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INSTALLATION AND MAINTENANCE INSTRUCTIONS
4AC16LT SERIES
Split System Air Conditioner
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WARNING
The equipment covered in this manual is to be installed by trained and experienced service
and installation technicians. Improper installation, modification, service, or use can cause
electrical shock, fire, explosion, or other conditions which may cause personal injury, death,
or property damage. Use appropriate safety gear including safety glasses and glov
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Inspection of Shipment INSTALLATION Upon receipt of equipment, carefully inspect it for possible shipping damage. If damage is found, it should be noted on General the carrier’s freight bill. Take special care to examine the Read this entire instruction manual, as well as the unit inside the carton if the carton is damaged. Any concealed instructions supplied in separate equipment, before damage discovered should be reported to the last carrier starting the installation. Observe and follow all i
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Thermostat Designations Slab Mounting Discharge Air Building Structure Mounting Slab See unit wiring diagram for power supply connections. Ground Level If the indoor unit is not equipped with a blower relay, one must be field supplied and installed. Figure 2 Do not connect C (common) connection between indoor unit and thermostat except when required by the indoor thermostat. Refer to thermostat installation instructions. C (common) connection between indoor unit and outdoor unit required for p
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Select line set diameters from Table 2 to ensure that oil return to the compressor. Size vertical suction riser to maintain WARNING minimum velocity at minimum capacity. Recommended line length is 50’ or less. If more than 50’ line set is required, Polyolester (POE) oils used with R-410A refrigerant contact Technical Service. absorb moisture very quickly. It is very important that the refrigerant system be kept closed as much as Table 2 shows the diameters for line sets up to 100’ although
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copper-to-brass or copper-to-steel brazing) which are rated for use with R410A refrigerant. Outside Unit Placement and Installation 4. Remove the Schrader core assemblies before brazing to protect them from damage due to extreme heat. Replace the cores when brazing is complete. Install unit away from windows 5. Remove light maroon washers from service valves and shield light maroon stickers to protect them during brazing. Wrap a wet cloth around the valve body and copper tube stub to protect it
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Refrigerant Line Sets: Transition from Vertical to Horizontal Automotive Anchored Muffler-Type Heavy Nylon Hanger Wire Tie Strap Liquid Strap Liquid Line to Vapor Line to Vapor Line Wall Wall Line Stud Stud Liquid Line Liquid Line Vapor Line – Wrapped Vapor Line – Wrapped Metal Sleeve in Armaflex Metal Sleeve in Armaflex Figure 6 Refrigerant Line Sets: Installing Vertical Runs (new construction shown) IMPORTANT: Refrigerant lines must not contact wall. Outside Wall Vapor Line Liquid Line NOTE: S
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Flushing Existing Line Set and Indoor Coil Flushing Procedure This procedure should not be performed on systems IMPORTANT: The line set and/or indoor coil must be which contain contaminants, such as compressor flushed with at least the same amount of refrigerant that burn out. previously charged the system. Check the charge in the flushing cylinder before flushing the unit. 1. Remove existing R22 refrigerant using the appropriate CAUTION procedure. When flushing existing line set and/or indoor
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(It may be necessary to bypass the low pressure switches 9. Close the valve on the inverted R-22 cylinder and the to ensure complete refrigerant evacuation.) gauge set valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off. When the low side system pressures reach 0 psig, close the suction line valve. Disconnect all power to the existing 10. Use nitrogen to break the vacuum on the refrigerant outdoor unit. Refer to the gauges after shutdown to confirm li
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Figure 9 Manifold Gauge Set Manifold guage sets used with systems charged with R410A refrigerant must be capable of handling the higher system operating pressures. The gauges should be rated for use with pressures 1 - 800 on the high side and a low side of 30” vacuum to 250 psi with dampened speed to 500 psi. Gauge hoses must be rated for use at up to 800 psi of pressure with a 4000 psi burst rating. Liquid and Suction Line Service Valves The liquid line and suction line service valves (See Fi
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2. With both manifold valves closed, connect the cylin- der of R410A refrigerant. Open the valve on the Ball Type Service Valve R410A cylinder (vapor only). (Valve Open) 3. Open the high pressure side of the manifold to allow R410A into the line set and indoor unit. Weigh in a trace amount of R410A. (A trace amount is a maxi- mum of 2 oz. of refrigerant or 3 lbs. pressure.) Close the valve on the R410A cylinder and the valve on the high pressure side of the manifold gauge set. Discon- nect the R
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of 22 of 222. 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 vacuum pump. 5. Evacuate the line set and indoor unit to a minimum of 500 microns or lower. During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once to determine if there is a rapid rise in pressure. A rapid rise in pressure indicates a relatively large leak. If this occurs, the leak
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START-UP Refrigerant Charge Adjustment CAUTION Liquid Line Set Oz. per 5 ft. adjust If unit is equipped with a crankcase heater, it Diameter from 15 ft. line set* should be energized 24 hours before unit 3. /8 in. 3 oz. per 5 ft start-up to prevent compressor damage as a result of slugging. * If line length is greater than 15 ft., add this amount. If line length is less than 15 ft., remove this amount. 1. Rotate fan to check for frozen bearings or binding. Table 4 2. Inspect all factory and fi
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2. Close manifold gauge set valves. Connect the center manifold hose to an upright cylinder of R410A. Blocking Outdoor Coil Outdoor coil should be 3. If room temperature is below 70°F, set the room thermo- blocked one side at a time stat to call for heat. This will create the necessary load with cardboard or plastic for properly charging the system in the cooling cycle. sheet until proper testing pressures are reached. 4. Use a digital thermometer to record the outdoor ambient temperature. Cardb
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R410A Temperature/Pressure Chart Subcooling Values Temp. Pressure Temp. Pressure Temp. Pressure F Psig F Psig F Psig 32 100.8 74 214.0 116 396.0 33 102.9 75 217.4 117 401.3 34 105.0 76 220.9 118 406.7 35 107.1 77 224.4 119 412.2 Table 6 36 109.2 78 228.0 120 417.7 37 111.4 79 231.6 121 423.2 38 113.6 80 235.3 122 428.8 39 115.8 81 239.0 123 434.5 ° Liquid Line Temperature °F _ 40 118.0 82 242.7 124 440.2 ° Outdoor Ambient Temperature °F 41 120.3 83 246.5 125 445.9 = ° Approac
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Normal Operating Pressures L = Liquid S = Suction Values provided above are typical pressures. Indoor unit matchup, indoor air quality, and indoor load will cause pressures to vary. Table 8 506467-01 Issue 1008 Page 15
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Thermostat Demand Wiring OPERATION Outdoor unit and indoor blower cycle on demand from the The diagnostic module requires a thermostat demand room thermostat. When the thermostat blower switch is signal to operate properly. The thermostat demand signal moved to the ON position, the indoor blower operates input, labeled Y on the module, should always be con- continuously. nected to the compressor contactor coil so that when the coil is energized, the demand signal input is 24VAC. When System Diag
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Flash Codes LED Fault Description Troubleshooting Information Status POWER Ms odule has power Supply voltage is present at module terminal (Green) 1. Compressor protector is open * Check for high head pressure Thermostat demand * Check compressor supply voltage TRIP signal Y1 is present, 2. Outdoor unit power disconnect is open (Red) but the compressor 3. Compressor circuit breaker or fuse(s) is open is not running 4. Broken wire or connector is not making contact 5. Low pressure switch open if
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Flash Codes (cont.) LED Fault Description Troubleshooting Information Status ALERT Short Cycling 1. Thermostat demand signal is intermittent (Yellow) Compressor is 2. Time delay relay or control board defective Flash running 3. If high pressure switch present, go to Flash Code 2 info Code 3 only briefly 4. If low pressure switch present, go to Flash Code 1 info 1. Run capacitor has failed ALERT 2. Low line voltage (contact utility if voltage at disconnect is low) * Check wiring connections (Yell
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Miswired Module Troubleshooting Miswired Module Indication Recommended Troubleshooting Action Determine if both R and C module terminals are connected. Verify voltage is present Green LED is not on, at module's R and C terminals. Review 24VAC Power Wiring section on page 16 for module does not power up. R and C wiring. Green LED intermittent, Determine if R and Y terminals are wired in reverse. Verify module's R and C module powers up only terminals have a constant source. Review 24VAC Power Wir
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4. Check all wiring for loose connections. MAINTENANCE 5. Check for correct voltage at unit (with unit operating). WARNING 6. Check amp-draw on blower motor. Before performing maintenance operations on system, turn the electric power to unit OFF at Unit nameplate _________ Actual _________ disconnect switch(es). Unit may have multiple power supplies. Electrical shock could cause personal injury or death. Maintenance and service must be performed by a quali- fied installer or service agency. At
