2100-241(j) (2000 11) - bardhvac.com
TRANSCRIPT
Installation Instructions
Manual No.: 2100-241JSupersedes: 2100-241IFile: Volume I, Tab 4Date: 11-01-00
Bard Manufacturing CompanyBryan, Ohio 43506
Since 1914...Moving ahead, just as planned.
© Copyright 2000
Split Air ConditionerOutdoor Section
Models: HAC181-AHAC241-AHAC301-AHAC361-AHAC421-AHAC481-AHAC481-BHAC601-AHAC601-B
For Use With:Matching IndoorBlower Coil Unitsand Matching AddOn Coil Units Only
Contents
i
Split Air Conditioner General Information ......... 1Split Air Conditioner Model Nomenclature ............... 1
Application and Location .................................... 4General .................................................................... 4Shipping Damage .................................................... 4Application ............................................................... 4Location ................................................................... 4Mounting Unit Outside on Slab ................................. 4Important Installer Note ............................................ 4Installing Refrigerant Tubing ..................................... 4Sweat Style Tubin Connections: SweatIndoor Unit and Sweat Outdoor Unit ........................ 5Field Fabricated Tubing Connections:Quick Connect Indoor Unit and SweatOutdoor Unit Using CTO Kit ..................................... 6
Wiring Instructions .............................................. 9General .................................................................... 9Control Circuit Wiring ............................................... 9Wall Thermostats ..................................................... 9Optional Controls ................................................... 12Installation Instructions – CMA-5 ............................ 12Installation Instructions – CMA-6 ............................ 12Installation Instructions – CMA-10A........................ 13Installation Instructions – CMA-13A........................ 14
Charging Instructions........................................ 15Pressure Service Ports .......................................... 15System Start-Up (Indoor Unitswithout Expansion Valves ....................................... 15
Service ................................................................ 17Service Hints .......................................................... 17Fan Blade Setting Dimensions ............................... 17Pressure Tables ................................................ 20-23
FIGURESFigure 1 .................................................................... 1Figure 2 .................................................................... 4Figure 3 .................................................................... 5Figure 4 .................................................................... 5Figure 5 .................................................................. 12Figure 6 .................................................................. 12Figure 7 .................................................................. 12Figure 8 .................................................................. 13Figure 9 .................................................................. 14
TABLESTable 1 ..................................................................... 1Table 2 ..................................................................... 2Table 3 ..................................................................... 3Table 4 ..................................................................... 6Table 6 ..................................................................... 9Table 7 ..................................................................... 9Table 8 ..................................................................... 9Table 9 ................................................................... 15Table 10 ................................................................. 15Table 11 ................................................................. 16Table 12 ................................................................. 17Table 13 ................................................................. 20Table 14 ................................................................. 20Table 15 ................................................................. 21Table 16 ................................................................. 21Table 17 ................................................................. 22Table 18 ................................................................. 22Table 19 ................................................................. 23
Manual 2100-241Page 1
SPLIT AIR CONDITIONER MODEL NOMENCLATURE
MIS-617
TABLE 1DIMENSIONS
.oNledoM"W"htdiW
"D"htpeD
"H"thgieH
181CAH142CAH
"04 "51 "62
103CAH163CAH
"54 "51 "62
124CAH184CAH106CAH
"05 "51 "23
Customized Unit Code
Electrical CharacteristicsA – 230/208-60-1B – 230/208-60-3
Modification Code
Capacity – 3 Ton or approx. 36,000 BTU
Basic Model Number
HAC 36 1 – A DXXX
FIGURE 1
Manual 2100-241Page 2
� Measured across the evaporator coil assembly, including drain pan.� External static pressure available for the duct system -- supply and return. All blower coils have
multispeed motors, and value shown is at the recommended rated speed. Consult specificationair flow charts with the blower coil units for complete information at other speeds.
* IMPORTANT INFORMATIONProper sized orifice is not factory installed in indoor section. Proper orifice size is shipped withindoor coil packaged with its installation instructions for indoor sections listed on this page. Theorifice must be replaced with the proper system orifice shown above in Table 2.
For other evaporator coil models not listed, see indoor coil installation instructions for proper orificeinformation.
TABLE 2
RATED CFM AND AIR FLOW DATA(WET COIL – COOLING)
wolfriAdetaR
gnisnednoCtinU
.oNledoM
rotaropavElioC
.oNledoM MFCerusserP
HporD 2OdednemmoceRegnaRwolFriA
ecifirOmetsySderiuqeR
A-181CAH A-SA03A 056 51. 517-055 250. *
A142CAH A-SA03A 008 81. 019-007 550.
A-103CAH A-SA63A 000,1 02. 571,1-058 360.
A-163CAH A-SA73A 001,1 81. 022,1-029 960.
A-124CAHA-SA24AA-SA84A
004,1005,1
03.62.
055,1-072,1526,1-052,1
870.870.
B-,A-184CAH B-SA16A 007,1 82. 578,1-054,1 180. *
B-,A-106CAH B-SA16A 067,1 03. 059,1-005,1 290.
Manual 2100-241
Page 3
TABLE 3
SPECIFICATIONS
SLEDOM A-181CAH A-142CAH A-103CAH A-163CAH A-124CAH A-184CAH B-184CAH A-106CAH B-106CAH
)HP/V/ZH06(gnitaRlacirtcelE 1-802/032 1-802/032 1-802/032 1-802/032 1-802/032 1-802/032 3-802/032 1-802/032 3-802/032
egnaRegatloVgnitarepO 352-791 352-791 352-791 352-791 352-791 352-791 352-781 352-791 352-781
yticapmAtiucriCmuminiM 51 51 91 02 52 62 71 53 12
� eziSeriWdleiF 41 41 21 21 01 01 21 8 01
� rekaerBtiucriCromumixaMesuFyaleD 02 02 03 03 04 54 52 06 53
802/032spmAtinUlatoT 6.8/9.7 4.11/2.01 0.41/4.31 8.51/5.41 6.91/1.91 0.12/4.91 4.31/8.21 7.62/7.22 2.71/3.51
ROSSERPMOC
802/032stloV 802/032 802/032 802/032 802/032 802/032 802/032 802/032 802/032 802/032
spmAdaoLdetaR 5.7/8.6 3.01/1.9 9.21/3.21 7.41/4.31 1.81/6.71 5.91/9.71 9.11/3.11 2.52/2.12 7.51/8.31
tnerruCnoitceleStiucriChcnarB 6.8 3.01 7.31 7.41 1.81 5.91 6.21 3.62 7.51
802/032spmArotoRkcoL 94/94 65/65 57/57 28/28 501/501 201/201 19/19 531/531 051/051
taeHesacknarC enoN enoN enoN enoN noisremmIepyT
noisremmIepyT
noisremmIepyT enoN enoN
RESNEDNOCdnaROTOMNAF
MPR/PHrotoMnaF 5286/1 5286/1 5286/1 5286/1 5284/1 5284/1 5284/1 5284/1 5284/1
spmArotoMnaF 1.1 1.1 1.1 1.1 5.1 5.1 5.1 5.1 5.1
retemaiDnaF 000,2"02 000,2"02 000,2"02 000,2"02 006,2"42 006,2"42 006,2"42 006,2"42 006,2"42
METSYSTCENNOCTAEWS
DIeziSeniLnoitcuS "8/5 "4/3 "4/3 "4/3 "8/7 "8/7 "8/7 "8/7 "8/7
DIeziSeniLdiuqiL "4/1 "8/3 "8/3 "8/3 "8/3 "8/3 "8/3 "8/3 "8/3
.zO22-RegnahCyrotcaF .zo37 .zo97 .zo48 .zo69 .zo201 .zo551 .zo551 .zo351 .zo351
.SBLTHGIEWGNIPPIHS 551 551 081 081 052 052 052 552 552
Manual 2100-241Page 4
APPLICATION and LOCATION
GENERAL
These instructions explain the recommended method toinstall the air cooled remote type condensing unit, theinterconnecting refrigerant tubing and the electricalwiring connections to the unit.
The condensing units are to be used in conjunction withthe matching evaporator coils or evaporator blower unitsfor comfort cooling applications as shown in thespecification sheet.
These instructions and any instructions packaged withany separate equipment required to make up the entire airconditioning system should be carefully read beforebeginning the installation. Note particularly “StartingProcedure” and any tags and/or labels attached to theequipment.
SHIPPING DAMAGE
Upon receipt of equipment, the carton should be checkedfor external signs of shipping damage. If damage isfound, the receiving part must contact the last carrierimmediately, preferably in writing, requesting inspectionby the carrier’s agent.
APPLICATION
Size of unit for a proposed installation should be basedon heat loss calculation and air duct sizing madeaccording to methods of Air Conditioning Contractors ofAmerica. The air duct should be installed in accordancewith the Standards of the National Fire ProtectionAssociation for the Installation of Air Conditioning andVentilating Systems of Other Than Residence Type,NFPA 90A, and Residence Type Warm Air Heating andAir Conditioning Systems, NFPA 90B. Where localregulations are at a variance with instructions, installershould adhere to local codes.
LOCATION
The condensing unit is designed to be located outsidewith free and unobstructed condenser air inlet anddischarge. It must also permit access for service andinstallation. Condenser air enters the coil from the rear ofthe unit as shown in Figure 2 with electrical serviceaccess.
MOUNTING UNIT OUTSIDE ON SLAB
A solid level base or platform, capable to support theunit’s weight, must be set at the outdoor unitpredetermined location. The base should be at least twoinches larger than the base dimensions of the unit and atleast two inches higher than surrounding grade level. Therequired unit minimum installed clearances must bemaintained as called out in Figure 2 when locating andsetting the base.
Remove the unit from its shipping carton and position theunit on the prepared base or platform.
NOTE: These units employ internally sprungcompressors; therefore, it is not necessary toremove or loosen the base mounting bolts on thecompressor prior to operation.
Consideration should be given to the electrical and tubingconnections when placing the unit to avoid unnecessarybends or length of material.
IMPORTANT INSTALLER NOTE
For improved start up performance, wash the indoor coilwith a dishwashing detergent.
INSTALLATION REFRIGERANT TUBING
The information that follows on installing refrigeranttubing and for changing the system orifice (if required)covers applications listed in the front of this installationinstruction only. Although other indoor units may be ofsimilar construction, the installation instructions for theseunits should be consulted for proper installation of thoseunits prior to installation.
This information is provided for the field servicepersonnel to install refrigerant tubing in compliance withSection 608 of Title VI National Recycling and EmissionReduction Program for the U.S. Clean Air Act effectiveJuly 1, 1992.
Consult manual 2100-002 on procedure for leak test –evacuation – charging before installation refrigeranttubing that requires any refrigerant recovery or systemevacuation. Manual 2100-002 is included with the unitinstallation instruction package when shipped from thefactory.
FIGURE 2INSTALLATION CLEARANCE
MIS-589
Manual 2100-241Page 5
SWEAT STYLE TUBING CONNECTIONS:SWEAT INDOOR UNIT and SWEAT OUTDOORUNIT
Use only refrigeration grade (dehydrated and sealed)copper tubing. Care must be taken to insure that thetubing is kept clean and dry before and duringinstallation. Do not remove the plugs from the tubingends, coil connections or base valves until the connectionis ready to be brazed.
The suction line must be insulated with a minimum of3/8” Armaflex or equivalent before cutting and makingconnections.
1. Being careful not to kink, route both the suction lineand liquid line between the indoor unit and outdoorunit. Use a tubing bender to make any necessarybends in tubing. When necessary to bend theinsulated tube suction line, cut the insulation aroundits circumference at a distance far enough beyond thepoint of the bend so as to clear the tubing bender.Slip the insulation back together and vapor seal thejoint with tape. Coil any excess tubing in ahorizontal place with the slope of the tubing towardthe condensing unit. See Figure 3.
NOTE: Do not braze line to units! If orifice needs to bechanged, change out orifice first.
If the orifice does not have to be changed, skip theinstructions outlined further in Step 3 and proceed to Step8.
3. Disassemble Flow Control Assembly by turningbody hex.
4. If existing orifice has not dropped out of the bodywhen disassembled, remove by using a pin or paperclip. Discard this original orifice.
5. Insert proper sized orifice fully into the flow controlbody with rounded “bullet” nose towards the unit asshown in Figure 4. Insure the orifice stays insertedin body before connecting mating half. See chart inthe outdoor unit installation instructions for propersize.
6. Thread assembly halves together by hand to insureproper mating of threads and tighten until bodies“bottom” or a definite resistance is felt.
7. Using a marker pen or ink pen, mark a linelengthwise from the union nut to the bulkhead. Thentighten an additional 1/6 turn (or 1 hex flat). Themisalignment of the line will show the amount theassembly has been tightened. This final 1/6 turn isnecessary to insure the formation of the leakproofjoint.
8. Wrap a wet rag around the copper stub beforebrazing.
9. Flux the copper tube and insert into the stub. Brazethe joint using an alloy of silver or copper andphosphorus with a melting temperature above 1,100°F for copper to copper joints. The phosphorus willact as a flux, therefore, no flux will be required.
FIGURE 3INSTALLING REFRIGERANT TUBING
pp5
CAUTION1. Be careful not to tear the insulation whenpushing it through hole in masonry or framewalls. 2. When sealing the tube opening inhouse wall, use a soft material to prevent tubedamage and vibration transmission. 3. Avoidexcessive bending in any one place to avoidkinking.
CAUTIONBe sure there is no dirt introduced into the flowcontrol - orifice assembly. Be sure to install theorifice with the bullet nose pointing in the properdirection as shown in Figure 4. Failure to do sowill result in improper operation.
2. The tubing ends should be cut square. Make sure itis round and free of burrs at the connecting ends.Clean the tubing to prevent contaminants fromentering the system.
FIGURE 4
FLOW CONTROL ASSEMBLYFIELD ORIFICE REPLACEMENT INSTRUCTIONS
pp5
Manual 2100-241Page 6
A copper-silver alloy with a high silver contentshould be used when iron or steel material isinvolved in the joint. These alloys require the use ofsilver solder flux. Alloys containing phosphorusshould not be used with iron or steel. Phosphorusreacts with the iron forming iron phosphate which isextremely brittle.
To further prevent the formation of copper oxideinside the tubing, dry nitrogen may be purgedthrough the refrigerant system during brazing.
10. After brazing, quench with wet rag to cool the jointand remove any flux residue.
11. Leak test all connections using an electronic leakdetector or a halide torch.
12. Evacuate suction line, liquid line and indoor unitthrough outdoor unit base valves.
13. Open both the suction and liquid base valves to thefully open position. Refer to section later ininstallation instructions for details on setting propersystem charge.
FIELD FABRICATED TUBING CONNECTIONS:QUICK CONNECT INDOOR UNIT and SWEATOUTDOOR UNIT USING CTO KIT
Use only refrigeration grade (dehydrated and sealed)copper tubing. Care must be taken to insure that thetubing is kept clean and dry before and duringinstallation. Do not remove the plugs from the tubingends, coil connections or base valves until the connectionis ready to be brazed.
The suction line must be insulated with a minimum of 3/8” Armaflex or equivalent before cutting and makingconnections.
1. Being careful not to kink, route both the suction lineand liquid line between the indoor unit and outdoorunit. Use a tubing bender to make any necessarybends in tubing. When necessary to bend theinsulated tube suction line, cut the insulation aroundits circumference at a distance far enough beyondthe point of the bend so as to clear the tubing bender.Slip the insulation back together and vapor seal thejoint with tape. Coil any excess tubing in ahorizontal place with the slope of the tubing towardthe condensing unit. See Figure 3.
TABLE 4
TUBING CHART
cisaBgnisnednoCledoMtinU
).tF(htgneLeniLtnaregirfeR
02-0 06-12 001-16
diuqiL noitcuS diuqiL noitcuS diuqiL noitcuS
181CAH "4/1 "8/5 "4/1 "8/5 "8/3 "4/3
142CAH "8/3 "8/5 "8/3 "4/3 "8/3 "4/3
103CAH "8/3 "8/5 "8/3 "4/3 "8/3 "4/3
163CAH "8/3 "8/5 "8/3 "4/3 2/1 "8/7
124CAH "8/3 "4/3 "8/3 "8/7 2/1 "8/7
184CAH "8/3 "8/7 "8/3 "8/7 2/1 "8/1-1
106CAH "8/3 "8/7 "8/3 "8/7 2/1 "8/1-1
CAUTION1. Brazing alloys with a melting temperaturebelow 700° F should not be used. 2. Lead-tinor tin-antimony solders should not be used dueto their low melting point and necessity forcorrosive fluxes.
WARNINGNever purge or pressurize a system withoxygen. An explosion and fire will result. CAUTION
1. Be careful not to tear the insulation whenpushing it through hole in masonry or framewalls. 2. When sealing the tube opening inhouse wall, use a soft material to prevent tubedamage and vibration transmission. 3. Avoidexcessive bending in any one place to avoidkinking.
Manual 2100-241Page 7
CAUTION1. Brazing alloys with a melting temperaturebelow 700° F should not be used. 2. Lead-tinor tin-antimony solders should not be used dueto their low melting point and necessity forcorrosive fluxes.
WARNINGNever purge or pressurize a system withoxygen. An explosion and fire will result.
5. After brazing, quench with wet rag to cool the jointand remove any flux residue.
6. Leak test all connections using an electronic leakdetector or a halide torch.
7. Evacuate suction line and liquid line through outdoorunit base valves.
If orifice does not have to be changed, skip theinstructions outlined further in Step 8 and proceed toStep 15.
8. Recover charge from the indoor unit.
A. Connect the suction line only to the indoor unitas outlined in Steps 15, 16, and 17.
B. Recover indoor unit and suction line unit chargethrough service port located on outdoor unit basevalve.
9. Disassemble Flow Control Assembly by turningbody hex.
10. If existing orifice has not dropped out of the bodywhen disassembled, remove by using a pin or paperclip. Discard this original orifice.
11. Insert proper sized orifice fully into the flow controlbody with rounded “bullet” nose towards the unit asshown in Figure 4. Insure the orifice stays insertedin body before connecting mating half. See chart inthe outdoor unit installation instructions for propersize.
NOTE: Do not make any tubing connection at indoor unitat this time. Make all brazing of joints andevacuate both suction and liquid line first.
3. Wrap a wet rag around the copper stub beforebrazing.
4. Flux the copper tube and insert into the stub. Brazethe joint using an alloy of silver or copper andphosphorus with a melting temperature above 1,100°F for copper to copper joints. The phosphorus willact as a flux, therefore, no flux will be required.
A copper-silver alloy with a high silver contentshould be used when iron or steel material isinvolved in the joint. These alloys require the use ofsilver solder flux. Alloys containing phosphorusshould not be used with iron or steel. Phosphorusreacts with the iron forming iron phosphate which isextremely brittle.
To further prevent the formation of copper oxideinside the tubing, dry nitrogen may be purgedthrough the refrigerant system during brazing.
2. The tubing ends should be cut square. Make sure itis round and free of burrs at the connecting ends.Clean the tubing to prevent contaminants fromentering the system.
CAUTIONBe sure there is no dirt introduced into the flowcontrol – orifice assembly. Be sure to install theorifice with the bullet nose pointing in the properdirection as shown in Figure 4. Failure to do sowill result in improper operation.
14. Evacuate the suction line and indoor unit through theoutdoor unit base valve before connecting all othertubing. Refer to section later in installationinstructions for details on setting the properrefrigerant charge.
15. Remove (remaining) protector caps and plugs (iforifice was changed). Inspect fittings and ifnecessary carefully wipe coupling seats and threadedsurfaces with a clean cloth to prevent the inclusion ofdirt or any foreign material in the system.
12. Thread assembly halves together by hand to insureproper mating of threads and tighten until bodies“bottom” or a definite resistance is felt.
13. Using a marker pen or ink pen, mark a linelengthwise from the union nut to the bulkhead. Thentighten an additional 1/6 turn (or 1 hex flat). Themisalignment of the line will show the amount theassembly has been tightened. This final 1/6 turn isnecessary to insure the formation of the leakproofjoint.
Manual 2100-241Page 8
16. Lubricate male half diaphragm and synthetic rubberseal with refrigerant oil. Thread coupling halvestogether by hand to insure proper mating of threads.Be sure to hold the coupling firmly to preventmovement of the coupling and tubing. Failure to doso could tear out the diaphragm causing a blockageof the system. Use proper size wrenches (oncoupling body hex and on union nut) and tightenuntil coupling bodies ”bottom” or a definiteresistance is felt.
18. Leak test all connections using an electronic leakdetector or a halide torch.
19. When tubing is installed in attics or drop ceilings,insulate the couplings on the larger tube thoroughlywith 3/8” wall thickness, closed cell sponge tubeinsulation or equivalent. Failure to insulate willresult in water damage to ceiling since the fitting will“sweat” and drop water on the ceiling.17. Using a marker or ink pen, mark a line lengthwise
from the coupling union nut to the bulkhead. Thentighten an additional 1/4 turn. The misalignment ofthe line will show the amount the coupling has beentightened. This final 1/4 turn is necessary to insurethe formation of leakproof joint. If a torque wrenchis used, the torque values shown in Table 5 arerecommended.
CAUTIONAfter starting to tighten up the fitting, never tryto back it off or take it apart.
TABLE 5
COUPLINGS
eziSgnilpuoC sdnuoPteeF
6- 21-01
01- 54-53
11- 54-53
21- 56-05
Manual 2100-241Page 9
WIRING INSTRUCTIONS
GENERAL
All wiring must be installed in accordance with theNational Electrical Code and local codes. In Canada, allwiring must be installed in accordance with the CanadianElectrical Code and in accordance with the regulations ofthe authorities having jurisdiction. Power supply voltagemust conform to the voltage shown on the unit serialplate. A wiring diagram of the unit is attached to theinside of the electrical cover. The power supply shall besized and fused according to the specification supplied.A ground lug is supplied in the control compartment forequipment ground.
The unit rating plate lists a “Maximum Time Delay Fuse”or HACR type” circuit breaker that is to be used with theequipment. The correct size must be used for propercircuit protection and also to assure that there will be nonuisance tripping due to the momentary high startingcurrent of the compressor motor.
CONTROL CIRCUIT WIRING
For split systems, the minimum control circuit wiringgauge needed to insure proper operation of all controls inboth indoor and outdoor units will depend on two factors:
1. The rated VA of the control circuit transformer.
2. The maximum total distance of the control circuitwiring. (This is the distance between the wallthermostat to the indoor unit plus the distancebetween the indoor unit to the outdoor unit.)
The following table should be used to determine propergauge of control circuit wiring required.
Example: 1. Control circuit transformer rated at 40 VA2. Maximum total distance of control circuit
wiring 85 feet.
From Table 6, minimum of 18 gauge wire should be usedin the control circuit wiring.
For control circuit transformers rated other than thoselisted, use the next lower rated transformer listed.
Example: 1. Control circuit transformer rated at 55 VA
From table use 50VA transformer.
There are two (2) separate control diagrams for fossil fuelfurnaces with air conditioners.
Control diagrams for the various circuit which could beencountered with blower coils can be found in theinstallation instructions of the blower coil.
WALL THERMOSTATS
The following wall thermostats and subbases should beused as indicated, depending on the application.
TABLE 6
CONTROL CIRCUIT WIRING
foAVdetaRtiucriClortnoC
remrofsnarT
remrofsnarTyradnoceS
ALF @ V42
latoTmumixMfoecnatsiD
tiucriClortnoCteeFnigniriW
04 6.1
56eguag0209eguag81541eguag61032eguag41
05 1.2
54eguag0206eguag81001eguag61061eguag41052eguag21
56 7.2
04eguag0255eguag8158eguag61531eguag41012eguag21
TABLE 7
CONTROL DIAGRAMS
metsySecanruFsaGmargaiDlortnoC
ecanruFliOmargaiDlortnoC
sledoMllA 001-1904 101-1904
TABLE 8
WALL THERMOSTAT and SUBBASE COMBINATIONS
tatsomrehT esabbuS serutaeFetanimoderP
200-3048113F78T
300-40480221A925Q
yrucreM;loocegats1,taehegats1otua-no:naFlooc-ffo-taeh:metsyS
140-3048C-4308T
---yrucreM;loocegats1,taehegats1otua-no:naFlooc-ffo-taeh:metsyS
530-304808-59F1
---loocegats2,taehegats2
elbammargorPcinortcelE
240-3048G1158T
---loocegats1,taehegats2looc-otua-ffo-taeh:metsyS
cinortcelEotua-no:naF
340-3048002MC
---loocegats1,taehegats1
otua-no:naFlooc-ffo-taeh:metsySnoitcApanS
720-304817-29F1
---loocegats2,taehegats3
elbammargorPcinortcelE
Manual 2100-241Page 10
Manual 2100-241Page 11
Manual 2100-241Page 12
OPTIONAL CONTROLS
INSTALLATION INSTRUCTIONS — CMA-5
Disconnect all power to the unit. Remove control panelcover.
1. Mount compressor TDR in position shown in Figure5 with screw provided.
2. Disconnect yellow low voltage (Y) wire at thecompressor contactor coil and reconnect to the Y1 or#3 terminal of the TDR.
3. Connect yellow wire from terminal (Y) of the TDRto the (Y) terminal of the compressor contactor coil.This is the terminal that the wire was removed frominStep 2.
4. Recheck wiring. Refer to Figure 9. Energize unit.Compressor should start. Remove power andreapply. Compressor should not start until the 5minute time delay has expired.
5. Apply “This unit equipped with CMA-5 controlmodule” label to inside of the inner control panelcover above wiring diagram.
6. Replace all panels and covers. This completesinstallation.
INSTALLATION INSTRUCTIONS — CMA-6
Disconnect all power to unit. Remove control panel innerand outer cover.
1. Mount terminal block in position shown in Figure 5.
2. Disconnect black high voltage outdoor motor leadfrom compressor contactor and reconnect to terminalblock.
3. Route low ambient control wires up through thebushing in the bottom of the control panel. Connectthe low ambient control wires between the terminalblock and T2 of the compressor contactor.
4. Remove service port cap on discharge line. Installthe low ambient control on the discharge line withthe flare tee adapter that is brazed to the low ambientcontrol. Check for pressure at the flare tee dill valveafter installation to insure that the dill valve in theunit service port was depressed by the flare teeconnector. Check for leaks at the flare teeconnectors. Replace service port cap on the flare teeservice port and tighten.
5. Recheck wiring. See Figure 10. Check for properoperation of the unit by energizing in cooling mode.The condenser fan motor should not run until thedischarge pressure has exceeded 300 PSI. Should thedischarge pressure fall below 200 PSI while running,the condenser fan motor will de-energize until thehead pressure builds to 300 PSI.
6. Apply “This unit equipped with CMA-6 controlmodule” label to the inside of the control panel coverabove the wiring diagrams.
7. Replace all panels and covers. This completesinstallation.
FIGURE 5COMPONENT MOUNTING LOCATION
FIGURE 6INSTALLATION INSTRUCTIONS
FOR CMA-5 COMPRESSOR TIME DELAY RELAY
MIS-598
FIGURE 7INSTALLATION INSTRUCTIONS FOR
CMA-6 LOW AMBIENT FAN CYCLING CONTROL
MIS-594
MIS-1302
CMA-5 & CMA-13A LOWAMBIENT FAN CYCLINGCONTROL TERMINAL BLOCK
CMA-5 COMPRESSORTIME DELAY RELAY
SK109 LOW VOLTAGESTART KIT
CMA-10A & CMA-13ACOMPRESSORCONTROL
Manual 2100-241Page 13
INSTALLATION INSTRUCTIONS – CMA-10A
Disconnect all power to unit. Remove control panelcover.
1. Screw compressor control module and terminal blockinto control panel as shown in Figure 5.
2. Disconnect yellow low voltage wire formcompressor contactor and reconnect to terminal “Y”of the compressor control module.
3. Connect the yellow wire from the compressor controlmodule to “Y” side of the compressors contactorcoil. This is the same terminal from which the wirewas removed in Step 2.
4. Connect the black wire form the compressor controlmodule to common “C” side of the compressorcontactor coil.
5. Connect a field supplied wire from “R” of the indoorunit to “R” on the compressor control module.
6. Route the high (red) and low (blue) pressure switchwires through the bushing in the bottom of thecontrol panel. Connect the low pressure switch wireto terminals LPC of the compressor control module.
7. Remove service port caps on both the suction anddischarge lines. Install the high pressure switch onthe discharge line to the flare tee adapter that isbrazed to the controls. Install the low pressureswitch on the suction line. Check for pressure at theflare tee dill valves after installation to insure that thedill valve in the unit service port was depressed bythe flare tee connector. Check for leaks at the flaretee connectors. Replace service port caps on theflare tee service ports and tighten.
8. Adjust the compressor time delay relay to the desireddelay on break. Two minutes are recommended.This TDR is variable form 30 seconds to 5 minutes.
9. Recheck wiring. Energize unit is first stage cooling.Compressor should not start until the time delay hasexpired. This will be 10% of the delay on breakperiod. Run the unit for at least 5 minutes. The unitshould not go into lockout.
10. Apply “This unit equipped with CMA-10A controlmodule.” label to the inside of the inner control panelcover above the wiring diagram.
11. Replace all panels and covers. This completesinstallation.
FIGURE 8
INSTALLATION INSTRUCTIONS FORCMA-10A DUAL PRESSURE CONTROL and
COMPRESSOR TIME DELAY RELAY
MIS-1303
Manual 2100-241Page 14
INSTALLATION INSTRUCTIONS – CMA-13A
Disconnect all power to unit. Remove control panelcover.
1. Screw compressor control module and terminalblock into control panel as shown in Figure 5.
2. Disconnect yellow low voltage wire fromcompressor contactor and reconnect to terminal “Y”of the compressor control module.
3. Connect the yellow wire from the compressorcontrol module to “Y” side of the compressor’scontactor coil. This is the same terminal from whichthe wire was removed in Step 2.
4. Connect the black wire from the compressor controlmodule to common “C” side of the compressorcontactor coil.
5. Connect a field supplied wire from “R” of the indoorunit to “R” on the compressor control module.
6. Route the high (red) and low (blue) pressure switchwires through the bushing in the bottom of thecontrol panel. Connect the low pressure switch wireto terminals LPC of the compressor control module.Connect the high pressure switch wires to terminalsHPC of the compressor control module.
7. Disconnect the high voltage outdoor motor lead andreconnect to the terminal block installed in Step 1.
8. Route the LAC (black) wires up through the busingin the bottom of the control panel. Connect one wireto the terminal block and the other to “T2” of thecontactor. This will be the same terminal from
which the high voltage outdoor motor lead wasremoved in Step 7.
9. Remove service port caps on both the suction anddischarge lines. Install the high pressure switch andthe low ambient control on the discharge line withthe flare tee adapter that is brazed to the controls.Install the low pressure switch on the suction line.Check for pressure at the flare tee dill valves afterinstallation to insure that the dill valve in the unitservice port was depressed by the flare teeconnector. Check for leaks at the flare teeconnectors. Replace service port caps on the flaretee service ports and tighten.
10. Adjust the compressor time delay relay to the desireddelay on break. Two minutes are recommended.This TDR is variable from 30 seconds to 5 minutes.
11. Recheck wiring. Energize unit in first stage cooling.Compressor should not start until the time delay hasexpired. This will be 10% of the delay on breakperiod. Run the unit for at least 5 minutes. The unitshould not go into lockout. The condenser fan motorshould not run until the discharge pressure hasexceeded 300 PSI. Should the discharge pressurefall below 200 PSI while running the condenser fanmotor will de-energize until the head pressure buildsto 300 PSI.
12. Apply “This unit equipped with CMA-13A controlmodule.” label to the inside of the inner control panelcover above the wiring diagram.
13. Replace all panels and covers. This completesinstallation.
MIS-1304
FIGURE 9
INSTALLATION INSTRUCTIONS FORCMA-13A DUAL PRESSURE CONTROL, LOW AMBIENT FAN CYCLING CONTROL
and COMPRESSOR TIME DELAY RELAY
Manual 2100-241Page 15
PRESSURE SERVICE PORTS
High and low pressure service ports are installed on allunits so that the system operating pressures can beobserved. Pressure tables can be found later in themanual covering all models. It is imperative to match thecorrect pressure table to the unit by model number.
SYSTEM START-UP (INDOOR UNITSWITHOUT EXPANSION VALVES)
1. Close disconnect switch(es) and set the thermostat tocool and the temperature to the highest setting.
2. Check for proper airflow across the indoor coil byreferring to indoor unit installation.
3. Connect the service gauges and allow the unit to runfor at least 10 minutes or until pressures are stable.Check pressures to the system pressure tableattached to the outdoor unit service panel. Foroptimum system performance, go to Step 4.
4. Install a thermometer on the suction lineapproximately 6" to 10" from the compressor.Optimum system performance will occur with arefrigerant charge resulting in a suction linesuperheat as determined from the followingcalculations.
A. Measure outdoor air dry bulb temperature________ ºF
B. Measure indoor air wet bulb temperature________ ºF
C. Measure suction pressure _____ PSIG
D. Measure suction line temperature ________ ºF
E. Determine optimum system superheatfrom Table 9 using outdoor air dry bulb(Step B) and indoor air wet bulb (Step A)
________ ºF
F. Determine saturated suction temperaturefrom suction pressure using Table 10 _________
ºF
G. Determine system superheat:Suction line temperature (Step D) ________ ºF- Saturated suction temperature (Step F)
- _______ ºF= System superheat
= _______ ºF
H. Adjust the system superheat (Step G) to theoptimum system superheat (Step E) by addingcharge to lower the superheat or removingcharge to raise the superheat.
I. Check final system operating pressures to thesystem pressure tables as was done in Step 3.
CHARGING INSTRUCTIONS
TABLE 10
SATURATED SUCTION TEMPERATURE R-22
GISPerusserPnoitcuSnoitcuSdetarutaS)F(erutarepmeT
053555
628203
851636
234363
567607
839314
376797
345474
2868
9415
TABLE 9SYSTEM SUPERHEAT
tneibmAroodtuOerutarepmeT)bluByrDF(
erutarepmeTriAnruteRbluBteWF
95 36 76 17
5015909580857
1113801
13794102
5)8(41915203
0262339324
Manual 2100-241Page 16
TABLE 11
TOTAL SYSTEM OPERATING CHARGE(Includes charge for the basic outdoor unit,
indoor coil and 25’ of interconnecting tubing.)
noitceSroodtuO noitceSroodnI22-RlatoT
).zO(egrahC
A-181CAHA-SA03AA-SA42S
C42CB
.zo37
.zo37
.zo87
A-142CAHA-SA03AA-SA42S
C42CB
.zo08
.zo08
.zo97
A-103CAHA-SA63A
C63CB.zo48.zo59
A-163CAHA-SA73A
C63CB.zo89.zo69
A-124CAH
A-SA24AA-SA84A
C63CBC06CB
.zo201
.zo711
.zo501
.zo241
B-,A-184CAHB-SA16A
C06CB.zo551.zo571
B-,A-106CAHB-SA16A
C06CB.zo351.zo561
�
�
�
�
�
�
�
Installer Note: Stamp or mark the final systemcharge determined above on the outdoor unitserial plate.
SCHEDULE FOR TABLE 11
retemaiDeniLdiuqiL .tFreP22-R.zO
"4/1"8/3"2/1
52.006.002.1
�
�
Includes 25’ of 1/4” diameter liquid line. For other than25’ and other tube sizes, adjust the total charge accord-ing to the following schedule.Includes 25’ of 3/8” diameter liquid line. For other than25’ and other tube sizes, adjust the total charge accord-ing to the following schedule.
Manual 2100-241Page 17
SERVICE
TABLE 12
FAN BLADE SETTING
ledoM AnoisnemiD
181CAH142CAH103CAH163CAH124CAH184CAH106CAH
"4/1-3
FIGURE 10
FAN BLADE
MIS-1309
SERVICE HINTS
1. Caution homeowner to maintain clean air filters at alltimes. Also, not to needlessly close off supply andreturn air registers. This reduces air flow through thesystem, which shortens equipment service life, aswell as, increasing operating costs.
2. Check all power fuses or circuit breakers to be surethat they are the correct rating.
3. Periodic cleaning of the outdoor coil to permit fulland unrestricted air flow circulation is essential.
FAN BLADE SETTING DIMENSIONS
Shown in Figure 10 are the correct fan blade settingdimensions for proper air delivery across the outdoorcoil.
Any service work requiring removal or adjustment in thefan and/or motor area will require that the dimensionsbelow be checked and blade adjusted in or out on themotor shaft accordingly.
Manual 2100-241Page 18
Manual 2100-241Page 19
Manual 2100-241Page 20
roodnInoitceS
riAnruteR.pmeT erusserP
lioCroodtuOgniretnEerutarepmeTriA
56 07 57 08 58 09 59 001 501 011 511
A-SA03SAA-SA42S
BD57BW26
ediSwoLediShgiH
86051
07071
27781
47302
67622
87442
08452
28852
48552
58642
78023
BD08BW76
ediSwoLediShgiH
07961
37381
67891
97312
18822
48442
68062
88672
09392
29013
39823
BD58BW27
ediSwoLediShgiH
67771
97191
28602
58122
78632
09252
29962
49682
69403
89223
99043
42CB C
BD57BW26
ediSwoLediShgiH
55261
26871
86391
37902
87422
18042
48652
68272
78882
78403
78023
BD08BW76
ediSwoLediShgiH
77461
87081
87891
08312
18032
28642
48362
68082
88692
09313
39923
BD58BW27
ediSwoLediShgiH
67771
97191
28602
58122
78632
09252
29962
49682
69403
89223
99043
TABLE 13
PRESSURE TABLEHAC181-A
Low side pressure ± 2 PSIG (suction line 8 inches from compressor)High side pressure ± 5 PSIG (discharge line 8 inches from compressor, liquid at base valve approximately -20 PSIGfrom values listed)
Tests are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operatingchange being in the system. The charge should be removed, system evacuated and recharged to serial plateinstructions.
TABLE 14
PRESSURE TABLEHAC241-A
Low side pressure ± 2 PSIG (suction line 8 inches from compressor)High side pressure ± 5 PSIG (discharge line 8 inches from compressor, liquid at base valve approximately -20 PSIGfrom values listed)
Tests are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operatingchange being in the system. The charge should be removed, system evacuated and recharged to serial plateinstructions.
roodnInoitceS
riAnruteR.pmeT erusserP
lioCroodtuOgniretnEerutarepmeTriA
56 07 57 08 58 09 59 001 501 011 511
A-SA03SAA-SA42S
BD57BW26
ediSwoLediShgiH
06271
46091
86702
17422
47142
67852
87572
08292
18803
28523
28143
BD08BW76
ediSwoLediShgiH
66771
07591
37312
67032
97742
18562
38282
58992
68613
78333
88053
BD58BW27
ediSwoLediShgiH
37581
67302
97022
28832
58752
78372
98192
19903
29623
49443
59263
42CB C
BD57BW26
ediSwoLediShgiH
56971
96491
37902
77522
08142
28752
38372
48092
58603
68423
78143
BD08BW76
ediSwoLediShgiH
07401
37251
57291
77522
97152
18962
38082
58482
68182
88072
98252
BD58BW27
ediSwoLediShgiH
37581
67302
97022
28832
58652
78372
98192
19903
29623
49443
59263
Manual 2100-241Page 21
Low side pressure ± 2 PSIG (suction line 8 inches from compressor)High side pressure ± 5 PSIG (discharge line 8 inches from compressor, liquid at base valve approximately -20 PSIGfrom values listed)
Tests are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operatingchange being in the system. The charge should be removed, system evacuated and recharged to serial plateinstructions.
roodnInoitceS
riAnruteR.pmeT erusserP
lioCroodtuOgniretnEerutarepmeTriA
56 07 57 08 58 09 59 001 501 011 511
A-SA73A
BD57BW26
ediSwoLediShgiH
66181
86791
07312
27032
47642
67262
87872
08492
28013
48623
68343
BD08BW76
ediSwoLediShgiH
17681
37202
57912
77532
97252
18862
38582
58203
78813
98533
19153
BD58BW27
ediSwoLediShgiH
77191
97802
18622
38342
58062
78872
98592
19213
39033
59743
79463
C63CB
BD57BW26
ediSwoLediShgiH
36871
66591
86212
07822
27542
47262
67972
87692
97313
18133
28843
BD08BW76
ediSwoLediShgiH
66481
96002
27712
57432
87152
08962
28682
48403
58123
78933
88753
BD58BW27
ediSwoLediShgiH
27881
57602
87422
18242
38062
68872
88692
09413
29233
49153
59963
TABLE 16
PRESSURE TABLEHAC361-A
TABLE 15
PRESSURE TABLEHAC301-A
roodnInoitceS
riAnruteR.pmeT erusserP
lioCroodtuOgniretnEerutarepmeTriA
56 07 57 08 58 09 59 001 501 011 511
A-SA63A
BD57BW26
ediSwoLediShgiH
26261
56381
76402
96422
17442
37262
57082
77792
87313
08923
18443
BD08BW76
ediSwoLediShgiH
86761
07881
27012
47032
67052
87962
08782
28503
48123
58833
78353
BD58BW27
ediSwoLediShgiH
57171
77491
87612
08832
28852
48872
68792
88513
09333
29943
49563
C63CB
BD57BW26
ediSwoLediShgiH
16581
56102
96712
27432
57052
77662
97282
18892
28413
38133
48743
BD08BW76
ediSwoLediShgiH
76091
17702
47322
77932
08652
28272
48982
68603
78223
88933
98653
BD58BW27
ediSwoLediShgiH
47891
77512
08232
38842
68562
88282
09992
29613
39333
59153
69863
Low side pressure ± 2 PSIG (suction line 8 inches from compressor)High side pressure ± 5 PSIG (discharge line 8 inches from compressor, liquid at base valve approximately -20 PSIGfrom values listed)
Tests are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operatingchange being in the system. The charge should be removed, system evacuated and recharged to serial plateinstructions.
Manual 2100-241Page 22
TABLE 17
PRESSURE TABLEHAC 421-A
Low side pressure ± 2 PSIG (suction line 8 inches from compressor)High side pressure ± 5 PSIG (discharge line 8 inches from compressor, liquid at base valve approximately -20 PSIGfrom values listed)
Tests are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operatingchange being in the system. The charge should be removed, system evacuated and recharged to serial plateinstructions.
roodnInoitceS
riAnruteR.pmeT erusserP
lioCroodtuOgniretnEerutarepmeTriA
57 08 58 09 59 001 501 011 511
A-SA24A63CB C
BD57BW26
ediSwoLediShgiH
46302
76812
07332
27052
47662
67382
77003
87813
97633
BD08BW76
ediSwoLediShgiH
96802
27422
57042
77652
97372
28092
28803
48623
58543
BD58BW27
ediSwoLediShgiH
37612
77232
08842
38562
58282
78003
98813
09733
19953
A-SA84A06CB C
BD57BW26
ediSwoLediShgiH
37212
47822
67442
77062
97772
18492
28213
48033
68943
BD08BW76
ediSwoLediShgiH
77812
97432
18052
38762
58482
78203
98023
09933
29853
BD58BW27
ediSwoLediShgiH
38422
58142
78852
98672
19492
39492
59133
79053
99073
TABLE 18
PRESSURE TABLEHAC481-A, HAC481-B
Low side pressure ± 2 PSIG (suction line 8 inches from compressor)High side pressure ± 5 PSIG (discharge line 8 inches from compressor, liquid at base valve approximately -20 PSIGfrom values listed)
Tests are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operatingchange being in the system. The charge should be removed, system evacuated and recharged to serial plateinstructions.
roodnInoitceS
riAnruteR.pmeT erusserP
lioCroodtuOgniretnEerutarepmeTriA
57 08 58 09 59 001 501 011 511
B-SA16A
BD57BW26
ediSwoLediShgiH
47802
57322
77832
87452
08172
28882
38603
58423
78343
BD08BW76
ediSwoLediShgiH
87412
08922
28542
48162
68872
88692
09413
19333
39253
BD58BW27
ediSwoLediShgiH
48022
68632
88352
09072
29882
49603
69523
79443
99463
06CB C
BD57BW26
ediSwoLediShgiH
86242
07052
27062
47272
67582
87003
97713
08633
18653
BD08BW76
ediSwoLediShgiH
67842
77652
87662
08872
18292
28803
48523
58443
78563
BD58BW27
ediSwoLediShgiH
28752
38562
48672
68882
78203
88813
09633
19653
39873
Manual 2100-241Page 23
TABLE 19
PRESSURE TABLEHAC601-A, HAC601-B
Low side pressure ± 2 PSIG (suction line 8 inches from compressor)High side pressure ± 5 PSIG (discharge line 8 inches from compressor, liquid at base valve approximately -20 PSIGfrom values listed)
Tests are based upon rated CFM (airflow) across the evaporator coil. If there is any doubt as to correct operatingchange being in the system. The charge should be removed, system evacuated and recharged to serial plateinstructions.
roodnInoitceS
riAnruteR.pmeT erusserP
lioCroodtuOgniretnEerutarepmeTriA
57 08 58 09 59 001 501 011 511
B-SA16A
BD57BW26
ediSwoLediShgiH
76722
96342
17062
37672
57392
67013
87623
97343
97953
BD08BW76
ediSwoLediShgiH
27232
47942
67662
87482
08103
28813
48633
68353
88073
BD58BW27
ediSwoLediShgiH
87042
08852
28672
48392
68113
88923
09643
29463
49283
C06CB
BD57BW26
ediSwoLediShgiH
46322
76932
07752
27572
47592
67613
77933
87363
87883
BD08BW76
ediSwoLediShgiH
96032
27642
57462
77382
97303
18523
28843
38273
48893
BD58BW27
ediSwoLediShgiH
67732
87552
08372
28392
58413
58633
78063
98583
09114