INSTALLATION INSTRUCTIONS FOR

AIR COOLED CONDENSING UNITS

MODEL SERIES
1 TO 5 TON

92-21354-10-00
WARNING: THE MANUFACTURER’S WARRANTY DOES watering systems, and various chemical contaml&ts from
NOT COVER ANY DAMAGE OR DEFECT TO THE AIR CON- industries such as paper mills and petroleum refineries are
DITIONER CAUSED BY THE ATTACHMENT OR USE OF ANY especially corrosive.
COMPONENTS, ACCESSORIES OR DEVICES (OTHER THAN If the unit is to be installed in an area where contaminants
THOSE AUTHORIZED BY THE MANUFACTURER) INTO, ON- are likely to be a problem, special attention should be given
TO OR IN CONJUNCTION WITH THE AIR CONDITIONER. to the equipment location and exposure.
YOU SHOULD BE AWARE THAT THE USE OF UNAUTHO- 38
RIZED COMPONENTS, ACCESSORIES OR DEVICES MAY 1. Avoid having lawn sprinkler heads spray directly on the ST
ADVERSELY AFFECT THE OPERATION OF THE AIR CON- unit cabinet.
DITIONER AND MAY ALSO ENDANGER LIFE AND PROPER- 2. In coastal areas, locate the unit on the side of the
TY. THE MANUFACTURER DISCLAIMS ANY RESPONSIBILI- building away from the waterfront.
TY FOR SUCH LOSS OR INJURY RESULTING FROM THE
3. Shielding provided by a fence or shrubs may give some
USE OF SUCH UNAUTHORIZED COMPONENTS, ACCES-
protection.
SORIES OR DEVICES.
4. Elevating the unit off its slab or base enough to allow
GENERAL air circulation will help avoid holding water against the
basepan.
The information contained in this manual has been prepared
to assist in the proper installation, operation and Regular maintenance will reduce the buildup of con-
maintenance of the air conditioning system. Improper in- taminants and help to protect the unit’s finish.
stallation, or installation not made in accordance with these WARNING: DISCONNECT ALL POWER TO UNIT BEFORE
instructions, can result in unsatisfactory operation and/or STARTING MAINTENANCE.
dangerous conditions, and can cause the related warranty
not to apply. Frequent washing of the cabinet, fan blade and coil with
fresh water will remove most of the salt or other con-
Read this manual and any instructions packaged with taminants that build up on the unit.
separate equipment required to make up the system prior
to installation. Retain this manual for future reference. Regular cleaning and waxing of the cabinet with a good
automobile polish will provide some protection.
CHECKING PRODUCT RECEIVED A good liquid cleaner may be used several times a year
Upon receiving unit, inspect it for any shipping damage. to remove matter that will not wash off with water.
Claims for damage, either apparent or concealed, should be Several different types of protective coatings are offered in
filed immediately with the shipping company. Check con- some areas. These coatings may provide some benefit, but
densing unit model number, electrical characteristics and the effectiveness of such coating materials cannot be
accessories to determine if they are correct. Check system verified by the equipment manufacturer.
components (evaporator coil, condensing unit, evaporator
The best protection is frequent cleaning, maintenance and
blower, etc.) to make sure they are properly matched. 7
minimal exposure to contaminants.
Remove shipping bracket under compressor if supplied.
CONDENSiNG UNIT LOCATION AND
With thermostat in the “Off” position, turn the power on INSTALLATION
to the furnace and the condensing unit. Before starting
condensing unit allow 12 hours time to elapse, giving the Location and Clearances
crankcase heater (if provided) time to drive refrigerant from The condensing unit must be installed outdoors and must
the compressor, thus preventing damage during start-up. not be connected to any duct work. To prevent air recircula-
Start the condensing unit and the furnace with the ther- tion, it is recommended that the unit not be installed under
mostat. Make sure the indoor air handler is operating. an overhang, but if necessary allow a minimum of 60 inches
SHIPPING WEIGHTS above the unit for air discharge.

NOMINAL COOLING
After selecting a site for location of the condensing unit,
CAPACITY WEIGHT (LBS) allow 12 inches minimum clearance for air intake on both
1
sides, and 24 inches for service access.

Concrete Slab or Rooftop Installations

Locate the slab for the above clearances and make the slab
3 inches longer than the unit on all sides and 3 inches above
ground level to prevent water flooding. The slab should be
level and should not be connected or in contact with the
4 TON 223
building foundation or structure to prevent noise transmis-
sion.
5 TON 248
When installing the condensing unit on a flat roof, it should
PROTECTING EQUIPMENT FROM THE be mounted on 4 inch x 4 inch wood stringers to distribute
the load and prevent roof damage. These stringers should
ENVIRONMENT not be tied directly to the roof structure. This type of mount-
The metal parts of this unit may be subject to rust or ing arrangement will also help prevent noise transmission
deterioration in adverse environmental conditions. This ox- to the building. Commercial type rubber mounting pads may
idation could shorten the equipment’s useful life. Salt spray, be used on top of the stringers underneath the unit to fur-
fog or mist in seacoast areas, sulphur or chlorine from lawn ther help prevent noise transmission.

2
Air Flow Sweat Fittings
Insure that the proper air flow is available as recommended All lines should be assembled with type “L” refrigerant tub-
for matched systems. See specifications. ing and not with copper water pipe. They should be brazed
with the following alloys:
Duct System
Copper to Copper - 5% Silver Alloy (no flux)
In an uninsulated attic or crawl space, 1’ fiberglass insula- Copper to Steel or Brass - 35% Silver Alloy (with flux) ,‘>
tion with avapor barrier skin is required. Make sure the ducts
are tight and leak-free. Duct must be of adequate size for Use the following procedure in making tubing connections: ,’
required air flow with furnace and coil. NOTE: 3/16” and 5/16” Allen wrenches are required for
refrigerant shutoff valves.
INTERCONNECTING TUBING 1. Be sure both refrigerant shutoff valves at the condens-
Suction and Liquid Lines ing units are closed. (Turn fully clockwise.)
Keep all lines sealed until connection is made. Connect the 2. Unseal tubing stubs on sweat unit.
tubes to the evaporator coil first. Refer to the refrigerant line
3. Clean the inside of the fitting and the outside of the tub-
size charts. Tables 2 and 3 for correct piping sizes.
ing with steel wool or abrasive cloth before soldering.
Always use the shortest length possible with a minimum Always keep chips, steel wool, dirt, etc., out of the in-
number of bends. Use a tube bender for short bends to in- side when cleaning. Assemble tubing part way into the
sure that there are no kinks in the line. To prevent noise fitting. Apply flux all around the outside of the tubing
transmission, never position the suction or liquid lines in when required, and push tubing into the stop. This pro-
direct contact with the building structure. Also use an cedure will keep flux from getting inside the system.
isolated or suspension type hanger when possible.
4. Wrap a wet rag around the brass valves before brazing.
After brazing - cool joint.
Maximum Length of Interconnecting Tubing
There is no fixed maximum length for interconnecting tub- 5. Service valves are not backseating type valves. Use
ing, but if over 200 feet add 3 ounces of dry refrigerant oil charging hoses with valve depressors.
for each 10 feet of line over 200 feet. Oil may be added not 6. Braze the tubing between condensing unit and cooling
to exceed 3 fluid ounces for each ten feet over 60 feet. Con- coil. Flow dry nitrogen into the shutoff valve port
necting lines should be kept as short as possible as there through the tubing while brazing (Refrigerant 22 will
is a capacity loss for each foot of suction line tubing used. decompose and form harmful acids at high soldering
The multiplier chart, Table 2, shows multipliers to be used temperatures).
to determine capacity for various suction line length and
7. Replace the service port cap and build up pressure in
diameters. The losses that occur due to lines being exposed
the lines and coil. Do not exceed the test pressures
to outdoor conditions are not included. NOTE: Systems with
marked on the unit rating plate.
over 60’ of lines must be equipped with crankcase heaters
and the application of a pump down cycle or a suction
accumulator. WARNING: DO NOT USE OXYGEN TO PURGE LINES OR ,.;
Refrigerant charging for units using capillary tubes must PRESSURIZE SYSTEM FOR LEAK TEST. OXYGEN
be by the suction line superheat method. Units using ther- REACTS VIOLENTLY WITH OIL WHICH CAN CAUSE AN
mostatic expansion valves must be charged by the head EXPLOSION RESULTING IN SEVERE PERSONAL IN-
pressure method. See charging data attached inside the ser- JURY OR DEATH.
vice panel of the unit.

Condensing Unit Installed Below Evaporator Leak test all joints using a liquid detergent. If leak is
found, release pressure and repair.
Maximum height of evaporator above the condensing unit
is 40 feet. If over 20 feet, the liquid lines should be increased
to the next size larger than shown in Table 2 to prevent
flashing in the liquid line. Liquid refrigerant in avertical col- CHARGING SYSTEM WITH REFRIGERANT 22
umn will exert a downward pressure of 5 to .6 PSI per foot Evacuation
of elevation, in effect adding to pressure drop when flow Since the condensing unit itself will not have to be
is up. evacuated unless it has lost all its charge, leave the suc-
tion and liquid shutoff valves closed. Use the following pro-
Condensing Unit Installed Above Evaporator cedures when evacuating the tubing and indoor coil.
There is no absolute fixed limit as to how high the condens-
ing unit may be above the evaporator, but if over 10 feet, Use a vacuum pump capable of evacuation to 30 inches
close attention must be given to line sizing, addition of oil of mercury.
and refrigerant charging. Oil traps are not required. The ver- Connect the vacuum pump to a gauge set that will read
tical portion of the liquid line must be sized as shown in from 30 inches of mercury to 400 PSIG. Connect the
Table 3 for use with capillary tube coils. Erratic operating gauge set to both the high side and low side of the
pressure can result if piping is not properly sized. system.
For expansion valve coils, size vertical and horizontal liquid Evacuate the tubing and cooling coil. The pressure
line as shown for horizontal run in Table 3. gauge should read at least 29%’ of vacuum.

4
Repaired or Lost Charge Units Time Delay Switch (TDC)
If the condensing unit has lost its entire refrigerant charge, The time delay (TDC) is in the low voltage control circuit.
the refrigerant should be replaced by weight. See instruc- When the compressor shuts off due to a power failure or
tions on the unit service cover for calculating and marking thermostat operation, this control keeps it off at least 5
total charge on the rating plate. It is also necessary to minutes which allows the system pressure to equalize, thus
evacuate the complete system as under Evacuation above, not damaging the compressor or blowing fuses on start-up.
except with valves open, then charge per the following
procedure: Low Ambient Control (LAC)
1. Connect a tank of Refrigerant 22 to the liquid line ser- This component senses compressor head pressure and
vice port. shuts the condenser fan off when the head pressure drops
to approximately 175 PSIG. This allows the unit to build a
2. With an accurate scale, set refrigerant tank so its weight sufficient head pressure at lower ambient in order to main-
can be measured while in a position to charge liquid. tain system balance and obtain improved capacity. Low am-
3. Open valve on refrigerant tank. bient control should be used on all equipment operated
below 65” ambient.
CAUTION: Never start unit while unit is under a vacuum.
4. Charge unit with the exact weight as calculated or High and Low Pressure Controls (HPC or LPC)
shown on rating plate. When unit has been charged with These controls keep the compressor from operating in
correct amount, turn tank valve off. pressure ranges which can damage it. Both controls are in
5. Check all joints for leaks. the low voltage control circuit.
6. Unit may be started at this point. Check and adjust High pressure control (HPC) is a manual reset which
charges as described on charging table attached to the operates near450 PSIG. Do not reset arbitrarily without first
condensing units service cover. When the unit is run- determining what caused it to function.
ning charge with vapor only into the suction line. The low pressure control (LPC) is an automatic reset which
operates near 15 PSIG and resets near 40 PSIG.
SERVICE
Operation POWER SUPPLY AND CONTROL CIRCUITS
Most single phase units are operated PSC (no starting com- Power Supply
ponents). It is important that such systems be off for a
All wiring must comply with NEC’ and local codes. See
minimum of 5 minutes before restarting to allow equaliza-
Table 5 and rating plate on the unit for volts, frequency,
tion of pressure. The thermostat should not be moved to
phase, maximum fuse size and minimum branch circuit am-
cycle unit without waiting 5 minutes. To do so may cause
pacity. Refer to the wiring diagram inside the unit service
the compressor to go off on an automatic overload device
cover before connecting to power supply.
or blow a fuse. Poor electrical service can also cause
nuisance tripping on overloads or blow fuses. This generally For branch circuit wiring (main power supply to unit discon-
can be corrected by adding start components. Check with nect), the minimum wire size for the length of run can be
factory for recommended start components, if required. For determined from Table 4 using the circuit ampacity found
PSC type operation, refrigerant metering must be done with on the unit rating plate. From the unit disconnect to unit,
cap tubes or bleed type expansion valves because of low the smallest wire size allowable in Table 4 should be used,
starting torque. If model expansion valve coils are used, start as the disconnect must be in sight of the unit. Only copper
components are required. wire can be attached to the unit contactor.

,Single-Pole Contactor (CC) ‘CEC in Canada

Single-pole contactors are used on all standard single phase
units up through 3% tons. Caution must be exercised when
servicing as only one leg of the power supply is broken with
the contactor. Two pole contactors are used on some three TABLE 4
phase units. COPPER WIRE SIZE - AWG.
(1% Voltage Drop)
OPTIONAL FIELD INSTALLED ACCESSORIES
(Available thru the Sales Order Center)
Compressor Crankcase Heat (CCH)
All heaters are located on the lower half of the compressor
shell. Its purpose is to drive refrigerant from the compressor
shell during long off cycles, thus preventing damage to the
compressor during starting. Must be used on all systems
with over60 of refrigerant piping.
SUPPLY CIRCUIT AMPACITY
At initial start-up or after extended shutdown periods make NOTE:
sure the heater is energized for at least 12 hours before the 1. Wire size based on 6O’C rated wire.
compressor is started. (Disconnect switch on and wall ther- 2. For more than 3 conductors in a raceway or cable, see the
mostat off.) N.E.C. for derating the ampacity of each conductor.

Hard Start Components (SC and SR)

(Available thru Parts Department Only)
The start component kit includes start capacitor (SC) and Special instructions for power wiring with aluminum con-
start relay (SR). Start components are required with all ex- ductors: Warranty void if connections are not made per in-
pansion valve coils. structions.

6
 TROUBLE SHOOTING CHART
WARNING - DISCONNECT ALL POWER TO UNIT BEFORE SERVICING. CONTACTOR MAY BREAK ONLY ONE SIDE OF LINE.

SYMPTOM POSSIBLE CAUSE REMEDY

High head-low suction a. Restriction in liquid line or capillary tube or filter drier a. Remove or replace defective component
High head-high or a. Dirty condenser coil a. Clean coil
normal suction b. Overcharged b. Correct system charge
c. Condenser fan not running c Repair or replace

Low head-high suction a. Incorrect capillary tube a Replace evaporator assembly

b. Defective compressor valves b. Replace compressor
Unit will not run a. Power off or loose electrical connection a. Check for unit voltage at contactor in condensing unit
b. Thermostat out of calibration-set too high b. Reset
c. Defective contactor c. Check for 24 volts at contactor coil -
replace if contacts are open
d. Blown fuses d. Replace fuses
e. Transformer defective e. Check wiring-replace transformer
f. High pressure control open f. Reset-also see high head pressure remedy.
The high pressure control opens at 430 PSI
g. Compressor overload contacts open g. If external overload - replace OL.
If internal replace compressor.
NOTE: Wait at least 2 hours for overload to reset
Condenser fan runs, a. Run or start capacitor defective a. Replace
compressor doesn’t b. Start relay defective b. Replace
C. Loose connection c. Check for unit voltage at compressor
- check & tighten all connections
d. Compressor stuck, grounded or open motor winding, d. Watt at least 2 hours for overload to reset
open internal overload. If still open, replace the compressor.
e. Low voltage condition e. Add start kit components
Low suction - cool compressor a. Low indoor airflow a. Increase speed of blower or
Iced Evaporator Coil reduce restriction-replace air filter
Compressor short cycles a. Defective overload protector a. Replace - check for correct voltage
Registers sweat a. Low airflow a. Increase speed of furnace blower or reduce restriction
replace air filter
High suction pressure a. Excessive load a. Recheck load calculation
b. Defective compressor b. Replace

Insufficient cooling a. Improperly sized unit a. Recalculate load

b. Improper airflow b. Check - should be approximately 400 CFM per ton.
c. Incorrect refrigerant charge , c. Charge per procedure attached to unit service panel
d. Incorrect voltage d. At compressor terminals. voltage must be within 10% of
nameplate volts when unit is operating

8 CM 790