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Installation and Operation Manual Condensing Units
11-AC50D1-1C-EN 3 D H W Table 2.1 Section 2. Unit Location Considerations 2.1 Unit Dimensions and Weight When mounting the outdoor unit on a roof, be
Installation Guide for American Standard models including: 11-AC50D1-1C-EN, AST5A7A5042A100, 5A7A5018 060 Condensing Units, 5A7A5018 060, Condensing Units, Units
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Document DEVICE REPORTAST5A7A5042A100 INTA11-AC50D1-1C-EN Installation and Operation Manual Condensing Units 5A7A5018 060 ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES IMPORTANT This Document is customer property and is to remain with this unit. Please return to service information pack upon completion of work. These instructions do not cover all variations in systems or provide for every possible contingency to be met in connection with the installation. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser's purposes, the matter should be referred to your installing dealer or local distributor. Note: The manufacturer recommends installing only approved matched indoor and outdoor systems. Some of the benefits of installing approved matched indoor and outdoor split systems are maximum efficiency, optimum performance and the best overall system reliability. Note: R-454B refrigerant is an "A2L" refrigerant meaning: A = non-toxic, 2 = flammable, L = low burning velocity. The term "A2L" is used throughout this document. Table of Contents Section 1. Safety ..................................................................................... 2 Section 2. Unit Location Considerations.............................................. 3 Section 3. Unit Preparation.................................................................... 4 Section 4. Setting the Unit ..................................................................... 4 Section 5. Refrigerant Line Considerations......................................... 4 Section 6. Refrigerant Line Routing ..................................................... 5 Section 7. Refrigerant Line Brazing...................................................... 7 Section 8. Refrigerant Line Leak Check ............................................... 8 Section 9. Evacuation............................................................................. 8 Section 10. Service Valves ..................................................................... 8 Section 11. Electrical - Low Voltage ..................................................... 9 Section 12. Electrical - High Voltage .................................................. 11 Section 13. Start Up.............................................................................. 11 Section 14. System Charge Adjustment............................................. 12 Section 15. Checkout Procedures....................................................... 16 Section 16. Refrigeration Circuits........................................................18 Section 17. Wiring Diagrams................................................................20 Section 18. Pressure Curves................................................................23 Section 1. Safety ! WARNING Only qualified personnel should install and service the equipment. The installation, starting up, and servicing of heating, ventilating, and air-conditioning equipment can be hazardous and requires specific knowledge and training. Improperly installed, adjusted or altered equipment by an unqualified person could result in death or serious injury. When working on the equipment, observe all precautions in the literature and on the tags, stickers, and labels that are attached to the equipment. ! WARNING RISK OF FIRE! Flammable refrigerant used. To be repaired only by trained service personnel. Do not puncture refrigerant tubing. Dispose of properly in accordance with federal or local regulations. Flammable refrigerant used. ! WARNING This information is intended for use by individuals possessing adequate backgrounds of electrical and mechanical experience. Any attempt to repair a central air conditioning product may result in personal injury and/or property damage. The manufacture or seller cannot be responsible for the interpretation of this information, nor can it assume any liability in connection with its use. ! WARNING UNIT CONTAINS R-454B REFRIGERANT! Proper service equipment is required. Failure to use proper service tools may result in equipment damage or personal injury. SERVICE USE ONLY R-454B REFRIGERANT AND APPROVED COMPRESSOR OIL. ! WARNING Extreme caution should be exercised when opening the Liquid Line Service Valve. Turn counterclockwise until the valve stem just touches the rolled edge. No torque is required. Failure to follow this warning will result in abrupt release of system charge and may result in personal injury and/or property damage. ! WARNING Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. ! WARNING The appliance shall be stored in a room without continuously operating ignition sources (for examples: open flames, an operating gas appliance or an operating electric heater). Do no pierce or burn. Be aware that refrigerants may not contain an odor. ! WARNING LIVE ELECTRICAL COMPONENTS! During installation, testing, servicing, and troubleshooting of this product power should be disconnected. It may be necessary to work with live electrical components. Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury. ! WARNING The appliance is not to be used by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction. ! WARNING Children should be supervised to ensure that they do not play with the appliance. ! CAUTION If using existing refrigerant lines should be brazed not soldered. Solder alloys with a melting temperature less than 427°C are not acceptable. ! CAUTION Scroll compressor dome temperatures may be hot. Do not touch the top of compressor; it may cause minor to severe burning. ! WARNING This product can expose you to chemicals including lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov ! WARNING VENTILATION Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work. Table 1. Operating Range Mode Model Cooling 1.5 5 Ton Operating Range 55°F 120°F 2 11-AC50D1-1C-EN Section 2. Unit Location Considerations 2.1 Unit Dimensions and Weight Table 2.1 Unit Dimensions and Weight Models H x D x W (in) Weight* (lb) 5A7A5018A 37 x 30 x 33 184 5A7A5024A 33 x 30 x 33 156 5A7A5030A 37 x 30 x 33 184 5A7A5036A 33 x 30 x 33 156 5A7A5042A 37 x 34 x 37 212 5A7A5048A 45 x 34 x 37 252 5A7A5060A 45 x 34 x 37 252 * Weight values are estimated. When mounting the outdoor unit on a roof, be sure the roof will support the unit's weight. Properly selected isolation is recommended to alleviate sound or vibration transmission to the building structure. W H D 2.2 Refrigerant Piping Limits 1. The maximum TOTAL length of refrigerant lines from outdoor to indoor unit should NOT exceed 150 feet (including lift). 2. The maximum vertical change should not exceed 50 feet. 3. Service valve connection diameters are shown in Table 5.1. Note: For other line lengths, refer to Refrigerant Piping Application Guide, SS-APG006-EN or Refrigerant Piping Software Program, 32-3312-03 (or latest revision). Standard Line Set 150' Max TOTAL Line Length 50' Max Vertical Change 2.3 Suggested Locations for Best Reliability Ensure the top discharge area is unrestricted for at least five (5) feet above the unit. Three (3) feet clearance must be provided in front of the control box (access panels) and any other side requiring service. Do not locate close to bedrooms as operational sounds may be objectionable. Position the outdoor unit a minimum of 12" from any wall or surrounding shrubbery to ensure adequate airflow. Outdoor unit location must be far enough away from any structure to prevent excess roof runoff water from pouring directly on the unit. Please reference Indoor Unit Installer's Guide for correct specifications on indoor unit install. 11-AC50D1-1C-EN Avoid Install Near Bedrooms Min. 12" to Shrubbery 50' Max Vertical Change Min 5' Unrestricted Min 3' Unrestricted Access Panel 3 2.4 Coastal Considerations If installed within one mile of salt water, including seacoasts and inland waterways, models without factory supplied Seacoast Salt Shields require the addition of BAYSEAC001 (Seacoast Kit) at installation time. Section 3. Unit Preparation 3.1 Prepare The Unit For Installation STEP 1 - Check for damage and report promptly to the carrier any damage found to the unit. STEP 2 - To remove the unit from the pallet, remove tabs by cutting with a sharp tool. Section 4. Setting the Unit 4.1 Pad Installation When installing the unit on a support pad, such as a concrete slab, consider the following: · The pad should be at least 1" larger than the unit on all sides. · The pad must be separate from any structure. · The pad must be level. · The pad should be high enough above grade to allow for drainage. · The pad location must comply with National, State, and Local codes. Section 5. Refrigerant Line Considerations 5.1 Refrigerant Line and Service Valve Connection Sizes RATED LINE SIZES 5A7A5018A 5A7A5024A 5A7A5030A 5A7A5036A 5A7A5042A 5A7A5048A 5A7A5060A Table 5.1 Line Sizes Service Valve Connection Sizes Vapor Line Liquid Line Vapor Line Connection Liquid Line Connection 3/4 5/16 3/4 3/4 5/16 3/4 3/4 5/16 3/4 3/4 5/16 3/4 7/8 5/16 7/8 7/8 5/16 7/8 1-1/8 5/16 7/8 5/16 5/16 5/16 5/16 5/16 5/16 5/16 ALTERNATE LINE SIZES 5A7A5018A 5A7A5024A 5A7A5030A 5A7A5036A 5A7A5042A 5A7A5048A 5A7A5060A Line Sizes Vapor Line Liquid Line 5/8 3/8 5/8 3/8 5/8 3/8 5/8 3/8 3/4 3/8 3/4 3/8 7/8 3/8 Service Valve Connection Sizes Vapor Line Connection Liquid Line Connection 3/4 5/16 3/4 5/16 3/4 5/16 3/4 5/16 7/8 5/16 7/8 5/16 7/8 5/16 5.2 Factory Charge The outdoor condensing units are factory charged with the system charge required for the outdoor condensing unit, ten (10) feet of tested connecting line, and the smallest rated indoor evaporative coil match. Always verify proper system charge via subcooling (TXV/EEV) or superheat (fixed orifice) per the unit nameplate. 4 11-AC50D1-1C-EN 5.3 Required Refrigerant Line Length Determine required line length and lift. You will need this later in STEP 2 of Section 14. Total Line Length = __________ Ft. Total Vertical Change (lift) = __________ Ft. 5.4 Refrigerant Line Insulation Important: The Vapor Line must always be insulated. DO NOT allow the Liquid Line and Vapor Line to come in direct (metal to metal) contact. Line Length Liquid Line Vapor Line Insulation Section 6. Refrigerant Line Routing 6.1 Precautions Important: Take precautions to prevent noise within the building structure due to vibration transmission from the refrigerant lines. Comply with National, State, and Local Codes when isolating line sets from joists, rafters, walls, or other structural elements. For Example: · When the refrigerant lines have to be fastened to floor joists or other framing in a structure, use isolation type hangers. · Isolation hangers should also be used when refrigerant lines are run in stud spaces or enclosed ceilings. · Where the refrigerant lines run through a wall or sill, they should be insulated and isolated. · Isolate the lines from all ductwork. · Minimize the number of 90º turns. 8 Feet Maximum Joist/Rafter Isolator Side View 8 Feet Maximum Secure Vapor line from joists using isolators every 8 ft. Secure Liquid Line directly to Vapor line using tape, wire, or other appropriate method every 8 ft. Isolation From Joist/Rafter 11-AC50D1-1C-EN Line Set 5 8 Feet Maximum Side View 8 Feet Maximum Secure Vapor Line using isolators every 8 ft. Secure Liquid Line directly to Vapor Line using tape, wire, or other appropriate method every 8 ft. Isolation In Wall Spaces Wall Isolator Line Set Wall Sealant Insulation Vapor Line Ductwork Isolator Isolation Through Wall Line Set DO NOT hang line sets from ductwork Section 7. Refrigerant Line Brazing 7.1 Braze The Refrigerant Lines STEP 1 - Remove caps or plugs. Use a deburing tool to debur the pipe ends. Clean both internal and external surfaces of the tubing using an emery cloth. STEP 2 - Remove the pressure tap cap and valve cores from both service valves. STEP 3 - Purge the refrigerant lines and indoor coil with dry nitrogen. STEP 4 - Wrap a wet rag around the valve body to avoid heat damage and continue the dry nitrogen purge. Braze the refrigerant lines to the service valves. Continue the dry nitrogen purge. Do not remove the wet rag until all brazing is completed. Important: Remove the wet rag before stopping the dry nitrogen purge. Note: Install drier in Liquid Line. NOTE: Precautions should be taken to avoid heat damage to basepan during brazing. It is recommended to keep the flame directly off of the basepan. STEP 5 - Replace the pressure tap valve cores after the service valves have cooled. 6 11-AC50D1-1C-EN STEP 1 STEP 2 STEP 3 3-4" from valv STEP 4 STEP 5 Section 8. Refrigerant Line Leak Check 8.1 Check For Leaks After completion of field piping for split systems, the field pipework shall be pressure tested with nitrogen and then vacuum tested prior to refrigerant charging. Important: Under no circumstances shall potential sources of ignition be used in the searching for or detection of refrigerant leaks. Important: The following leak detection methods are deemed acceptable for all refrigerant systems: · Electronic leak detectors calibrated for R-454B (with a sensitivity of 5 grams/year). Important: The outdoor unit should not be tested higher than 450 psig for servicing or component replacement. The indoor unit and linesets should be tested to the max pressure specified on the outdoor or indoor unit nameplate. The service valves should be closed when pressure testing the evaporator coil and linesets to separate the outdoor unit from the indoor unit. STEP 1 (Final Pressure Check) - Isolate the outdoor unit from the evaporator coil and linesets using the service valves. Pressurize the evaporator coil and linesets to the max pressure specified on the outdoor or indoor unit nameplate for a minimum of 60 minutes. Do not add additional refrigerant or test gas after reaching the evaporator coil specified pressure. The system should show no loss of pressure once pressurized. Once the pressure test is complete follow the steps for evacuation. *OPTIONAL (Preliminary Pressure Check) - Pressurize the refrigerant lines and evaporator coil to 150 PSIG using dry nitrogen. Check for leaks by using a soapy solution or bubbles at each brazed location. Remove pressure and repair any leaks before continuing. 11-AC50D1-1C-EN 7 Section 9. Evacuation and Servicing 9.1 Evacuate the Refrigerant Lines and Indoor Coil Important: Do not open the service valves until the refrigerant lines and indoor coil leak check and evacuation are complete. STEP 1 - Evacuate until the micron gauge reads no higher than 350 microns, then close off the valve to the vacuum pump. 0350 Microns ON OFF STEP 2 - Observe the micron gauge. Evacuation is complete, if the micron gauge does not rise above 500 microns in one (1) minute and 1500 microns in ten (10) minutes. STEP 3 - Once evacuation is complete, blank off the vacuum pump and micron gauge, and close the valve on the manifold gauge set. 1 MIN. 9.2 Servicing · If repairs must be made after system is charged, properly and safely remove or isolate refrigerant and purge the section of the system needing repair with Nitrogen gas or oxygen free nitrogen prior to opening the circuit. · The REFRIGERANT CHARGE shall be recovered into the correctly marked recovery cylinders. · Ensure that the outlet for the vaccum pump is not close to any potential ignition sources and the ventilation is available. · Prior to recharging the system, it shall be pressure-tested with the appropriate purging gas. The system shall be leak-tested on completion of charging but prior to commissioning. A follow up leak test shall be carried out prior to leaving the site. · Ensure that only appropriate refrigerant recovery cylinders are employed. Ensure that the correct number of cylinders for holding the total system charge is available. Only use cylinders designated for the recovered refrigerant and labelled for the refrigerant. Cylinders shall be complete with pressure-relief valve and associated shut-off valves in good working order. · A set of caliberated weighing scales shall be available and in good working order. Hoses shall be complete with leak-free disconnect couplings and in good condition. Ensure any associated electrical components are sealed. · The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder. Do not mix refrigerants. · If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that FLAMMABLE REFRIGERANT does not remain within the lubricant. 8 11-AC50D1-1C-EN Section 10. Service Valves 10.1 Open the Gas Service Valve Important: Leak check and evacuation must be completed before opening the service valves. NOTE: Do not vent refrigerant gases into the atmosphere. STEP 1 - Remove valve stem cap. STEP 2 - Using an adjustable wrench, turn valve stem 1/4 turn counterclockwise to the fully open position. STEP 3 - Replace the valve stem cap to prevent leaks. Tighten finger tight plus an additional 1/6 turn. 10.2 Open the Liquid Service Valve ! WARNING Extreme caution should be exercised when opening the Liquid Line Service Valve. Turn counterclockwise until the valve stem just touches the rolled edge. No torque is required. Failure to follow this warning will result in abrupt release of system charge and may result in personal injury and /or property damage. Important: Leak check and evacuation must be completed before opening the service valves. STEP 1 - Remove service valve cap. STEP 2 - Fully insert 3/16" hex wrench into the stem and back out counterclockwise until valve stem just touches the rolled edge (approximately five (5) turns.) STEP 3 - Replace the valve cap to prevent leaks. Tighten finger tight plus an additional 1/6 turn. CAP UNIT SIDE OF VALVE 1/4 TURN ONLY COUNTERCLOCKWISE FOR FULL OPEN POSITION VALVE STEM Cap Unit Side of Service Valve 3/16" Hex Wrench Rolled Edge to Captivate Stem Hex Headed Valve System PRESSURE TAP PORT GAS LINE CONNECTION Gas Service Valve Section 11. Electrical - Low Voltage 11.1 Low Voltage Maximum Wire Length Table 11.1 defines the maximum total length of low voltage wiring from the outdoor unit, to the indoor unit, and to the thermostat. Service Port Liquid Service Valve Table 11.1 WIRE SIZE 18 AWG 16 AWG 14 AWG 24 VOLTS MAX. WIRE LENGTH 150 Ft. 225 Ft. 300 Ft. 11-AC50D1-1C-EN 9 11.2 Low Voltage Hook-up Diagrams With 5TEM6 Thermostat Air Handler Outdoor Unit R 24 VAC HOT R FAN G 24 VAC Common B/C O Y COOL/HEAT 1st STAGE l HEATING 1st STAGE HEATING 2nd STAGE W1 5) W2 G B B Blue O Yl 3) Y2 YO Y W1 White W2 Pink BK WH/BLK 1. Units with pigtails require wirenuts for connections. 2. Cap all unused wires. 3. When BK is used, do not connect Y2 at the air handler. 4. When BK is used, cut the jumper between R and BK on the control board. See indoor wiring schematic for details. 5. In AC systems, for multiple stages of electric heat, jumper W1 and W2 together if comfort control has only one stage of heat. With 5TEM4 Thermostat Air Handler Outdoor Unit R 24 VAC HOT R FAN G G 24 VAC Common B/C B Blue B O O Y COOL/HEAT 1st STAGE l Yl Y2 YO Y HEATING 1st STAGE HEATING 2nd STAGE W1 3) W2 W1 White W2 Pink 1. Units with pigtails require wirenuts for connections. 2. Cap all unused wires. 3. In AC systems for multiple stages of electric heat, jumper W1 and W2 together if comfort control has only one stage of heat. With 5TAM5 Thermostat Air Handler Outdoor Unit R 24 VAC HOT R FAN G G 24 VAC Common B/C B Blue B O O Y COOL/HEAT 1st STAGE l Yl Y2 YO Y HEATING 1st STAGE HEATING 2nd STAGE W1 3) W2 W1 White W2 Pink HEATING 3rd STAGE W3 Brown W3 Brown 1. Units with pigtails require wirenuts for connections. 2. Cap all unused wires. 3. In AC systems, for multiple stages of electric heat, jumper W1 and W2 together if comfort control has only one stage of heat. With Furnace Thermostat R 24 VAC HOT FAN G 24 VAC Common B/C O COOL Y HEATING W1 3) W2 BK Evaporator Coil MCB Furnace R R R G G G B B B O Yl Yl Yl 3) YO Y2 W1 W2 3) BK BKi BK Outdoor Unit B Y/Y1 1. Units with pigtails require wirenuts for connections. Cap all unused wires. 2. For 24V control, connect factory supplied harness to circuit board at evaporator. Complete all other wiring connections at the furnace 3. For 2 stage systems, connect W2 to W2 and Y2 to Y2. 3) Y2 10 11-AC50D1-1C-EN With 5TEM6 Thermostat Air Handler Outdoor Unit R 24 VAC HOT R FAN G 24 VAC Common B/C Y1 COOL/HEAT 1st STAGE Y2 COOL 2ND STAGE HEATING 1st STAGE HEATING 2nd STAGE W1 5) W2 G B B Blue O Y 3) Y2 YO Y W1 White W2 Pink BK WH/BLK 1. Units with pigtails require wirenuts for connections. 2. Cap all unused wires. 3. When BK is used, do not connect Y2 at the air handler. 4. When BK is used, cut the jumper between R and BK on the control board. See indoor wiring schematic for details. 5. In AC systems, for multiple stages of electric heat, jumper W1 and W2 together if comfort control has only one stage of heat. With 5TEM4 Thermostat Air Handler Outdoor Unit R 24 VAC HOT R FAN G G 24 VAC Common B/C B Blue B O Y1 COOL/HEAT 1st STAGE Yl Y2 COOL 2ND STAGE Y2 YO Y HEATING 1st STAGE HEATING 2nd STAGE W1 3) W2 W1 White W2 Pink 1. Units with pigtails require wirenuts for connections. 2. Cap all unused wires. 3. In AC systems for multiple stages of electric heat, jumper W1 and W2 together if comfort control has only one stage of heat. With 5TAM5 Thermostat Air Handler Outdoor Unit R 24 VAC HOT R FAN G G 24 VAC Common B/C B Blue B O Y1 COOL/HEAT 1st STAGE Yl COOL 2ND STAGE Y2 Y2 YO Y HEATING 1st STAGE HEATING 2nd STAGE W1 3) W2 W1 White W2 Pink HEATING 3rd STAGE W3 Brown W3 Brown 1. Units with pigtails require wirenuts for connections. 2. Cap all unused wires. 3. In AC systems, for multiple stages of electric heat, jumper W1 and W2 together if comfort control has only one stage of heat. Mitigation Board Guidelines · The approved ID/OD combination will provide sufficient safe ventilation in case of a leak. · Refer to Indoor Unit Installer's Guide for correct specifications on indoor unit install. · All systems require mitigation boards so an altitude adjustment factor may be required. · Mitigation Control Board needs to be included in an A2L System. Section 12. Electrical - High Voltage 12.1 High Voltage Power Supply ! WARNING LIVE ELECTRICAL COMPONENTS! Failure to follow this Warning could result in property damage, severe personal injury, or death. Follow all electrical safety precautions when exposed to live electrical components. It may be necessary to work with live electrical components during installation, testing, servicing, and troubleshooting of this product. The high voltage power supply must agree with the equipment nameplate. Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects. Power wiring must comply with national, state, and local codes. Follow instructions on unit wiring diagram located on the inside of the control box cover. 11-AC50D1-1C-EN 11 12.2 High Voltage Disconnect Switch Install a separate disconnect switch at the outdoor unit. For high voltage connections, flexible electrical conduit is recommended whenever vibration transmission may create a noise problem within the structure. 12.3 High Voltage Ground Ground the outdoor unit per national, state, and local code requirements. Section 13. Start Up 13.1 System Start Up STEP 1 - Ensure Sections 7 through 12 have been completed. STEP 2 - Set System Thermostat to OFF. STEP 3 - Turn on disconnect(s) to apply power to the indoor and outdoor units. STEP 4 - Wait one (1) hour before starting the unit if compressor crankcase heater accessory is used and the Outdoor Ambient is below 70ºF. STEP 5 - Set system thermostat to ON. Section 14. System Charge Adjustment 14.1 Temperature Measurements (Systems can be rated with TXV, EEV or Piston. Ensure charging method is correct). Important: Installer must mark/write the total refrigerant charge on the OD unit label after adjusting for indoor coil and lineset. Technicians must have their refrigerant cylinder on a scale during the charging procedure and measure how much additional refrigerant is put in the system (additional over the factory charge). The additional charge must be recorded on the label provided on the outdoor unit as well as the resulting total system charge. Important: Standard service trucks and vans may not carry more than six 25# cylinders (< 220 lb of A2L refrigerant total) Important: A2L approved equipment required for leak detection, charge and recovery. Important: Ensure that contamination of different refrigerants does not occur when using charging equipment. Important: A set of calibrated weighing scales shall be available and in good working order. Hoses shall be complete with leak-free disconnect couplings and in good condition. Ensure any associated electrical components are sealed. STEP 1 - Check the outdoor temperatures. Subcooling (in cooling mode) is the only recommended* method of charging above 55º F ambient outdoor temperature. Note: For Superheat (In Cooling Mode), refer to the Superheat Charging Table on pg 18. *Weigh-In Method can be used for initial installation, or system replacement when power is not available or when the desired temperatures for the standard charging method are outside normal bounds. See Section 14.3. For best results the indoor temperature should be kept between 70º F to 80º F. Note: It is important to return in the spring or summer to accurately charge the system in the cooling mode when outdoor ambient temperature is above 55º F. 12 11-AC50D1-1C-EN 14.2 Subcooling Charging in Cooling (Above 55º F Outdoor Temp.) STEP 1 - Use the refrigerant line total length and lift measurements from Section 5.3. Total Line Length = __________ Ft. Vertical Change (Lift) = __________ Ft. LIFT STEP 2 - Determine the final subcooling target using total Line Length and Lift measured in STEP 1 and the charts below. Figure 1. Subcool Charging Corrections 018A, 024A, 030A, 036A Figure 2. Subcool Charging Corrections 042A, 048A REFRIGERANT LINE LIFT (FEET) 50 40 30 Use Design Subcooling 20 10 0 10 20 30 40 50 75 100 TOTAL REFRIGERANT LINE LENGTH (FEET) 125 150 Figure 3. Subcool Charging Corrections 060A 50 40 30 7/8 vapor line 20 Use Design Subcooling 10 0 10 20 30 40 50 75 100 TOTAL REFRIGERANT LINE LENGTH (FEET) 125 150 REFRIGERANT LINE LIFT (FEET) 50 40 30 Use Design Subcooling 20 10 0 10 20 30 40 50 75 100 TOTAL REFRIGERANT LINE LENGTH (FEET) 125 150 Design Subcooling Value = __________º F (from nameplate or Service Facts) Subcooling Correction = __________º F Final Subcooling Value = __________º F REFRIGERANT LINE LIFT (FEET) STEP 3 - Stabilize the system by operating for a minimum of 20 minutes whenever charge is removed or added before accurate measurements can be made. STEP 4 - Measure the liquid line temperature and pressure at the outdoor unit's service valve. Measured Liquid Line Temp = __________ º F Liquid GaXge Pressure = __________ PSI Final Subcooling Target = __________ º F STEP 5 - Use the final subcooling target, refrigerant temperature and pressure from STEP 4, to determine the proper liquid gaXge pressure using Table 14.2. Example: Assume a 12º F Final Subcooling Target and liquid temp of 90º F. 1. Locate 12º F Final Subcooling in Table 14.2. 2. Locate the Liquid Temperarature (90º F) in the left column. 3. The Liquid GaXge Pressure should be approx 327 PSI. (This is the shown as the intersection of te Final Subcooling column and the Liquid Temperature row). 11-AC50D1-1C-EN 13 Table 14.2 R-454B REFRIGERANT CHARGING CHART LIQUID TEMP (°F) DESIGN SUBCOOLING (°F) 8 9 10 11 12 13 14 LIQUID GAUGE PRESSURE (PSI) 107 °F 55 170 172 175 178 181 184 187 60 184 187 190 194 197 200 203 65 200 203 206 210 213 217 220 70 217 220 223 227 230 234 238 75 234 238 241 245 249 252 256 80 252 256 260 264 268 272 276 85 272 276 280 284 288 292 297 90 292 297 301 305 309 314 318 95 314 318 323 327 332 336 341 100 336 341 346 351 355 360 365 105 360 365 370 375 380 385 390 110 385 390 396 401 406 412 417 115 412 417 422 428 433 439 445 120 439 445 450 456 462 468 474 125 468 474 480 486 492 498 504 STEP 6 - Adjust refrigerant level to attain proper gaXge pressure. Add refrigerant if the Liquid GaXge Pressure is lower than the chart value. 1. Connect gaXges to refrigerant bottle and unit as illustrated. 2. Purge all hoses. 3. Open bottle. 4. Stop adding refrigerant when liquid line temperature and Liquid GaXge Pressure matches the chargiQg chart Final Subcooling Target. Recover refrigerant if the Liquid Gauge Pressure is higher than the chart value. STEP 7 - Stabilize the system. 1. Wait 20 minutes for the system condition to stabilize between adjustments. Note: When the Liquid Line Temperature and GaXge Pressure approximately match the chart, the system isproperly charged. 2. RemovegaXges. 3. Replace service port caps to prevent leaks. Tighten finger tight plus an additional 1/6 turn. STEP 8 - Verify typical performance. Refer to System Pressure Curves at the end of the document to verify typical performance. 14 SUCTION PRESSURE (PSIG) DISCHARGE PRESSURE (PSIG) PRESSURE CURVE SAMPLE Cooling @ 1450 SCFM Heating @ 1350 SCFM 550 INDOOR ENTERING WET BULB CURVES 500 TOP TO BOTTOM 71, 67, 63 AND 59 DEG F. 450 400 350 (4) (3) 300 250 (1) 200 40 60 80 100 (2) 120 500 INDOOR ENTERING DRY BULB CURVES 450 TOP TO BOTTOM 80, 70, AND 60 DEG F. 400 350 300 250 200 -5 5 15 25 35 45 55 65 OUTDOOR TEMPERATURE (Degree F) 170 INDOOR ENTERING 165 WET BULB CURVES TOP TO BOTTOM 160 71, 67, 63 AND 59 DEG F. 155 150 145 (5) 140 (3) 135 130 125 120 115 (1) 110 40 60 80 100 (2) 120 140 INDOOR ENTERING 130 DRY BULB CURVES TOP TO BOTTOM 120 80, 70, AND 60 DEG F. 110 100 90 80 70 60 50 40 30 -5 5 15 25 35 45 55 65 11-AC50D1-1C-EN STEP 9 - Record System Information for reference. Record system pressures and temperatures after charging is complete. Outdoor model number = _________________ Measured Outdoor Ambient = __________ º F Measured Indoor Ambient = __________ º F Measured Liquid Line Temp = __________ º F Measured Suction Line Temp = __________ º F Liquid GaXge Pressure = __________ PSI Suction GaXge Pressure = __________ PSI STEP 10 - If repairs must be made after system is charged, properly and safely remove and isolate refrigerant and purge the section of the system needing repair with oxygen free nitrogen prior to opening the circuit. The refrigerant charge should be recovered into the correctly marked recovery cylinders. Ensure that the correct number of cylinders for holding the total system charge is available. Only use cylinders designated for the recovered refrigerant and labelled for that refrigerant. Cylinders shall be complete with pressure-relief valve and associated shut-off valves in good working order. Ensure that the outlet for the vacuum pump is not close to any potential ignition sources and that ventilation is available. The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder. Do not mix refrigerants. If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that FLAMMABLE REFRIGERANT does not remain within the lubricant. Flow Rate CuFT/Hr 15 30 60 < 50 feet Nitrogen Purge Times Lineset Length < 100 feet < 150 feet 2 Minutes 4 Minutes 6 Minutes 1 Minute 2 Minutes 3 Minutes 1 Minute 1 Minute 2 Minutes Fixed Orifice Superheat Charging Table < 200 feet 8 Minutes 4 Minutes 2 Minutes Indoor Wet Bulb Temp (F) 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 55 7 9 10 11 12 14 15 17 18 20 21 23 24 26 27 29 30 60 5 7 8 9 10 12 13 15 16 18 19 21 22 24 25 27 28 30 31 65 4 6 8 10 11 13 14 16 17 18 19 21 22 24 25 27 28 27 31 70 5 7 8 10 11 13 14 16 17 18 19 21 22 24 25 27 28 30 31 Outdoor 75 Dry 80 Bulb Temp. 85 (F) 90 5 6 7 9 10 12 14 16 18 19 21 22 24 26 28 29 31 32 4 6 7 9 10 11 12 14 16 18 19 21 23 25 26 28 29 31 33 4 6 7 9 10 13 14 16 18 20 21 23 24 26 28 29 30 31 32 4 6 8 10 11 13 14 16 18 20 22 24 25 27 28 30 31 95 4 6 8 10 13 14 16 18 20 22 23 25 26 28 29 100 6 8 10 12 13 16 18 20 21 23 25 27 29 105 4 6 7 9 11 13 15 18 20 22 24 26 28 110 4 7 9 11 13 16 18 21 23 26 28 115 6 9 12 14 16 19 21 24 26 Using a digital psychrometer, measure the return air wet-bulb temperature at the unit just before the coil. Also measure the outdoor dry-bulb temperature. Use these temperatures to locate the target superheat on the charging table. Do not attempt to charge the system if these conditions fall outside of this charging table. ADD refrigerant to DECREASE total superheat. REMOVE refrigerant to INCREASE total superheat. Always allow 10 to 15 minutes of operature after any refrigerant or air flow change prior to determining the final superheat. 11-AC50D1-1C-EN 15 14.3 Weigh-In Method for Charging Weigh-In Method can be used for the initial installation, or anytime a system charge is being replaced. Weigh-In Method can also be used when power is not available to the equipment site or operating conditions (indoor/outdoor temperatures) are not in range to verify with the subcooling charging method. Calculating Charge Using the Weigh-In Method STEP 1 - Measure in feet the distance between the outdoor unit and the indoor unit and record on Line 1. Include the entire length of the line from the service valve to the IDU (minus 10 ft). STEP 2 - Enter the charge multiplier (0.47 oz./ft for 3/8" & 0.30 oz./ft for 5/16"). STEP 3 - Multiply the total length of refrigerant tubing (Line 1) times the value on Step 2. Record the result on Line 3 of the Worksheet. STEP 4 - This is the amount of refrigerant to weigh-in prior to opening the service valves. 1. Line length (ft) 2. Charge multiplier 3. Step 1 x Step 2 4. Refrigerant ______________ = for 3/8", use 0.47 oz. per foot and for 5/16", use 0.30 oz. per foot = _____________ = _____________ Section 15. Checkout Procedures 15.1 Operational And Checkout Procedures Final phases of this installation are the unit Operational and Checkout Procedures. To obtain proper performance, all units must be operated and charge adjustments made. Important: Perform a final unit inspection to be sure that factory tubing has not shifted during shipment. Adjust tubing if necessary so tubes do not rub against each other when the unit runs. Also be sure that wiring connections are tight and properly secured. CHECKOUT PROCEDURE After installation has been completed, it is recommended that the entire system be checked against the following list: 1. Leak check refrigerant lines. ........................................ [ ] 2. Properly insulate suction lines and fittings.................... [ ] 3. Properly secure and isolate all refrigerant lines............ [ ] 4. Seal passages through masonry. If mortar is used, prevent mortar from coming into direct contact with copper tubing. .......................... [ ] 5. Verify that all electrical connections are tight................ [ ] 6. Observe outdoor fan during on cycle for clearance and smooth operation................................................... [ ] 7. Be sure that indoor coil drain line drains freely. Pour water into drain pan................................................................ [ ] 8. Be sure that supply registers and return grilles are open and unobstructed.......................................................... [ ] 9. Be sure that a return air filter is installed. ..................... [ ] 10. Be sure that the correct airflow setting is used. (Indoor blower motor) ................................................... [ ] 11. Operate complete system in each mode to ensure safe operation................................................... [ ] 12. Check that MCB or RDS is operational.. ...................... [ ] 16 11-AC50D1-1C-EN 15.2 Markings and Instructions [symbol ISO 7010-W021 (2011-05)] warning; flammable materials [symbol ISO 7000-1659 (2004-01)] service indicator; read technical manual A2L symbol warning; low burning velocity material [symbol ISO 7000-1701 (2004-01)] pressure UV [symbol IEC 60417-6040 2010-08)] ultraviolet radiation, instructional safeguard [symbol ISO 7000-1641 (2004-01)] operator's manual; operating instructions Refrigerant class per ISO 817 11-AC50D1-1C-EN 17 Section 16. Refrigeration Circuits 018, 030 & 042 Models PRINTED FROM D158514P01 024 & 036 Models PRINTED FROM D157394P01 18 11-AC50D1-1C-EN 048 & 060 Models Printed from D159175 16.1 Refrigerant Detection System The approved ID/OD combination will provide sufficient safe ventilation. Airflow provided is sufficient to cover minimum room area including adjustments for altitude. All systems require a refrigerant detection system so no altitude adjustment factors are required. Installer must ensure refrigerant detection system is connected and placed in appropriate orientation per application. The control system power shall not be interrupted to ensure the refrigerant detection system is always functioning. Please reference Indoor Unit installers guide for correct specification on refrigerant detection system. 11-AC50D1-1C-EN 19 Section 17. Wiring Diagrams 018 - 048 Models 20 11-AC50D1-1C-EN 060 Models 11-AC50D1-1C-EN 21 22 11-AC50D1-1C-EN Section 18. Pressure Curves COOLING PERFORMANCE CAN BE CHECKED WHEN THE OUTDOOR TEMP IS ABOVE 65 DEG F. TO CHECK COOLING PERFORMANCE, SELECT THE PROPER INDOOR CFM, ALLOW PRESSURES TO STABILIZE. MEASURE INDOOR WET BULB TEMPERATURE, OUTDOOR TEMPERATURE, LIQUID AND SUCTION PRESSURES. ON THE PLOTS LOCATE OUTDOOR TEMPERATURE (1); LOCATE INDOOR WET BULB (2); FIND INTERSECTION OF OD TEMP. & ID W.B. (3); READ LIQUID (4) OR SUCTION (5) PRESSURE IN LEFT COLUMN. EXAMPLE: (1) OUTDOOR TEMP. 82 F. (2) INDOOR WET BULB 67 F. (3) AT INTERSECTION ACTUAL: (4) LIQUID PRESSURE @ 600 CFM IS 304 PSIG LIQUID PRESSURE SHOULD BE +/- 10 PSI OF CHART (5) SUCTION PRESSURE @ 600 CFM IS 145 PSIG SUCTION PRESSURE SHOULD BE +/- 3 PSIG OF CHART LIQUID PRESSURE (PSIG) PRESSURE CURVES for 5A7A5018A1 520 INDOOR ENTERING WET BULB CURVES 470 TOP TO BOTTOM 71, 67, 63 AND 59 DEG F. (2) 420 370 320 (4) (3) 270 220 (1) 170 40 50 60 70 80 90 100 110 120 OUTDOOR TEMPERATURE (Degree F) 170 INDOOR ENTERING 165 WET BULB CURVES 160 TOP TO BOTTOM 71, 67, 63 AND 59 DEG F. 155 150 145 140 (5) 135 130 125 120 115 110 40 50 60 70 (3) (1) 80 90 71 67 (2) 63 59 100 110 120 OD Model Cooling @SCFM 5A7A5018A1 600 OUTDOOR TEMPERATURE (Degree F) SUCTION PRESSURE (PSIG) 11-AC50D1-1C-EN 23 LIQUID PRESSURE (PSIG) PRESSURE CURVES (Refer below table for models) 520 INDOOR ENTERING WET BULB CURVES 470 TOP TO BOTTOM (2) 71, 67, 63 AND 59 DEG F. 420 370 320 (4) (3) 270 220 (1) 170 40 50 60 70 80 90 100 OUTDOOR TEMPERATURE (Degree F) 170 INDOOR ENTERING 165 WET BULB CURVES 160 TOP TO BOTTOM 71, 67, 63 AND 59 DEG F. 155 150 145 (3) 140 (5) 135 130 125 120 115 (1) 110 40 50 60 70 80 90 100 110 120 71 67 (2) 63 59 110 120 OD Model 5A7A5024A1 5A7A5030A1 5A7A5036A1 5A7A5042A1 5A7A5048A1 Cooling @SCFM 750 850 950 1150 1350 OUTDOOR TEMPERATURE (Degree F) SUCTION PRESSURE (PSIG) 24 11-AC50D1-1C-EN LIQUID PRESSURE (PSIG) PRESSURE CURVES for 5A7A5060A1 520 INDOOR ENTERING WET BULB CURVES (2) 470 TOP TO BOTTOM 71, 67, 63 AND 59 DEG F. 420 370 320 (4) (3) 270 220 (1) 170 40 50 60 70 80 90 100 OUTDOOR TEMPERATURE (Degree F) 170 INDOOR ENTERING 165 WET BULB CURVES 160 TOP TO BOTTOM 71, 67, 63 AND 59 DEG F. 155 150 145 140 135 (5) (3) 130 125 120 115 (1) 110 40 50 60 70 80 90 100 110 120 71 67 (2) 63 59 110 120 OD Model 5A7A5060A1 Cooling @SCFM 1450 OUTDOOR TEMPERATURE (Degree F) SUCTION PRESSURE (PSIG) 11-AC50D1-1C-EN 25 About American Standard Heating and Air Conditioning American Standard has been creating comfortable and affordable living environments for more than a century. For more information, please visit www.americanstandardair.com. 11-AC50D1-1C-EN 17 Oct 2024 Supersedes 11-AC50D1-1B-EN August 2023 The AHRI Certified mark indicates company participation in the AHRI Certification program. For verification of individual certified products, go to ahridirectory.org. The manufacturer has a policy of continuous data improvement and it reserves the right to change design and specifications without notice. We are committed to using environmentally conscious print practices. © 2024 American Standard Heating and Air Conditioning
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