1

WARNING: READ SAFE OPERATION RULES AND MANUAL CAREFULLY

INSTALLATION OPERATION and MAINTENANCE MANUAL 100% Outside Air Cooling/Dehumidifying Units High Efficiency Split Systems

CONTENTS PAGE

Product Description ................................................3-5 Unit Location...........................................................5, 6 Pre-Installation and Code Requirements..................6 Blower Performance ...................................................7 Condensing Unit Dimensions................................8, 9 Air Handler Unit Dimensions .............................10, 11 Electrical Data ...........................................................12 Low Voltage Wiring ..................................................13 Typical Wiring Diagram .......................................14,15 Piping/Diagram ................................................... 16-18 Leak Testing and Evaluation ...................................17 Preparing Equipment for Operation/Start-Up .........19 Capacity Control .......................................................20 Sequence of Operation.............................................20 Service ..................................................................21-24 Check, Test and Start Form .....................................25

APPLICATION RCA split cooling/dehumidifying systems are designed to cool and dehumidify 100% outside air for those applications requiring make up air cooling. These units should not be used as the primary source of cooling or heating the conditioned space. Cond. Unit Air Handler Nominal

Model Model MBH EER* RCA051 V/HCA051 49.4 10.7 RCA061 V/HCA071 61.6 10.3 RCA071 V/HCA071 69.5 10.1 RCA101 V/HCA101 101.4 10.1 RCA141 V/HCA141 127.6 9.9 RCA201 V/HCA201 201.9 11.0 RCA271 V/HCA271 271.9 9.3 RCA361 V/HCA361 339.8 9.9

* @ 95°F DB, 80°F WB Air Entering Evaporator and Condenser. Table 1

Safe Operation Rules Please take a few minutes to read our instructions before you install and use your air conditioner. This will help you obtain the full value from your air conditioner. It will also help you avoid any needless service costs that result from causes we cannot control and cannot cover in our warranty. Follow these rules and the instructions carefully. Failure to do so could cause a malfunction of the air conditioner, resulting in injury, death and/or property damage. Check local codes and utility standards. The installation must comply with their rules. Always shut off electric power before making unit connections or removing any panels. During installation or servicing, be extremely careful to avoid injury. Components may have sharp edges or protrusions which can cut you. Tubing and compressor contain high pressure refrigerant—they must not be exposed to high temperature or be punctured.

Form # 0527N-0598 Rev. B (0897)

!

2

SAFETY LABELING AND SIGNAL WORDS Danger, Warning and Caution The signal words DANGER, WARNING and CAUTION are used to identify levels of hazard seriousness. The signal word DANGER is only used on product labels to signify an immediate hazard. The signal words WARNING and CAUTION will be used on product labels and throughout this manual and other manuals that may apply to the product. Signal Words DANGER – Immediate hazards which WILL result in severe personal injury or death. WARNING – Hazards or unsafe practices which COULD result in severe personal injury or death. CAUTION – Hazards or unsafe practices which COULD result in minor personal injury or product or property damage. Signal Words in Manuals The signal word WARNING is used throughout this manual in the following manner: The signal word CAUTION is used throughout this manual in the following manner: CAUTION Product Labeling Signal words are used in combination with colors and/or pictures on product labels. Following are examples of product labels with explanations of the colors used.

Operational failure of this unit for any reason, including but not limited to mechanical or electrical failure of devices internal or external to the unit, loss of fuel such as natural or LP gas, or interruption of electric power may result in the introduction of large volumes of air into the conditioned space that could cause freeze or other damage to property. It is the responsibility of the installer and/or user of this unit to provide equipment such as a source of emergency heat, alarm systems, or supervisory systems to warn of such failures.

Electric Shock Hazard. Turn Off All Power Before Servicing.

Fire Hazard. Use copper wire only. Failure to observe could result in property damage, bodily injury or death.

WARNING !

Danger Label White lettering on a black background except the word DANGER which is white with a red background.

Warning Label White lettering on a black background except the word WARNING which is white with an orange background.

DANGER !

Cuts and Abrasion Hazard. Wear gloves and handle with care. Failure to observe could result in bodily injury.

CAUTION !

Caution Label White lettering on a black background except the word CAUTION which is white with a yellow background.

WARNING !

CAUTION

3

PRODUCT DESCRIPTION THE CONDENSING UNIT CONSISTS OF THE FOLLOWING COMPONENTS: Compressor: A welded hermetic compressor used in model sizes 051 through 141 and a serviceable semi-hermetic compressor in model sizes 201 and larger. All compressors have crankcase heaters and the motors are equipped with internal-overload protection (4D compressors use solid state module).The serviceable semi-hermetic compressors are also equipped with isolation valves and oil pressure failure protection. Condenser: The condenser coils are aluminum plate finned formed on multiple rows of seamless copper tubing arranged in a staggered tube configuration. Condenser Air Fan(s): Each condenser air fan is a propeller type, electronically balanced and direct-driven. Condenser air is drawn through the coil(s) horizontally and discharged vertically. Therefore, heated air can not be recirculated. A vinyl coated fan guard is provided. Condenser Fan Motor(s): On standard RCA units the fan motors are single phase and are controlled by a low ambient head pressure control, which cycles the fan, or fans to maintain high side pressure. Units with optional hot gas reheat are different. One condenser fan is direct-driven by a 1075 rpm single phase PSC fan motor, and it is controlled by a variable speed head pressure control. This electronic device is factory set for proper operation. The inherently protected motor has sealed ball bearings that do not require lubrication. On dual and multiple fan units, the other condenser fan motor(s) are three phase and are controlled by a separate low ambient control. REFRIGERANT CIRCUIT COMPONENTS Accumulator: A storage tank located in the suction line of the system. It separates the liquid refrigerant to protect the compressor from liquid slugging by allowing small amount of liquid refrigerant to boil away before entering the compressor. Filter-Drier (liquid): A filter used in the refrigerant line to remove moisture and small particles. High Pressure Safety Control: A manual-reset high pressure control switch will stop the compressor if the system pressure exceeds 400 PSIG. This protects the compressor in case of blockage in the high side of the system. Low Pressure Control/Loss of Charge Protector: An automatic-reset low pressure control switch will stop the compressor if the low side of the system pressure drops below 30 PSIG. This is to protect the compressor in case of blockage in the low side of the system or loss of charge. This control is also used as an operating control-recycling pumpdown. Dual Service Connections: Used for high and low pressure readings. 24 Volt Pump Down Solenoid Valve: Shipped loose with the condensing unit and is to be field installed in the liquid line as close to the evaporator, at the air handling unit, as

possible. The liquid line solenoid is factory installed on units with hot gas reheat. Hot Gas Bypass Circuit: Provided for capacity control by maintaining a constant suction pressure at the compressor. Consists of an adjustable pressure regulator which introduces compressor discharge gas into the evaporator, providing a false load. ELECTRIC CONTROLS Internally wired controls include; Compressor Anti-Short Cycle Timer: Prevents the compressor from rapid starting and stopping due to power interruptions. Fan and Compressor Motor Contactors or Starters: These controls are rated for the connected load. 24 Volt Transformer: Mounted in the sheet metal control panel. The 24 Volt control circuit includes a low voltage terminal board. Condenser Fan Cycling Head Pressure Control: The standard RCA unit utilizes this control to assure adequate head pressure control during low ambient conditions. This head pressure control system cycles the condenser fans off at 180 PSIG and on at 250 PSIG. This setting will be adequate for most systems. If trim adjustment is made, maintain wide differential to prevent rapid cycling of the fan motor. On systems with optional hot gas reheat this low ambient control is only used for the additional fan motor(s). The recommended settings are as follows; cut-off at 230 PSIG, and cut in at 280 PSIG. Variable Speed Condenser Head Pressure Control: (furnished with hot gas reheat) Condenser head pressure is controlled by a variable speed control located in the compressor section. Through sensing of compressor discharge pressure, the voltage to the fan motor is adjusted to speed up or slow down the condenser fan speed. This action produces relatively constant discharge pressure at varying load and ambient conditions. The control is factory set to ensure consistent performance. (See Supplemental Instructions for Hot Gas Reheat for more information). Adjustable Ambient Thermostat (Compressor Lockout Thermostat): A remote field supplied and installed system switch, such as time clock or exhaust fan interlock, is required to start-stop the air handler blower motor and energize the controls. The compressor adjustable ambient lock-out thermostat controls the cooling operation at a setting between 65 and 70 degrees F. Operation of the compressor is thus limited to outside air temperatures above the setpoint. Typically, blower operation is continuous. The leaving air temperature will be maintained by compressor capacity control, accomplished through suction-pressure sensing, thus tracking the outside air temperature variations. The use of discharge air or space sensing devices (duct or room thermostats) to control the compressor will produce unpredictable results and is not recommended.

4

PRODUCT DESCRIPTION Continued

Specifications Condensing Unit

Compressor Condenser Coil(s) Condenser Fan(s) Refrigerant Connections O.D.* Weight Face Fins Hot Gas Nom Area Rows Per Total Hot Gas Reheat Unit Unit Model Type Tons Sq.Ft. Deep Inch No. HP CFM Suction Liquid Bypass Ea. of 2 Oper Ship

RCA051 H 3 1/2 7.7 3 12 1 1/2 4,000 7/8 3/8 3/8 3/8 265 315 RCA061 H 4 1/2 7.7 3 12 1 1/2 4,000 1 1/8 3/8 1/2 3/8 290 340 RCA071 H 5 7.7 4 12 1 1/2 3,900 1 1/8 3/8 1/2 1/2 310 360 RCA101 H 7 1/2 15.4 3 12 1 1 6,000 1 1/8 1/2 5/8 1/2 525 600 RCA141 H 10 15.4 4 12 1 1 5,800 1 3/8 1/2 5/8 1/2 600 675 RCA201 SH 15 23.1 3 12 2 1 12,000 1 5/8 5/8 3/4 1/2 975 1,070 RCA271 SH 24 23.1 4 12 2 1 11,600 1 5/8 5/8 3/4 5/8 1,100 1,200 RCA361 SH 27 38.5 4 12 3 1 18,000 2 1/8 3/4 3/4 5/8 1,470 1,600

Notes: H = Welded Hermetic SH = Serviceable Semi-Hermetic *Optional Hot Gas Reheat is connection size for each of two connections.

For recommended line size, see page 16. Contact factory for additional models not listed above.

Table 2 THE AIR HANDLING UNIT CONSISTS OF THE FOLLOWING COMPONENTS: Evaporator: The evaporator coil is aluminum plate-finned formed on multiple rows of seamless copper tubing arranged in a staggered tube configuration. Blower: A forward curved, Double wheel double inlet centrifugal blower is used for the indoor air. The blower wheel is mounted on a solid steel shaft supported by sealed ball bearings. The shaft is driven by adjustable belt drive sheaves connected to a 1725 rpm motor. The blower has sealed ball bearings that do not require lubrication. Blower Motor: The blower motor operates at 1725 rpm. The motor has sealed ball bearings that do not require lubrication. Motors through 3 horsepower are inherently protected (auto reset) and motors 5 horsepower and larger are externally protected (manual reset).

Control Kit: Shipped loose for field mounting next to the air handler; the control kit includes the blower motor contactor or starter. REFRIGERANT CIRCUIT COMPONENTS Thermostatic Expansion Valve: The expansion valve is adjustable and factory installed. Distributor tubes from the expansion valve meter the refrigerant evenly to the evaporator refrigerant circuits. Hot Gas Bypass Tee: Provided to facilitate piping of this circuit to the condensing unit. The hot gas bypass circuit is provided for capacity control by maintaining a constant suction pressure at the compressor.

Specifications Air Handler

Coil Blower Cond. Filters 1" Weight Face Fins Motor H.P. Drain Metal Mesh Pounds

Vertical Horizontal Area Rows Per DWDI Std. Opt. Opt. Size Unit Unit Model Model Sq.Ft. Deep Inch Size “S” “M” “L” No. F.P.T. No. Size Oper. Ship

VCA015 HCA051 2.8 4 12 10 x 4 1/2 NA NA 1 3/4 1 20 x 25 140 170 VCA071 HCA071 4.5 4 12 10 x 4 1/2 NA NA 1 3/4 2 16 x 22 210 240 VCA101 HCA101 8.0 3 12 12 x 12 1/2 3/4 NA 2 3/4 2 16 x 25 400 440

1 20 x 25 VCA141 HCA141 8.0 4 12 12 x 12 1/2 3/4 1 2 3/4 2 16 x 25 460 500

1 20 x 25 VCA201 HCA201 14.6 4 12 15 x 15 3/4 1 1 1/2 2 1 1/4 6 16 x 25 780 840 VCA271 HCA271 14.6 4 12 15 x 15 1 1 1/2 2 2 6 16 x 25 800 860 VCA361 HCA361 19.5 4 12 15 x 15 1 1/2 2 3 2 1 1/4 4 20 x 24 935 995

2 20 x 30 Table 3

5

PRODUCT DESCRIPTION Continued

OPTIONAL FEATURES (which may be furnished with the system) Heat Recovery Water Heater (Desuperheater): By factory installing a refrigerant- to- water heat exchanger on top of the condensing unit, and piping the refrigerant side into the compressor discharge, waste heat recovery is accomplished in a straight forward manner. The two water connections are stubbed out for field piping to other heat recovery units or directly to the domestic hot water supply which also must include a circulating pump, temperature control valve, and storage tank.. Sure-Trip™: Phase loss and low voltage safety monitor automatically stops the unit whenever a phase is lost, phases are out-of-sequence, or when voltage level drops too low. Restart is automatic, with time delay when proper power supply conditions are restored. Hot Gas Reheat Coil: For closer humidity control, a one row copper tube, aluminum fin (12 fins per inch) hot gas reheat system can be factory installed. The system includes the heat reclaim coil, located downstream from the evaporator coil in the air handler, condenser variable speed head pressure control, check valve and a differential pressure regulator valve in the condensing unit. Available reheat capacity is 4,500 btu per ton. A field adjustable thermostat controls the hot gas reheat solenoid valve. The Heat Recovery Water Heater Coil is not recommended to be used with units equipped with Hot Gas reheat.

Clogged Filter Indicator: Dirty or clogged filters are red flagged by the indicator when the preset pressure differential across the filters is reached. The indicator is field installed and manual-reset. Electric Heaters: Add-on electric heaters are available in a wide kilowatt range. The heater is shipped loose for field mounting to the supply air duct connection of the air handler. Heaters are furnished with open coil heating elements of high grade nickel-chromium, auto reset primary and manual reset secondary safety devices, differential air pressure switch, and branch circuit fusing per NEC/UL. A hinged cover control panel is provided on the welded galvanized steel cabinet. A separate field installed and wired system switch and disconnect for the electric heater may be required.

Air Handler Model Heater kW* Available V/HCA051 1-9 V/HCA071 1-12 V/HCA141 1-25 V/HCA201 5-39 V/HCA271 5-50 V/HCA361 10-60

*Minimum 80 CFM per kW Table 4

UNIT LOCATION Condensing Unit Location Locate as near as possible to the inside section in order to keep connecting refrigerant tubing lengths to minimum and thus minimize loss of capacity due to long lines (see Table 9 Notes 5 & 6). An intake louver protects the service end and clearance at this point should be maintained. A 36" clearance must be allowed for access to the compressor and electrical panel. A 24" clearance must be maintained for the air inlet to the condenser coil(s). Do not locate the unit under an overhang that will short circuit hot air to the coil intakes. When installed at ground level, the unit should be mounted on a level concrete slab which should extend at least 2" beyond the unit on all sides. The top of the slab should be 2" above the ground level. The depth of the slab below the ground level and its structural design is governed by the type of soil and climatic conditions. The slab must not be in contact with any part of the building wall or foundation. The space between the slab and building wall prevents the possibility of transmitting vibration to the building.

The dimensions of the slab or roof mount should be checked and verified before the equipment arrives. Unit supports, roof opening, roof curb flashing, drain requirements, and electric locations are important to a good installation. When installing the equipment on top of a building, the following should be considered: Structural members supporting the unit must be sufficiently strong for the weight of the unit and mounting rails. Locate the unit as near as possible to the center of the area to be environmentally controlled. Sufficient clearance must be available for service, edge of roof, other units, or hazards. The condenser air inlet and discharge air must be unobstructed by overhang, walls, or other equipment. Avoid locations next to exhaust fans or flues. Select a location where external water drainage cannot collect around the unit. Locate the unit so roof runoff water does not pour directly on the unit. Provide gutter or other shielding at roof level. Where snowfall is anticipated, mount the unit above the maximum snow depth for the area.

6

AIR HANDLER UNIT LOCATION When locating the air handlers, make sure there is sufficient free area to allow for adequate airflow to the filters. The air handler must be situated so that it can be serviced and the filters changed. Access panels are located on four sides of vertical units and two sides of horizontal units. However, consideration for the adjustments of the drive belt and motor are important when locating the units adjacent to walls or other units. The cabinets of these units are well insulated. In most installations, this construction will prevent sweating on the

outside of the unit. However, in cases where units are installed above ceilings which are over areas where high humidity conditions are prevalent, it is recommended that an insulated watertight pan with adequate drain connection be constructed and installed under the air handler. This separate drain pan should extend approximately 2" beyond the unit on all sides to ensure collection of any condensate forming on the outside of the cabinet. When this additional pan is used, the unit must be suspended above the pan. Air handlers are designed for a ducted supply application. Inlet air may be ducted as required.

PRE-INSTALLATION AND CODE REQUIREMENTS GENERAL These instructions are to be used as a guide only and in no way supersede local codes or ordinances. Comply with local mechanical and electrical codes. Insure proper strength for unit support at mounting location. Install proper electrical power service and disconnect switch. Provide drainage as necessary. Maintain minimum clearance for airflow into and out of unit. Inspection of Product Received Before acceptance upon its arrival at the job site, all equipment should be carefully inspected for damage incurred during shipment. If necessary remove panels for more complete inspection. Damage claims must be noted on the shipping voucher or bill of lading and reported at once, a concealed damage report must be filed with the shipper in order to process claim. It is important to check the unit model number, heating size, electrical characteristics ,and accessories to ensure they are correct. Ductwork Properly sized and installed ductwork is critical to reliable performance of the unit and system. Unit connections size are shown in Figures 6 through 10 and in the engineering specification manual. All ductwork must be installed according to local codes, practices and requirements. Industry manuals should be used as a guide to sizing and designing the duct system. Ducts passing through unconditioned spaces must be well insulated with vapor barrier to prevent condensation. Condensate Drain Trap It is important that the unit be level for condensate drainage. The condensate trap must exceed the total

operating static pressure (inches of water). Most units of this type will have a condensate drain connection on both sides. Plug the unused drain connection, if necessary. The trap must be primed before operating the unit. See Figure 1. Ensure the condensate line is properly pitched for drainage.

7

PRE-INSTALLATION AND CODE REQUIREMENTS Continued

Air Handler Evaporator Blower Performance External Static Pressure – Inches H2O 0.4 0.6 0.8 1.0 1.2 1.4 1.6

Model CFM R.P.M. B.P.H. R.P.M. B.P.H. R.P.M. B.P.H. R.P.M. B.P.H. R.P.M. B.P.H. R.P.M. B.P.H. R.P.M. B.P.H. 400 780 0.2 900 0.2 1,030 0.2 1,150 0.2 1,240 0.3 1,320 0.3 1,410 0.3

VCA/HCA 500 840 0.2 960 0.2 1,060 0.2 1,170 0.2 1,260 0.3 1,330 0.3 1,430 0.4 051 600 870 0.2 990 0.2 1,090 0.2 1,190 0.3 1,270 0.3 1,350 0.3 1,440 0.4 700 940 0.2 1,030 0.2 1,120 0.3 1,220 0.3 1,300 0.4 1,380 0.4 1,450 0.4 500 720 0.2 840 0.2 960 0.2 1,060 0.2 1,160 0.2 1,260 0.3 1,340 0.3

VCA/HCA 600 750 0.2 860 0.2 980 0.2 1,080 0.2 1,770 0.3 1,270 0.3 1,350 0.3 071 700 800 0.2 890 0.2 1,000 0.2 1,090 0.3 1,190 0.3 1,280 0.4 1,360 0.4 800 840 0.2 930 0.2 1,040 0.3 1,110 0.3 1,210 0.4 1,290 0.4 1,370 0.5 900 890 0.3 970 0.3 1,070 0.3 1,150 0.4 1,230 0.5 1,300 0.5 1,380 0.5 900 610 0.2 720 0.3 820 0.3 910 0.3 990 0.4 1,050 0.5 1,120 0.5

VCA/HCA 1,100 640 0.2 750 0.3 840 0.3 930 0.4 1,020 0.4 1,080 0.5 1,140 0.6 101 1,300 660 0.2 760 0.3 850 0.4 950 0.4 1,030 0.5 1,090 0.6 1,160 0.7 1,500 680 0.3 780 0.3 870 0.4 960 0.5 1,040 0.6 1,100 0.7 – – 1,100 650 0.2 770 0.3 860 0.3 940 0.4 1,020 0.5 1,090 0.6 1,160 0.6

VCA/HCA 1,400 700 0.3 800 0.3 880 0.4 960 0.5 1,040 0.7 1,120 0.7 1,180 0.8 141 1,700 740 0.4 820 0.5 900 0.6 980 0.7 1,050 0.8 1,130 0.8 1,200 0.9 2,000 790 0.5 860 0.6 940 0.7 1,010 0.8 1,080 0.9 1,140 1.0 – – 1,500 480 0.3 590 0.3 670 0.4 740 0.5 810 0.6 860 0.7 920 0.8

VCA/HCA 2,000 510 0.4 600 0.5 680 0.6 750 0.6 820 0.8 870 0.9 930 1.1 201 2,500 550 0.5 630 0.6 690 0.7 760 0.8 830 1.0 880 1.2 940 1.3 3,000 580 0.7 650 0.8 720 0.9 780 1.1 840 1.3 890 1.5 – – 2,500 550 0.4 630 0.6 690 0.7 760 0.8 820 1.0 880 1.2 940 1.3

VCA/HCA 3,000 580 0.7 650 0.8 720 0.9 780 1.1 830 1.3 890 1.4 950 1.6 271 3,500 630 0.9 690 1.1 740 1.2 800 1.4 850 1.6 910 1.7 960 1.9 4,000 650 1.2 730 1.4 780 1.5 820 1.7 870 1.8 – – – – 3,200 530 0.6 600 0.7 660 0.8 720 1.0 780 1.2 840 1.3 900 1.5

VCA/HCA 3,800 570 0.8 620 1.0 680 1.2 750 1.3 800 1.5 850 1.7 910 1.8 361 4,400 600 1.2 660 1.3 720 1.5 770 1.7 820 1.8 870 2.1 920 2.3

5,000 640 1.6 700 1.7 750 1.8 800 2.1 850 2.4 900 2.6 940 2.7 Notes: Unshaded areas for “S” Models. Light Gray shaded areas for “M” Models. Dark Gray shaded areas for “L” Models.

Tables can be interpolated but not extrapolated. Table 5

8

DIMENSIONS

9

DIMENSIONS Continued

10

DIMENSIONS

11

DIMENSIONS Continued

12

ELECTRICAL

Electrical Data – Condensing Unit Condenser Max Compressor Fan Motors(s) Unit Fuse

Model Power RLA LRA No. HP FLA RLA MCA* Size* RCA051-1E 208/230-1-60 21.5 95.4 1 1/2 3.5 25.0 31 50 RCA051-3E 208/230-3-60 13.8 82.0 1 1/2 3.5 17.3 21 30 RCA051-4E 460-3-60 6.9 41.0 1 1/2 1.8 8.7 11 15 RCA051-6E 380/415-3-50 6.9 41.0 1 3/4 2.2 9.1 11 15 RCA061-1E 208/230-1-60 27.6 125.0 1 1/2 3.5 31.1 38 60 RCA061-3E 208/230-3-60 16.0 90.0 1 1/2 3.5 19.5 24 35 RCA061-4E 460-3-60 7.7 45.0 1 1/2 1.8 9.5 12 15 RCA061-6E 380/415-3-50 7.7 45.0 1 3/4 2.2 9.9 12 15 RCA071-1E 208/230-1-60 30.8 142.0 1 1/2 3.5 34.3 42 70 RCA071-3E 208/230-3-60 19.3 130.0 1 1/2 3.5 22.8 28 45 RCA071-4E 460-3-60 8.7 65.0 1 1/2 1.8 10.5 13 20 RCA071-6E 380/415-3-50 8.7 65.0 1 3/4 2.2 10.9 14 20 RCA101-3E 208/230-3-60 27.1 183.0 1 1 6.2 33.3 41 60 RCA101-4E 460-3-60 14.2 91.0 1 1 3.1 17.3 21 35 RCA101-6E 380/415-3-50 14.2 91.0 1 3/4 2.2 16.4 20 30 RCA141-3E 208/230-3-60 34.6 193.0 1 1 6.2 40.8 50 80 RCA141-4E 460-3-60 17.3 97.0 1 1 3.1 20.4 25 40 RCA141-6E 380/415-3-50 17.3 97.0 1 3/4 2.2 19.5 24 40 RCA201-3E 208/230-3-60 48.2 275.0 2 1 6.2 60.6 73 110 RCA201-4E 460-3-60 23.6 138.0 2 1 3.1 29.8 36 50 RCA201-6E 380/415-3-50 23.6 138.0 2 3/4 2.2 28.0 34 50 RCA271-3E 208/230-3-60 86.0 428.0 2 1 6.2 98.4 120 200 RCA271-4E 460-3-60 43.0 214.0 2 1 3.1 49.2 60 100 RCA271-6E 380/415-3-50 43.0 214.0 2 3/4 2.2 47.4 59 100 RCA361-3E 208/230-3-60 118.0 470.0 3 1 6.2 136.6 167 250 RCA361-4E 460-3-60 59.0 235.0 3 1 3.1 68.3 84 125 RCA361-6E 380/415-3-50 59.0 235.0 3 3/4 2.2 65.6 81 125

* MCA – Minimum Circuit Ampacity Max. Fuse Size – Maximum Time Delay fuse or HACR Circuit Breaker Table 6

Electrical Data Air Handler Blower Motor

Motor Horse Power Power FLA MCA*

Max Fuse Size*

208/230-1-60 4.4 6 15 208/230-3-60 2.0 3 15

460-3-60 1.0 2 15 1/2

380/415-3-50 1.5 2 15 208/230-1-60 5.4 7 15 208/230-3-60 2.8 4 15

460-3-60 1.4 2 15 3/4

380/415-3-50 2.1 3 15 208/230-1-60 6.4 8 15 208/230-3-60 3.6 5 15

460-3-60 1.8 3 15 1

380/415-3-50 1.9 3 15 208/230-1-60 7.7 10 15 208/230-3-60 4.6 6 15

460-3-60 2.3 3 15 1 1/2

380/415-3-50 2.7 4 15 208/230-1-60 13.0 17 25 208/230-3-60 6.2 8 15

460-3-60 3.1 4 15 2

380/415-3-50 3.5 5 15 208/230-3-60 8.0 10 15

460-3-60 4.0 5 15 3 380/415-3-50 4.7 6 15

*MCA – Minimum Circuit Ampacity Max. Fuse Size – Maximum Time Delay Fuse or HACR Circuit Breaker Table 7

Requirements All electrical work shall conform to theNational Electric Code and Local Codes.The power supply should be checkedagainst the unit nameplate characteristics.It must be within 10% of rated voltage andnot more than 2% phase unbalance. Thepower supply cables must be sized tocarry the minimum circuit ampacity listedon the nameplate. For your safety, make sure that the unithas been properly grounded at ground lugconnection. Do not obstruct service panelsor service areas with electrical gear.

13

ELECTRICAL CONTINUED LOW VOLTAGE WIRING Control System Wiring: For commercial equipment the following table lists the minimum size of 24 volt class 2 wire to be used.

Ft. Run From Unit to Wire Size System Switch or Longest Run 18 AWG Maximum Run 50 Feet 16 AWG Maximum Run 75 Feet 14 AWG Maximum Run 100/125 Feet 14 AWG Maximum Run 150/200 Feet

Table 8 Due to the complex refrigerant circuitry of these models, strict adherence to recommended line sizes and maximum line length is required. The maximum wire length shown above is not permitted for refrigerant line length. See Table 9 for recommended refrigerant line sizes and length restrictions. Temperature Controls: The Ambient Compressor Thermostat controls compressor on/off operation. The use of space or duct mounted sensors to control the compressor will produce unpredictable results. On systems with optional Hot Gas Reheat a discharge air thermostat is mounted in the air handler. A sensor located in the conditioned space may be used in conjunction with the control for Hot Gas Reheat. A remote system switch such as a timeclock or interlock may be used to energized the controls.

Once it is established that supply voltage is within the utilization range; check and calculate if an unbalanced condition exists between phases. Calculate percent voltage unbalance as follows:

Percent Maximum Voltage Deviation Voltage = 100x From Average Voltage Unbalance Average Voltage

FOR EXAMPLE - With voltage of 220, 215, and 210 (Measure L1-L2, L1-L3, L2-L3).

Average voltage = 645 ÷ 3 = 215 Maximum voltage deviation from Average voltage = 220 - 215 = 5

Percent 100 x 5 = 500 Voltage Unbalance

215 215 = 2.3% Percent voltage unbalance must not exceed (2%) two percent. Contact power company if phase unbalance exceeds 2%. A means of disconnecting power from the unit must be placed adjacent to the unit in accordance with national electrical code or local codes. Aluminum power wire is not recommended.

Note: Wiring – Consult the wiring diagram furnished with the unit. These units are custom designed for each application. The following wiring diagrams are furnished only as a guide to the installing contractor. The unit wiring diagram is located inside the control panel of each unit.

14

TYPICAL FIELD WIRING DIAGRAM

15

16

PIPING

Recommended Refrigerant Line Sizes – O.D. Equivalent Line Length - Feet

0 to 25 26 to 50 51 to 75 Hot Gas Hot Gas Hot Gas Hot Gas Hot Gas Hot Gas

RCA Model

Suction Liquid Bypass Reheat Suction Liquid Bypass Reheat Suction Liquid Bypass Reheat 051 7/8 3/8 1/2 3/8 3/8 7/8 3/8 1/2 3/8 3/8 7/8 3/8 1/2 1/2 3/8 061 1 1/8 3/8 1/2 1/2 3/8 1 1/8 1/2 5/8 1/2 3/8 1 1/8 1/2 5/8 1/2 3/8 071 1 1/8 3/8 1/2 1/2 3/8 1 1/8 1/2 5/8 1/2 3/8 1 1/8 1/2 5/8 1/2 3/8 101 1 1/8 1/2 5/8 5/8 3/8 1 1/8 1/2 5/8 5/8 3/8 1 3/8 1/2 5/8 5/8 3/8 141 1 3/8 1/2 3/4 5/8 1/2 1 3/8 5/8 3/4 5/8 1/2 1 3/8 5/8 3/4 5/8 1/2 201 1 5/8 5/8 3/4 5/8 1/2 1 5/8 5/8 3/4 3/4 1/2 1 5/8 3/4 3/4 3/4 1/2 271 1 5/8 5/8 3/4 3/4 1/2 1 5/8 3/4 3/4 7/8 1/2 2 1/8 3/4 3/4 7/8 1/2 361 2 1/8 5/8 3/4 3/4 5/8 2 1/8 3/4 7/8 7/8 5/8 2 1/8 3/4 7/8 7/8 5/8

Notes: 1. Line lengths are equivalent, Including all fittings. Use long radius elbows only. 2. Line sizes are for both vertical and horizontal runs. 3. Over 75 equivalent feet, consult factory for sizing recommendations. 4. Liquid line sizes are designed to minimize system refrigerant charge.

5. Over 75 lineal feet, a special hot gas bypass system must be installed in the condensing unit with an oil separator. Contact factory. 6. On hot gas reheat line sizes, the first column is supplied from condensing unit, the second column is return to condensing unit.

Table 9

Installation of Piping Read these instructions completely before proceeding with piping. WARNING: This system contains dry nitrogen under pressure and must be relieved before making connections Nitrogen is nonpolluting and may be vented to the atmosphere. Remove access panels from compressor section. Prepare to connect the two sections with clean dehydrated refrigeration grade tubing. Recommended line sizes can be found in Table 9. In order to assure oil return a velocity of 1000 FPM must be maintained. Use standard industry methods to install piping including traps and risers as recommended for the total equivalent feet. Locations where copper tubing will be exposed to mechanical damage should be avoided. If it is necessary to use such locations, the tubing should be enclosed in rigid or flexible conduit. Horizontal piping runs should be supported enough to prevent high binding stresses in the tubing. The weight of vertical piping may be either supported with riser clamps bearing on structural members of the building or by a platform at the bottom of the riser. Supports should be strong enough to handle any load by thermal expansion or contraction of the pipe so that stresses will not be placed on the equipment to which the piping is connected. The suction line, hot gas bypass, and both hot gas reheat lines (if included) should be insulated with 5/8" minimum thickness closed cell foamed insulation, to prevent sweating or heat loss. All lines, except the liquid line, must

be insulated. However, on installations where the liquid line is exposed to high ambient areas, the liquid line must be insulated to prevent subcooling loss. Refrigerant lines run underground should be insulated with 3/4" minimum thickness closed cell foamed insulation. Suction horizontal lines must be pitched toward the compressor unit, see Figure 13 on page 15. When the air handler is installed at a higher elevation than the compressor, provide a vertical loop in the suction line adjacent to the air handler to a point at least to the top of the evaporator coil. Do not insulate the refrigerant or condensate drain lines until all joints in these lines are leak tested. WARNING: This system contains dry nitrogen under pressure and must be relieved before making connections. Nitrogen is nonpolluting and may be vented to the atmosphere. Purge holding charge from the condensing unit by opening both the high and low pressure gauge ports on the condensing unit and allow holding charge to bleed off to atmospheric pressure. Drill a 1/16" bleed hole in the cap on the suction line fitting of the air handler (Larger of the two fittings) and allow holding charge to reduce to atmospheric pressure. Remove caps on the suction and liquid lines of the outside section by drilling a small hole in the caps and then apply heat to caps to remove. The caps are soldered to the fittings with soft solder. Carefully clean the suction line and liquid line fittings on the outside and braze the refrigerant lines to these fittings. Leave gauge port open until all brazing is completed. Low pressure nitrogen purging is recommended while brazing.

!

!

17

PIPING Continued INSTRUCTIONS FOR PIPING HOT GAS BYPASS Before piping this refrigerant circuit it is important to read the Installation of Piping Instructions. See page 14. Locate the hot gas bypass tee (factory installed) at the evaporator coil. It is located between the thermostatic expansion valve and the distributor. Locate the hot gas bypass circuit connection in the condensing unit. The hot gas bypass valve and solenoid are factory installed. See Table 9, Notes 5 & 6.

Size the piping between the evaporator and condenser for a minimum pressure drop. See Table 9 for recommended line sizes. The piping should be free draining to the evaporator tee connection to ensure oil return to the compressor. Connect the piping with clean, dehydrated refrigerant grade tubing. Use standard industry practices to install the refrigerant line.

LEAK TESTING AND EVACUATION Charge system with R-22 trace gas and dry nitrogen. Pressurize to 150 PSIG. Check inside unit, and interconnecting piping with suitable leak detector. Recommend GEH10 or equivalent to be used for trace gas. Release testing charge and connect a good vacuum pump to the gauge connections. Do not open any other valves at this time. Connect a micron gauge to the vacuum pump. A deep vacuum of at least 500 microns is required. Wait at least 15 minutes, if there is no rise on the micron gauge the system is sealed. ! CAUTION: On units with optional Hot Gas Reheat. It is necessary to take some additional steps to ensure a complete evacuation of the system. The use of two suction points will be required due to the complexity of the refrigerant circuitry. It is recommended that a suction manifold be used at the vacuum pump for evacuation of these systems. Leaks Leaks occur at incorrectly made joints. Very small scratches or particles of dirt in a joint can cause a refrigerant leak. The leak may be so small that it is difficult to detect on a

Halide leak detector. Leaks can develop even years after the joint is made unless flux and solder specifically developed for refrigerant work are used. Any improperly made joint will cause trouble in time, as it will eventually leak enough refrigerant to reduce capacity of the system. Moisture Moisture in the refrigeration system will combine with fluorine in the refrigerant and form hydrofluoric acid which will corrode and pit the system. Hydrofluoric acid also decomposes the compressor lubrication oil causing sludge. Great care should be exercised in keeping moisture out of the refrigeration system when installing tubing, because an extremely small amount can cause trouble. For this reason, except on large sizes, only refrigeration grade, seamless annealed sealed copper tubing should be used. This tubing is available at refrigeration supply stores which have been dehydrated and cleaned inside and sealed at each end. Exposure of the inside of the tubing to the atmosphere must be kept to a minimum. Do not use tubing that has been exposed. Dirt Dirt and metal chips must be kept out of the refrigeration system, since they will accumulate at strainers and clog them, restricting the flow of refrigerant.

18

FIELD PIPING DIAGRAM

SPLIT SYSTEM - RCA

19

PREPARING EQUIPMENT FOR OPERTION PRE-START CHECKLIST Is the condenser and air handler unit properly located and level with proper clearance? See page 4. Is the ductwork correctly installed? Is the condensate line properly sized, run, trapped, pitched and primed? Is the air filter of the correct size and number, clean and in place? Is the wiring properly sized and connected according to the unit wiring diagram? Are all wiring connections tight including those in the unit and compressor electrical boxes? Has the unit been properly grounded and fused with the recommended fuse size? See wiring data. Has the unit been leak tested? See page 14. Do the condenser fans and indoor blower turn free without rubbing and are they tight on the shafts? Have all of the set screws been tightened on the blower motor and fan? Has the belt tension in the blower been checked and pulley aligned? Has all work been done in accordance with applicable local and national codes? Are all covers and access panels in place to prevent air loss and safety hazards? Has the voltage been checked? See pages 10 and 11. Has the crankcase heater been energized for 8 hours? Be sure the system switch is “OFF”. START-UP AND REQUIRED FIELD ADJUSTMENTS Do not attempt to start-up system below 50°F. ambient temperature. Be sure the crankcase heater has been energized for a minimum of 8 hours. Break the vacuum with liquid R-22. Add to the liquid line at the condenser until pressures are equalized. Turn system switch on and operate unit. Now add refrigerant vapor in the suction side until the liquid sight glass is clear of bubbles. It is recommended the system be charged initially by clearing the sightglass. Do not overcharge, verify subcooling. On systems with optional hot gas reheat it may be necessary to adjust the reheat thermostat to 50 degrees F. This setting will de-energize the reheat circuit. If not disconnect the reheat thermostat. On semi-hermetic compressors the cylinder unloading coil will also be energized. It is energized by the unloader pressure switch (senses suction pressure). The unloader pressure switch MUST be field adjusted. It should be set to open (unload) at 64 PSIG and close at 78 PSIG. This will maintain a refrigerant temperature in the evaporator of approximately 40 degrees F. The hot gas bypass valve should be energized and this should be the maximum charge required for these units. Units with reheat will require additional charge for the reheat circuit. Adjusting the hot gas bypass valve. This bypass valve Must be field adjusted. The valve must open at 62 PSIG. It may be necessary to simulate a light load if the outdoor

temperature is above 70-75 degrees F. Reduce the evaporator load (lower entering airflow) until the suction pressure lowers to the point at which bypass is desired (62 PSIG). If the hot gas bypass was de-energized to stop hot gas flow, make sure it is now energized. Turn the power assembly adjusting stem on top of the regulator in a clockwise direction until bypass occurs (you will hear the gas flowing or feel the hot gas line, it will be warm when the unit starts to bypass). Check or ensure suction pressure does not fall below the predetermined set point (56 PSIG). A clockwise turn of the adjusting stem will increase the pressure setting; a counterclockwise turn will decrease it. Adjustments should be made in small increments, allowing the system to stabilize after each turn. Vary the evaporator load to test at various conditions to ensure the suction pressure does not drop below the predetermined setpoint. Replace the seal cap on the adjusting stem. Check the airflow by checking the external static pressure. Verify the airflow is within the ratings. Check blower motor amperage. Make adjustments as needed to ensure airflow is correct and to specifications. On RCA units without hot gas reheat, the low ambient head pressure control should be factory set to cut-in at 250 PSIG and cut-out at 180 PSIG. Check calibration of this control. If trim adjustment is required maintain a wide differential. On systems with optional hot gas reheat, check the reheat control valve. This valve is factory set at a differential of 8-10 PSIG. This should be adequate for most applications. However, if additional reheat capacity is required, increase the differential pressure to a higher value. To do this, attach discharge pressure gauges to the Schraeder connections upstream and downstream of the valve. Remove the cap from the top of the valve and turn the stem clockwise to increase the pressure differential and counterclockwise to decrease the differential. Verify the operation of the reheat system by turning the reheat thermostat to a temperature 5-10 degrees F. above the leaving air temperature. The reheat solenoid will be energized and will cycle as the temperature changes. Set the reheat thermostat at the desired leaving air temperature. Adjustment should also include a calibration check of the head pressure control for the other fan motor(s) .The recommended settings are to cut in at 280 PSIG and cut-out at 230 PSIG. Disregard these steps if the unit is not equipped with hot gas reheat. These units utilize an electronic (P-66) variable speed head pressure control for one condenser fan motor. It is factory set to maintain a minimum head pressure of 205 PSIG. For more information on the reheat control valve, See Supplemental Instructions for Hot Gas Reheat. Readjust the reheat thermostat to 65-70 degrees F. The hot gas reheat circuit should be energized. Again clear the sight glass. This would be the maximum charge required for this system. The final adjustment of the refrigerant charge should be by subcooling. The recommended subcooling at the condensing unit should be around 15 degrees at 75 degrees F. and as low as 5 degrees at 105 degrees F. Verify proper operation of the thermostatic expansion valve by checking the superheat. The superheat should be 18-20 degrees at the suction line in the condensing unit.

20

CAPACITY CONTROL Cylinder Unloading Cylinder Unloading is utilized on all RCA units with semi hermetic compressors. The unloader pressure switch MUST be field adjusted on these units. It should be set to open (unload) at 64 PSIG and close at 78 PSIG. This will maintain a refrigerant temperature in the evaporator of approximately 40 degrees F. This is a general recommended setting and may have to be adjusted in up or down a few PSIG’s for optimum operation. A 14 PSIG differential should be maintained. If the compressor runs unloaded for long periods of time, it is an indication that the control is set too high, or that some other part of the system needs adjustment. Check airflow, expansion valve superheat, refrigerant charge or low ambient conditions. Hot Gas Bypass The purpose of the hot gas bypass refrigerant circuit is to maintain evaporator temperature above freezing (32 degrees), thus saving the compressor from failure and controlling capacity. Compressor capacity modulation by means of hot gas bypass is used where normal compressor cycling or the use of cylinder unloading alone may not be sufficient. This bypass valve is used on all

RCA units. It must be field adjusted. The bypass valve opens at the recommended setting and can bypass up to 50% to the evaporator. Due to the reduced power consumption at lower suction pressures, the hot gas bypass valve should be adjusted to bypass at the minimum suction pressure within the compressors operating limits. Be sure the hot gas setting is lower than the unloading pressure control when both are used (semi- hermetic). If the pressure setting of the cylinder unloading is increased, the hot gas bypass setting must also be increased. In order to make field adjustments to this regulator, it may require simulating a light load condition. Connect a pressure gauge to the suction line and block the entering air to the evaporator. Suction pressure will drop and the valve should begin to open at approximately 62 PSIG. It has a range of 6 PSIG and will be fully open at 56 PSIG. The hot gas bypass valve will get warm to the touch when the valve begins to open. To adjust, remove the cap and turn the adjusting stem clockwise to reduce the setpoint and counterclockwise to increase the setpoint. Allow 5 minutes between adjustments to allow the system to stabilize.

SEQUENCE OF OPERATION Control Sequence Refer to Figure 12 for typical wiring diagrams for these units. The field supplied system switch is closed. The “R” circuit from the transformer is fed through the system switch to the coil of the blower motor contactor. This energizes the coil and closes the contacts which brings power to the blower motor. From the low voltage terminal board “R” is connected to the “G” by the closing of the system switch. “G” is a series circuit through the compressor lockout thermostat. If the outdoor temperature is above the setting of the compressor lockout thermostat, “G” is connected to the “Y” terminal and continues to the coil of the cooling relay. This energizes the contacts of the cooling pilot relay which energizes the hot gas bypass solenoid. Another set of contacts from this relay apply power to the “A” terminal of the low voltage terminal board. This energizes the coil of the liquid line solenoid valve. In a parallel circuit power is applied to the high pressure control, and the adjustable time delay. The time delay begins when power is applied to the timer. After the time delay closes, the circuit continues through the low pressure switch, and the compressor overload protection module (if supplied). The coil of the compressor contactor is now energized. At this time the coil of the contactor for the condenser fans is fed through the low ambient control switch (units with reheat use the variable speed control). The contacts close and power is applied to the compressor and fan motors. On systems with semi-hermetic compressors, the compressor contactor and condenser fan contactor(s) are in a series circuit with the oil failure control, and the optional phase monitor. The unloading pressure control will energize and de-energize the unloader solenoid on the compressor as needed.

Systems with hot gas reheat (optional), power is applied from the reheat thermostat from “Y- H” to the reheat valve relay. The reheat thermostat is to be set between 65-70 degrees F. When the outlet or leaving air drops below this setting the thermostat contacts will close and energize the reheat valve relay. The reheat refrigerant circuit is now initiated. It should be noted that the high pressure control has a manual reset feature. The low pressure cutout is set at 30 PSIG and is automatic reset. Experience has indicated that fast cycling on the low pressure control is due to low refrigerant charge, dirty filters, dirty evaporator coil, loose belts, or reduced air flow and will ruin contactor points and compressors. Operating Pressures and Temperatures This information should only be used as a guide, due to the diversity of applications and various conditions (wet bulb and dry bulb) that may be present in the field; A properly charged system will have varied suction and discharge pressures depending on whether the unit is equipped with unloading, hot gas reheat, or in hot gas bypass. The head pressure will be controlled by the low ambient control bringing the fan motors on to lower and turning the fans off to raise the head pressure. The suction pressures will vary up and down reacting to the outdoor (WB) temperature and will depend on whether the unit is in hot gas bypass or unloaded. The head pressure will vary from 220-250 PSIG at average (85-95 degree DB) outdoor temperatures. The temperature difference between the return air (outside temperature DB) and the supply air should be approximately 30-40 degrees F at average entering (WB) conditions. CFM must be correct. The sub-cooling should be around 15 degrees at 75 degrees F and as low as 5 degrees at 105 degrees F. The superheat should be approximately 18-20 degrees F. at the suction line in the condensing unit.

21

SERVICE MAINTENANCE Filters must be checked at least once each month on commercial operations. It is not recommended that filters be allowed to load entirely with dirt before replacement since this practice will permit excess dirt to foul the cooling coil and introduce service problems by reducing air flow. Provisions have been made for ease in changing these items. Belts and Pulleys should be checked whenever filters are changed. Make sure belts and setscrews are set tight. Check for wear, cracking, alignment, tension and motor amperage. Condensate Drains should always be checked whenever filters are changed to ensure the condensate is draining properly. Condensate Drain Pan should be cleaned and flushed every six months. Bearings require no maintenance since sealed ball bearings are used in the blower motor and condenser fan motors. Lubrication is thus provided for the life of the bearing. Finishing of the sheet metal parts are done by painting in an Electro-deposition paint system for a dipped and baked enamel finish. Appearance can be restored with automotive wax. Seacoast Construction. Units furnished with the Seacoast Construction protection option or other corrosion protection coating (Heresite or Bronz Glow); it is imperative to clean and inspect the cabinet, coils and components on a semi-annual basis. Use a chemical cleaning agent to neutralize the contaminant. Then rinse thoroughly. Fresh water rinsing alone doesn’t not constitute cleaning. Controls require no routine maintenance. The points on the compressor contactors will become discolored through usage, but it will not effect system operation, Do not dress or file contact points. Should a surge of power or unusual condition damage points, replace them with identical items from the manufacturer. PARTS SECURITY CHECK Before leaving an installation or operating the unit, determine whether any loose parts should be tightened. Failure to do this may lead to noisy operation. Check all setscrews on blowers and fan blades. Adjust and tighten all thrust collars. Adjust all belts and check drives. Retighten all electric connections. PROCEDURE FOR COMPRESSOR REPLACEMENT It is standard practice to install a liquid line drier in a commercial split system. New system must be evacuated

as outlined on page 14 to remove air and non-condensables in the system. The liquid line drier will trap any moisture left in the system. System cleaning after compressor failure or burnout. Isolate the compressor and remove the refrigerant from system. Remove the inoperative compressor. Install a properly sized suction line filter-drier in the compressor suction line and replace liquid line drier. Examine expansion valves and solenoid valves to see if cleaning or replacement is required. Install the replacement compressor. Evacuate the compressor and system to 500 microns. Open the compressor service valves and charge the system with R-22 after compressor evacuation. See page 18 for instructions on initial start-up procedures. Operate the system. Check the pressure drop across the suction and liquid drier after the first 1 1/2 hours of operation. Pressure drop across a liquid line drier should not exceed 5 PSI and the suction line filter-drier should not exceed 3 PSI. After 8 to 24 hours, take an oil sample and test with an acid test kit. If the oil dirty or acidic, change the suction line and liquid line filter drier and recheck after 8 hours of compressor operation. After two weeks, recheck oil acidity to see if another change of suction line and liquid line filter-drier is necessary. In some cases non-condensable gases are produced during the burnout. Compare the equalized head pressure with the pressure (equivalent) to the outdoor temperature. If the pressures are different, then the system should be purged. System cleaning after compressor mechanical failures: Mechanical compressor failures such as oil pump, valve plates, etc. may not necessarily contaminate the system. Check oil of defective compressor by means of an oil acid kit and check compressor for shorts, grounds and continuity- if all checks negative, then it is only necessary to evacuate replacement or repaired compressor and install a new liquid line drier. Make an acid test after 8 hours of operation. ORDERING PARTS When reporting shortages or damaged parts, give the complete unit model and serial number which is stamped on the unit rating plate. These units are made special to order and the following parts list should only be used as a guide. Do not order parts from these lists.

22

GENERAL SERVICE GUIDE

SYMPTOM POSSIBLE TROUBLE METHOD OF FINDING Compressor Will Not Start.

Power off, loose electrical connections or fuse open. Compressor contactor not closing. Internal compressor thermal overload open. Compressor defective. High or low pressure switch open or defective. Oil pressure control open or defective.

Check disconnect switch, fuses and wiring. Check voltage to contactor coil, transformer slave relay, thermostat. If compressor is hot, allow 2 hours to cool – see below. Check compressor for electrical failure. Compressor may be seized, check for L.R.A. Check calibration of high or low pressure switch. Check oil failure control – see below.

Compressor Starts But Cuts Out On Low Pressure Switch.

Low on refrigerant. Airflow restricted. Restriction in liquid line. Defective low pressure switch.

Check sightglass and check pressures. Check for dirty evaporator coil, dirty filters, dampers closed, iced evaporator, improper belt tension, broken belt, check motor amps, duct design. Check head pressure, check and adjust TXV if not functioning properly, check pressure drop across filter drier. Check calibration of switch.

Compressor Starts But Cuts Out On High Pressure Switch.

Refrigerant overcharged. Condenser fan control has incorrect setting. Fan motor defective. Condenser coil inlet obstructed or dirty. Air or non-condensables in system. Defective high pressure switch. Restriction in discharge or liquid line.

Check pressures, charge by subcooling. Check calibration of the low ambient control. Check fan motor. Check coil and inlet clearances and for possible air re-circulation. Check high side equalized pressure reading with equivalent outdoor temperature. Check calibration of switch. Check discharge and liquid line pressures, check TXV.

Compressor Cuts Out On Thermal Overload.

Low voltage. Sustained high discharge pressure. High suction and discharge pressures. Defective compressor overload. Defective run capacitor. Improper refrigerant charge. Bearings or pistons too tight. Allow time for compressor to cool.

Check voltage. Check running amperage and conditions described under high discharge pressure. Check TXV setting, check for air in system. Allow compressor to cool for two hours if compressor is hot. Recheck for open circuit. Check run capacitor for compressor and fan motor. Check subcooling. Check for low oil level. Check dome temperature of compressor.

Compressor Cuts Out On Oil Failure Control (Semi-Hermetic).

Low oil level. Defective oil pump. Defective control. Liquid refrigerant is entering crankcase.

Check crankcase bull’s-eye – add to have oil level midway in sightglass. Check pump. Check oil failure control for calibration. Compressor will be wet. Check crankcase heater or cause for liquid feedback.

Noisy Compressor.

Scroll compressors are rotation sensitive.

Refrigerant overcharged. Excess or insufficient oil in compressor crankcase. Liquid floodback. Tubing rattle. Compressor defective.

Reverse wiring at disconnect switch may require blower be rechecked for rotation.

Check pressures and subcooling. Check oil level on hermetic compressors, check total equivalent feet of piping, add oil as recommended. Check TXV setting. Refrigerant overcharge refrigerant circuit problem. Dampen by taping or clamping, bend tubing away from contact where possible. Check internal parts. (Semi-hermetic).

23

GENERAL SERVICE GUIDE Continued

SYMPTOM POSSIBLE TROUBLE METHOD OF FINDING

Noisy Operation. Blower rotational noise. Air noise. Chattering contactor. Tubing rattle.

Check blower, motor and drive for faulty adjustment or noisy bearings, loose parts, blower out of balance. Check ductwork. Air Velocity too high. Check for adequate control voltage, check for shorts or breaks, check thermostat, check contactor points. Dampen by taping or clamping, bend tubing away from contact where possible.

High Suction Pressure.

Excessive load on evaporator coil. Broken compressor valves. Scroll compressors do not have valves. Compressor is unloaded. Leaking check valve. Expansion valve not secured to suction line or TXV defective.

Check for high entering wet bulb temperature. Check for excessive airflow. Remove head (semi-herm.) inspect valve reeds. Scroll compressors should not be pumped down below 5 PSI. Recalibrate unloader pressure switch. Check temperature across check valve. Check the TXV, ensure bulb is insulated.

High Discharge Pressure.

TXV setting. Air inlet to condenser dirty or obstructed. Condenser fan, motor defective. Condenser fan control has incorrect setting.

Check TXV setting and calibrate superheat. Check for proper clearances and possible air recirculation. Check condenser fan motor and run capacitor. Check calibration of low ambient head pressure control.

Suction Pressure Too Low.

Refrigerant undercharge. Blower running backwards. Loose blower pulley or belts. Defective or improperly adjusted expansion valve. Dirty filter. Too little airflow or low entering air temperature. Restriction in suction or liquid line.

Check pressures and subcooling. Interchange any two wires from 3 phase disconnect. Check drive, pulley alignment, belt tension. Check superheat and adjust TXV. Check filter and evaporator coil. Check airflow and entering air wet bulb conditions. Check refrigerant circuit for restriction.

Head Pressure Too Low.

Insufficient refrigerant charge. Defective or improperly adjusted expansion valve. Low suction pressure. Condenser fan control setting. Defective compressor.

Check subcooling, check for leak. Check superheat and adjust TXV. See above – suction pressure too low. Check calibration of low ambient control. See above – high suction pressure.

Compressor Short Cycles.

Thermostat location or malfunction. Improper refrigerant charge. Defective high or low pressure control. Cycling on internal overload. Defective expansion valve. Poor air distribution. High discharge pressure. Leaking discharge valves in compressor.

Check thermostat, check heat anticipator setting. Check subcooling, verify superheat. Check high or low pressure switch. Possible tight bearings – see above. Check TXV and superheat. Check ductwork for recirculation. See above – high discharge pressure. See above – high suction pressure.

24

GENERAL SERVICE GUIDE Continued SYMPTOM POSSIBLE METHOD OF FINDING Running Cycle Too Long Or Unit Operates Continuously.

Refrigerant undercharged. Dirty filter or evaporator coil. Dirty or clogged condenser coil. Air or other non-condensables in system. Defective compressor. Restriction in suction and liquid line. Control contacts stuck.

Check subcooling. Check filter, coil and airflow. Check coil and airflow. Check equalized high side pressure with equivalent outdoor temperature. See above – high suction pressure. Check for restrictions in refrigerant circuit. Check thermostat, shorts in wiring, slave relay compressor contactor.

Supply Air Temperature Too High.

Refrigerant undercharge or leak in system. Evaporator plugged with dirt or ice. Improperly adjusted or defective expansion valve. Defective compressor. High discharge pressure. Airflow is too high.

Check subcooling and check for leaks. Check evaporator, airflow and filter. Check superheat and adjust TXV, check bulb. Check compressor for proper operation. See above- high discharge pressure. Check external static pressure.

Supply Air Temperature Too Low.

Airflow is too low. Return air temperature too low.

Check evaporator coil, filter, check for closed dampers, grills, drive for loose parts, belts, misalignment, check external static pressure. Check entering air wet bulb conditions.

Liquid Line Too Hot.

Refrigerant undercharged. High discharge pressure.

Charge by subcooling. See above – high discharge pressure.

Liquid Line Frosted Or Wet.

Restriction in liquid line. Restriction upstream at point of frosting.

Suction Line Frosting.

Insufficient evaporator airflow. Restriction in suction or liquid line. Malfunctioning or defective expansion valve.

Check airflow, check drive for loose parts, belts, closed dampers. Restriction upstream at point of frosting. Check bulb of TXV.

Blower Motor Not Running.

Improper wiring. Defective motor. Defective thermostat or control circuit. Motor off on overload protector.

Check wiring diagram. Check motor controller. Check “R” and “G” Circuit. Allow motor to cool, check amperage.

25

CHECK, TEST AND START FORM GENERAL INFORMATION DATE

Customer Name______________________________ Dealer Name ______________________________ Address ____________________________________ Address __________________________________ City________________________________________ City _____________________________________ ST, Zip _____________________________________ ST, Zip___________________________________ Phone # ____________________________________ Phone # __________________________________ PRODUCT INFORMATION Unit Model #_________________________________ Unit Serial #_______________________________ Application: Total Equivalent Piping ___________________ Total Vertical Lift_______________ A/H Non-Cond. Space ___________________ Ductwork-Estimate Total Equivalent Feet ________________________ Liquid Line Solenoid Installed _________________________ Hot Gas Bypass Installed_________________________ Cylinder Unloading _____________________ Type of Head Pressure Control Used ___________________________ Hot Gas Reheat______________Phase Monitor Protection _________________Type of Thermostat ______________ Electric Heat Installed __________________Liquid Injection _________________ Other Optional _____________ OPERATING INFORMATION Supply Voltage L1-L2 ____________________ L2-L3 _______________________L1-L3 _______________________ (Return) Entering Air Temperature __________ DB _________ WB__________ Design Duct ESP ____________ (Supply) Leaving Air Temperature___________ DB _________ WB__________ Design CFM ________________ Outdoor Air (Inlet) Temperature ____________ DB _________ WB__________ Outdoor Fan Discharge Air Temperature __________ DB________ Suction Pressure ________ PSIG Suction Line Temperature___________Degrees Superheat _______ Degrees

Note: To Calculate Superheat Convert Suction Pressure to Saturation Temperature, Then Subtract the Suction Line Temperature From the Saturation Temperature of the Evaporator. Discharge Pressure ______ PSIG Liquid Line Head Pressure ______ PSIG Liquid Line Temperature _________ Degrees Subcooling _________ Degrees

Note: To Caluclate Subcooling Convert Head Pressure to Saturation Temperature, Then Subtract the Liquid Line Temperature From the Condensing Temperature (Saturation). Oil Level___________ Crankcase Heater Operating _____________Sight Glass Clear ____________ Noise Level ____________ Condition of Unit __________________________________________________________ Compressor(s) #1 FLA ______Voltage T1-T2 _______ T2-T3 ______ T1-T3 ______ Amperage 1PH _______ 2PH______3PH _____ #2 FLA ______Voltage T1-T2 _______ T2-T3 ______ T1-T3 ______ Amperage 1PH _______ 2PH______3PH _____ Condenser Fan(s) HP____________ FLA ____________ Blower Motor HP______________ FLA __________ #1 Voltage ________________ Amperage ______________ #3 Voltage _______________ Amperage ___________ #2 Voltage ________________ Amperage ______________ #4 Voltage _______________ Amperage __________

SETTINGS CUT-IN CUT-OUT CUT-IN CUT-OUT High Pressure Switch Low Pressure Switch Pumpdown Low Pressure Low Ambient Fan #1 Low Ambient Fan #2 Low Ambient Fan #3 Low Ambient Fan #4 Oil Failure Control Hot Gas Bypass Cylinder Unloader Switch

26

NOTES

27

NOTES

28