC018 9 (5)

10ACC024 18 (10)

10ACC030 22 (12)

10ACC036 11 (6)

10ACC042 13 (7)

10ACC048 8 (4.5)

10ACC060 13 (7)

NOTE For best results, use the same digital thermometer to check both

outdoor ambient and liquid temperatures.

IMPORTANT Use table 7 to perform maintenance checks. Table 7 is not a procedure for charging the system. Minor variations in these pressures may be due to differ- ences in installations. Significant deviations could mean that the system is not properly charged or that a problem exists with some component in the system. See table 7.

Page 15

Table 7

Normal Operating Pressures In psig (liquid and vapor +/ 2 psig)*

Unit / Metering

Out. Coil Entering

018 024 030 036 042 048 060

Device Air Temp. F (C)

LIQ. SUC. LIQ. SUC. LIQ. SUC. LIQ. SUC. LIQ. SUC. LIQ. SUC. LIQ. SUC.

65 (18.3) 153 71 163 70 175 76 162 70 173 73 159 71 170 74

75 (23.9) 180 72 193 71 206 77 187 74 201 74 188 72 201 76

10ACC /

85 (29.4) 209 73 225 72 241 78 219 75 234 74 220 73 234 77

TXV

95 (35.0) 240 77 260 73 277 80 253 77 269 75 251 76 270 79

105 (40.6) 274 79 298 74 316 81 291 79 307 76 290 77 309 79

110 (43) 292 80 318 75 336 82 310 80 326 77 309 78 331 80

115 (45) 311 81 338 75 357 83 329 81 346 78 328 79 351 81

65 (18.3) 155 62 165 63 181 69 168 67 178 67 163 68 189 72

75 (23.9) 182 68 194 67 211 73 195 71 202 70 190 71 203 74

85 (29.4) 211 72 224 70 242 76 224 75 235 71 220 74 233 77

10ACC / fixed orifice

95 (35.0) 242 77 257 73 276 79 255 78 270 74 251 77 265 79

105 (40.6) 274 80 293 76 313 81 289 82 308 78 288 79 301 82

110 (43) 291 81 313 78 332 82 305 83 326 79 307 80 319 83

115 (45) 308 83 332 79 353 84 324 84 347 80 325 82 339 84

*These are typical pressures only. Indoor indoor match up, indoor air quality, and indoor load will cause the pressures to vary.

System Operation

The outdoor unit and indoor blower cycle on demand from

the room thermostat. When the thermostat blower switch is

in the ON position, the indoor blower operates continuously.

Maintenance

Maintenance and service must be performed by a qualified

installer or service agency. At the beginning of each cooling

season, the system should be checked as follows:

WARNING Electric shock hazard. Can cause inju- ry or death. Before attempting to per- form any service or maintenance, turn the electrical power to unit OFF at dis- connect switch(es). Unit may have multiple power supplies.

1 Clean and inspect the outdoor coil. The coil may be

flushed with a water hose. Make sure power is off be-

fore cleaning.

2 Condenser fan motor is prelubricated and sealed. No

further lubrication is needed.

3 Visually inspect connecting lines and coils for evidence

of oil leaks.

4 Check wiring for loose connections.

5 Check for correct voltage at unit (unit operating).

6 Check ampdraw condenser fan motor.

Unit nameplate _________ Actual ____________ .

NOTE If the owner complains of insufficient cooling,

the unit should be gauged and the refrigerant charge

should be checked. Refer to the charging section in

this instruction.

Indoor Coil

1 Clean coil, if necessary.

2 Check connecting lines and coils for evidence of oil

leaks.

3 Check the condensate pan line and clean it if necessary.

Indoor Unit

1 Clean or change filters.

2 Adjust blower speed for cooling. Measure the pressure

drop over the coil to determine the correct blower CFM.

Refer to the unit information service manual for pressure

drop tables and procedure.

3 Belt Drive Blowers Check belt for wear and proper

tension.

4 Check all wiring for loose connections

5 Check for correct voltage at unit (blower operating).

6 Check ampdraw on blower motor

Unit nameplate_________ Actual ____________.

Page 16

Optional Accessories

Refer to the Engineering Handbook for optional accesso-

ries that may apply to this unit. The following may or may

not apply:

Loss of Charge Kit High Pressure Switc Kit Compressor Monitor

Compressor Crankcase Heater

Hail Guards Mounting Bases

Timed Off Control Standoff Kit

Sound Cover Low Ambient Kit

StartUp & Performance Check List

Startup and Performance Check List

Job Name

Job Location

Installer

Unit Model No.

Nameplate Voltage

Rated Load Ampacity

Maximum Fuse or Circuit Breaker

Refrigerant Lines:

Service Valves Fully Opened?

Outdoor Fan Checked?

Job No.

City

City

Serial No.

Date

State

State

Service Technician

Compressor Outdoor Fan

Indoor Filter Clean?Electrical Conne