Allied Air Enterprises 4AC16LT User Manual

INSTALLATION AND MAINTENANCE INSTRUCTIONS  
4AC16LT SERIES  
Split System Air Conditioner  
Save these instructions for future reference  
WARNING  
The equipment covered in this manual is to be installed by trained and experienced service  
and installation technicians. Improper installation, modification, service, or use can cause  
electrical shock, fire, explosion, or other conditions which may cause personal injury, death,  
or property damage. Use appropriate safety gear including safety glasses and gloves when  
installing this equipment.  
WARNING  
TABLE OF CONTENTS  
Risk of electrical shock. Disconnect all remote power  
supplies before installing or servicing any portion of the  
system. Failure to disconnect power supplies can result  
INSTALLATION ....................................................2  
in property damage, personal injury, or death.  
START-UP ..........................................................12  
OPERATION ......................................................16  
MAINTENANCE .................................................20  
CONNECTION DIAGRAM..................................22  
WARNING  
Installation and servicing of air conditioning equipment  
can be hazardous due to internal refrigerant pressure  
and live electrical components. Only trained and  
qualified service personnel should install or service this  
equipment. Installation and service performed by  
unqualified persons can result in property damage,  
personal injury, or death.  
Manufactured By  
Allied Air Enterprises, Inc.  
A Lennox International Inc. Company  
215 Metropolitan Drive  
West Columbia, SC 29170  
WARNING  
Sharp metal edges can cause injury. When installing  
the unit, use care to avoid sharp edges.  
*506467-01*  
506467-01  
Issue 1008  
Page 1  
Thermostat Designations  
Slab Mounting  
Discharge Air  
Building  
Structure  
Mounting Slab  
Ground Level  
See unit wiring diagram for power supply connections.  
If the indoor unit is not equipped with a blower relay, one must be field  
supplied and installed.  
Figure 2  
Do not connect C (common) connection between indoor unit and  
thermostat except when required by the indoor thermostat. Refer to  
thermostat installation instructions. C (common) connection between  
indoor unit and outdoor unit required for proper operation.  
Electrical Wiring  
Figure 4  
All field wiring must be done in accordance with the National  
Electrical Code (NEC) recommendations, Canadian  
Electrical Code (CEC) and CSA Standards, or local codes,  
where applicable.  
5. Do not bundle any excess 24V control wire inside control  
box. Run control wire through installed wire tie and tighten  
wire tie to provide low voltage strain relief and to maintain  
seperation of field-installed low and high voltage circuits.  
WARNING  
Unit must be grounded in accordance with national and  
local codes. Failure to ground unit properly can result in  
personal injury or death.  
Refrigerant Piping  
WARNING  
Refrigerand can be harmful if inhaled. Refrigerant must  
always be used and recovered responsibly. Incorrect or  
irresponsible use of refrigerant can result in personal  
injury or death.  
Refer to the furnace or blower coil installation instructions  
for additional wiring application diagrams and refer to unit  
rating plate for minimum circuit ampacity and maximum  
overcurrent protection size.  
1. Install line voltage power supply to unit from a properly  
sized disconnect switch. Any excess high voltage field wiring  
should be trimmed or secured away from the low voltage  
field wiring.  
If the 4AC16LT unit is being installed with a new indoor coil  
and line set, the refrigerant connections should be made as  
outlined in this section. If an existing line set and/or indoor  
coil will be used to complete the system, refer to this section  
as well as the section that follows entitled - Flushing  
Existing Line Set and Indoor Coil.  
2. Ground unit at unit disconnect switch or to an earth ground.  
To facilitate conduit, a hole is in the bottom of the control  
box. Connect conduit to the control box using a proper  
conduit fitting. Units are approved for use only with copper  
conductors. 24V Class II circuit connections are made in  
the low voltage junction box. Acomplete unit wiring diagram  
is located inside the unit control box cover (see also page  
22 of this instruction).  
If this unit is being matched with an approved line set or  
indoor coil which was previously charged with R-22  
refrigerant, the line set and coil must be flushed prior to  
installation. If the unit is being used with and existing indoor  
coil which was equipped with a liquid line which served as a  
metering device (RFCI), the liquid line must be replaced prior  
to the installation of the 4AC16LT unit.  
3. Install room thermostat on an inside wall that is not subject  
to drafts, direct sunshine, or other heat sources.  
Field refrigerant piping consists of liquid and suction lines  
from the outdoor unit (sweat connections) to the indoor coil  
(flare or sweat connections).  
4. Install low voltage wiring from outdoor to indoor unit and  
from thermostat to indoor unit (See Figure 3).  
506467-01  
Issue 1008  
Page 3  
Select line set diameters from Table 2 to ensure that oil return  
to the compressor. Size vertical suction riser to maintain  
minimum velocity at minimum capacity. Recommended line  
length is 50’ or less. If more than 50’ line set is required,  
contact Technical Service.  
WARNING  
Polyolester (POE) oils used with R-410A refrigerant  
absorb moisture very quickly. It is very important that  
the refrigerant system be kept closed as much as  
possible. DO NOT remove line set caps or service valve  
stub caps until ready to make connections.  
Table 2 shows the diameters for line sets up to 100’ although  
vertical lift applications and trapping requirements need to  
be reviewed with Technical Service for line sets over 50’.  
Refrigerant Line Set Diameters (in.)  
Installing Refrigerant Line  
During the installation of an air conditioning system, it is  
important to properly isolate the refrigerant line to prevent  
unnecssary vibration. Line set contact with the structure  
(wall, ceiling, or floor) may cause objectionable noise when  
vibration is translated into sound. As a result, more energy  
or vibration can be expected. Close attention to line set  
isolation must be observed. If refrigeration lines are routed  
through a wall, seal and isolate the opening so vibration is  
not transmitted to the building.  
Liquid Line  
Line S et Length and S ize  
B T UH  
12 f t. 25 ft. 50 ft. 75 ft. 100 ft.  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
3/8  
1/2  
1/2  
3/8  
1/2  
1/2  
1/2  
24,000  
36,000  
48,000  
60,000  
Following are some points to consider when placing and  
installing a high-efficiency outdoor unit:  
Placement  
Be aware that some localities are adopting sound ordinances  
based on how noisy the unit is at the neighbor’s home, not  
at the original installation. Install the unit as far as possible  
from the property line. When possible, do not install the unit  
directly outside a bedroom window. Glass has a verry high  
level of sound transmission. Figure 4 shows how to place  
the outdoor unit and line set to reduce line set vibration.  
S uction L ine  
L ine S et L ength a nd S ize  
12 f t . 25 ft. 50 ft. 75 ft. 10 0 f t .  
B T U H  
3/4  
3/4  
7/8  
3/4  
7/8  
3/4  
7/8  
24,000  
7/8  
36,000 7/8  
48,000 7/8  
1-1/8  
1-1/8  
1-1/8  
1-1/8  
1-1/8  
Line Set Isolation  
Illustrations on the pages 6 and 7 demonstrate procedures  
which ensure proper refrigerant line set isolation. Figure 6  
shows how to install line sets on horizontal runs. Figure 7  
shows how to make a transition from horizontal to vertical.  
Figure 9 shows how to install line sets on vertical runs.  
1-1/8 1-1/8  
60,000  
1-1/8 1-1/8  
1-1/8  
For installations exceeding 50’, contact  
Technical Services.  
Table 2  
Brazing Connection Procedure  
1. Cut ends of refrigerant lines square (free from nicks or  
dents). Debur the ends. The pipe must remain round; do  
not pinch end of line.  
2. Before making line set connections, use dry nitrogen to  
purge the refrigerant piping. This will help to prevent  
oxidation and the introduction of moisture into the system.  
3. Use silver alloy brazing rods (5% or 6% silver alloy for  
copper-to-copper brazing or 45% silver alloy for  
506467-01  
Issue 1008  
Page 4  
copper-to-brass or copper-to-steel brazing) which are  
rated for use with R410A refrigerant.  
Outside Unit Placement  
and Installation  
4. Remove the Schrader core assemblies before brazing  
to protect them from damage due to extreme heat.  
Replace the cores when brazing is complete.  
Install unit away  
from windows  
5. Remove light maroon washers from service valves and  
shield light maroon stickers to protect them during  
brazing. Wrap a wet cloth around the valve body and  
copper tube stub to protect it from heat damage.  
6. Braze the line set to the service valve. Quench the joints  
with water or a wet cloth to prevent heat damage to the  
valve core and opening port. The tube end must stay  
bottomed in the fitting during final assembly to  
ensure proper seating, sealing, and rigidity.  
7. Install a thermal expansion valve (which is sold  
separately and which is approved for use with R410A  
refrigerant) in the liquid line at the indoor coil (see  
Refrigerant Metering Device on page 8).  
Two 90° elbows installed in lineset  
will reduce lineset vibration  
Figure 4  
Refrigerant Line Sets: Installing Horizontal Runs  
To hang line set from joist or rafter,  
use either metal strapping material  
or anchored heavy nylon wire ties.  
Wire Tie  
(around vapor line only)  
8  
Strapping Material  
(around vapor line only)  
Floor Joist or  
Roof Rafter  
Tape or Wire Tie  
8’  
Strap the vapor line to the joist or rafter  
at 8intervals then strap the liquid line  
to the vapor line.  
Metal Sleeve  
Floor Joist or Roof Rafter  
Tape or Wire Tie  
Figure 5  
506467-01  
Issue 1008  
Page 5  
Refrigerant Line Sets: Transition from Vertical to Horizontal  
Automotive  
Muffler-Type  
Hanger  
Anchored  
Heavy Nylon  
Wire Tie  
Strap Liquid  
Line to Vapor  
Line  
Strap Liquid  
Line to Vapor  
Line  
Wall  
Stud  
Wall  
Stud  
Liquid Line  
Liquid Line  
Vapor Line Wrapped  
Vapor Line Wrapped  
Metal Sleeve  
in Armaflex  
Metal Sleeve  
in Armaflex  
Figure 6  
Refrigerant Line Sets: Installing Vertical Runs (new construction shown)  
IMPORTANT: Refrigerant  
lines must not contact wall.  
Outside Wall  
Vapor Line  
Liquid Line  
NOTE: Similar installation practices  
should be used if line set is to be  
installed on exterior of outside wall.  
Wood Block  
Between Studs  
Wire Tie  
Inside Wall  
Strap  
Sleeve  
Vapor Line Wrapped  
with Armaflex  
Wire Tie  
Liquid Line  
Outside Wall  
Wood Block  
IMPORTANT:  
Refrigerant  
lines must not  
contact structure.  
Wire Tie  
Strap  
Caulk  
Fiberglass  
PVC Pipe  
Insulation  
Sleeve  
Figure 7  
Issue 1008  
506467-01  
Page 6  
Flushing Existing Line Set and Indoor Coil  
Flushing Procedure  
This procedure should not be performed on systems  
which contain contaminants, such as compressor  
burn out.  
IMPORTANT: The line set and/or indoor coil must be  
flushed with at least the same amount of refrigerant that  
previously charged the system. Check the charge in the  
flushing cylinder before flushing the unit.  
1. Remove existing R22 refrigerant using the appropriate  
procedure.  
CAUTION  
When flushing existing line set and/or indoor  
coil, be sure to empty all existing traps. Residual  
mineral oil can act as an insulator, preventing  
proper heat transfer. It can also clog the thermal  
expansion valve, reducing system performance  
and capacity. Failure to properly flush system as  
explained in these instructions will void warranty.  
If the existing outdoor unit is not equipped with shutoff  
valves, or if the unit is not operational AND the existing  
R22 refrigerant will be used to flush the system:  
Disconnect all power to the existing outdoor unit.  
Connect the existing unit, a clean recovery cylinder, and  
the recovery machine according to the instructions  
provided with the recovery machine. Remove all R22  
refrigerant from the existing system. Refer to the  
gauges after shutdown to confirm that the entire system  
is completely void of refrigerant. Disconnect the liquid  
and suction lines from the existing outdoor unit.  
Required Equipment  
The following equipment is needed to flush the existing  
line set and indoor coil (see Figure 8): Two clean R22  
recovery bottles, an oil-less recovery machine with a  
“pump down” feature, and two sets of gauges (one for use  
with R22 and one for use with R410A).  
If the existing outdoor unit is equipped with manual  
shutoff valves AND new R22 refrigerant will be used  
to flush the system:  
Start the existing R22 refrigerant system in cooling mode  
and close the liquid line valve. Pump all the existing R22  
refrigerant back into the outdoor unit.  
Flushing Connections  
Note: The inverted R22 cylinder must contain  
at least the same amount of refrigerant  
as was recovered from the existing  
system.  
Figure 8  
506467-01  
Issue 1008  
Page 7  
(It may be necessary to bypass the low pressure switches  
to ensure complete refrigerant evacuation.)  
9. Close the valve on the inverted R-22 cylinder and the  
gauge set valves. Pump the remaining refrigerant out of  
the recovery machine and turn the machine off.  
When the low side system pressures reach 0 psig, close  
the suction line valve. Disconnect all power to the existing  
outdoor unit. Refer to the gauges after shutdown to confirm  
that the valves are not allowing refrigerant to flow back into  
the low side of the system. Disconnect the liquid and suction  
lines from the existing outdoor unit.  
10. Use nitrogen to break the vacuum on the refrigerant  
lines and indoor coil before removing the recovery machine,  
gauges, and R-22 refrigerant drum. Re-install pressure tap  
valve cores into the 4AC16LT unit’s service valves.  
11. Install the refrigerant expansion valve approved for use  
with R410A refrigerant in the liquid line at the indoor coil.  
2. Remove the existing outdoor unit. Set the new R410A  
unit and follow the brazing connection procedure outlined  
previously on this page to make line set connections. Do  
not install the R410A thermal expansion valve at this  
time.  
Refrigerant Metering Device  
4AC16LT units are designed for use with TXV systems only.  
Expansion valves equipped with Chatleff-type fittings are  
available from the manufacturer. See Table 3 for proper  
TXV for each unit.  
3. Make low voltage and line voltage connections to the  
new outdoor unit. Do not turn on power to the unit or  
open the outdoor unit service valves at this time.  
TXV Data  
4. Remover the existing R-22 refrigerant flow control orifice  
or thermal expansion valve before continuing with flushing  
procedures. R-22 flow control devices are not approved for  
use with R410A refrigerant and may prevent proper flushing.  
Use a field-provided fitting to reconnect the lines.  
MODEL  
PART NUMBER  
4AC16LT -24, -36  
4AC16LT -48  
A4TXV01  
A4TXV02  
4AC16LT -60  
A4TXV02  
5. Remove the pressure tap valve cores from the 4AC16LT  
units service valves. Connect an R-22 cylinder with clean  
refrigerant to the suction service valve. Connect the R-22  
gauge set to the liquid line valve and connect a recovery  
maching with an empty recovery tank to the gauge set.  
Table 3  
To install an expansion valve (See Figure 9 above):  
6. Set the recovery machine for liquid recovery and start  
the recovery machine. Open the gauge set valves to allow  
the recovery machine to pull a vacuum on the existing system  
line set and indoor coil.  
1. Separate the distributor assembly and remove the piston  
orifice and used teflon seal. Insert nozzle end of the  
expansion valve along with a new teflon seal into the  
distributor and tighten to 20 - 30 ft. lbs. Use backup wrench  
on all wrench flats. Overtightening will crush the teflon  
seal and may cause a leak.  
7. Invert the cylinder of clean R-22 and open its valve to  
allow liquid refrigerant to flow in to the system through the  
suction line valve. Allow the refrigerant to pass from the  
cylinder and through the line set and the indoor coil before it  
enters the recovery machine.  
2. Attach liquid line portion of distributor assembly along  
with new teflon seal to the inlet of the expansion valve.  
Tighten to 20 - 30 ft. lbs. Use backup wrench on all wrench  
flats. Overtightening will crush the teflon seal and may  
cause a leak.  
8. After all of the liquid refrigerant has been recovered, switch  
the recovery machine to vapor recovery so that all of the R-  
22 vapor is recovered. Allow the recovery machine to pull a  
vacuum on the sytem.  
3. Connect the external equalizer line to the equalizer port  
on the suction line and tighten to 8 ft.lbs.  
NOTE: Asingle system flush should remove all of the mineral  
oil from the existing refrigerant lines and indoor coil. Asecond  
flushing may be done (using clean refrigerant) if insufficient  
amounts of mineral oil were removed during the first flush.  
After each system flush, allow the recovery machine to  
pull a vacuum on the system at the end of the procedure.  
4. Strap the superheat sensing bulb to the suction header.  
If installing an expansion valve on an indoor coil that  
previously used a fixed orifice, be sure to remove the existing  
fixed orifice. Failure to remove a fixed orifice when installing  
an expansion valve to the indoor coil will result in improper  
operation and damage to the system.  
506467-01  
Issue 1008  
Page 8  
Figure 9  
Manifold Gauge Set  
Manifold guage sets used with systems charged with R410A  
refrigerant must be capable of handling the higher system  
operating pressures. The gauges should be rated for use  
with pressures 1 - 800 on the high side and a low side of 30”  
vacuum to 250 psi with dampened speed to 500 psi. Gauge  
hoses must be rated for use at up to 800 psi of pressure  
with a 4000 psi burst rating.  
Liquid and Suction Line Service Valves  
The liquid line and suction line service valves (See Figure  
11) and service ports are used for leak teating, evacuation,  
charging, and checking charge.  
Each valve is equipped with a service port which has a  
factory-installed Schrader valve. Aservice port cap protects  
the Schrader valve from contamination and serves as the  
primary leak seal.  
Figure 10  
To Close Liquid or Suction Line Service Valve:  
1. Remove the stem cap with an adjustable wrench.  
To Access the Schrader Port:  
1. Remove the service port cap with an adjustable wrench.  
2. Use a service wrench with a hex-head extension to turn  
the stem clockwise to seat the valve. Tighten firmly.  
2. Connect gauge to the service port.  
3. Replace the stem cap. Tighten finger tight, then tighten  
an additional 1/6 turn.  
3. When testing is completed, replace service port cap.  
Tighten finger tight, then an additional 1/6 turn.  
To Open Liquid or Suction Line Service Valve:  
Remove stem cap with an adjustable wrench.  
Suction Line (Ball Type) Service Valve  
Suction line (ball type) service valves function the same way  
as the other valves; the difference is in the construction.  
Use service wrench with a hex-head extension to back the  
stem out counterclockwise as far as it will go. Use a 3/16”  
hex head extension for liquid line service valves and a 5/16”  
extension for suction line service valves.  
The ball valve is equipped with a service port with a factory-  
installed Schrader valve. A service port cap protects the  
Schrader valve from contamination and serves as the  
primary seal.  
Replace the stem cap. Tighten finger tight, then tighten an  
additional 1/6 turn.  
506467-01  
Issue 1008  
Page 9  
2. With both manifold valves closed, connect the cylin-  
der of R410A refrigerant. Open the valve on the  
R410A cylinder (vapor only).  
Ball Type Service Valve  
(Valve Open)  
3. Open the high pressure side of the manifold to allow  
R410A into the line set and indoor unit. Weigh in a  
trace amount of R410A. (A trace amount is a maxi-  
mum of 2 oz. of refrigerant or 3 lbs. pressure.) Close  
the valve on the R410A cylinder and the valve on the  
high pressure side of the manifold gauge set. Discon-  
nect the R410A cylinder.  
4. Connect a cylinder of nitrogen with a pressure regulat-  
ing valve to the center port of the manifold gauge set.  
When using high pressure gas such as nitrogen  
for this purpose, be sure to use a regulator that  
can control the pressure down to 1 or 2 psig.  
5. Adjust nitrogen pressure to 150 psig. Open the valve  
on the high side of the manifold gauge set to pressur-  
ize the line set and the indoor coil.  
Use adjustable wrench. To open, rotate stem  
counterclockwise 1/4 turn (90°). To close, rotate  
stem clockwise 1/4 turn (90°).  
6. After a short period of time, open a refrigerant port to  
make sure that an adequate amount of refrigerant has  
been added for detection (refrigerant requirements will  
vary with lengths). Check all joints for leaks. Purge  
nitrogen and R410A mixture. Correct any leaks and  
recheck.  
Figure 11  
Leak Testing  
After the line set has been connected to the indoor and  
outdoor units, the line set connections and indoor unit  
must be checked for leaks.  
Evacuation  
Evacuating the system of noncondensables is critical for  
proper operation of the unit. Noncondensables are defined  
as any gas that will not condense under temperatures and  
pressures present during operation of an air conditioning  
system. Noncondensables and water vapor combine with  
refrigerant to produce substances that corrode copper  
piping and compressor parts.  
WARNING  
Fire, Explosion, and Personal Safety Hazard.  
Failure to follow this warning could result in  
damage, personal injury, or death.  
WARNING  
Never use oxygen to pressurize or purge  
refrigeration lines. Oxygen, when exposed to  
a spark or open flame, can cause damage by  
fire and/or an explosion, that could result in  
personal injury or death.  
Do not use a compressor to evacuate a sys-  
tem. Avoid deep vacuum operation. Extremely  
low vacuums can cause internal arcing and  
compressor failure. Danger of equipment  
damage. Damage caused by deep vacuum  
operation will void warranty.  
Using an Electronic Leak Detector  
1. Connect the high pressure hose of the manifold  
gauge set to the suction valve service port. (Normally  
the high pressure hose is connected to the liquid line  
port; however, connecting it to the suction ports helps  
to protect the manifold gauge set from damage  
caused by high pressure.)  
Use a thermocouple or thermistor electronic vacuum  
gauge that is calibrated in microns. Use an instrument that  
reads down to 50 microns.  
1. Connect the manifold gauge set to the service valve  
ports as follows:  
Low pressure gauge to suction line service valve  
High pressure gauge to liquid line service valve  
506467-01  
Issue 1008  
Page 10  
of 22 of 222. Connect micron gauge.  
3. Connect the vacuum pump (with vacuum gauge) to  
the center port of the manifold gauge set.  
4. Open both manifold valves and start vacuum pump.  
5. Evacuate the line set and indoor unit to a minimum of 500  
microns or lower. During the early stages of evacuation, it  
is desirable to close the manifold gauge valve at least  
once to determine if there is a rapid rise in pressure. A  
rapid rise in pressure indicates a relatively large leak. If  
this occurs, the leak testing procedure must be repeated.  
6. When 500 microns or lower is maintained, close the  
manifold gauge valves, turn off the vacuum pump, and  
disconnect the manifold gauge center port hose from  
the vacuum pump. Attach the manifold gauge center  
port hose to a nitrogen cylinder with pressure regulator  
set to 150 psig and purge the hose. Open the manifold  
gauge valves to break the vacuum in the line set and  
indoor unit. Close the manifold gauge valves.  
7. Shut off the nitrogen cylinder and remove the manifold  
gauge hose from the cylinder. Open the manifold  
gauge valves to release the nitrogen from the line set  
and indoor unit.  
8. Reconnect the manifold gauge to the vacuum pump,  
turn the pump on, and continue to evacuate the line  
set and indoor unit until 500 microns is maintained  
within a 20-minute period after shutting off the  
vacuum pump and closing the manifold gauge valves.  
9. When the requirements above have been met,  
disconnect the manifold hose from the vacuum pump.  
Open the service valves to break the vacuum in the  
line set and indoor unit.  
506467-01  
Issue 1008  
Page 11  
START-UP  
CAUTION  
Refrigerant Charge Adjustment  
Liquid Line Set  
Diameter  
Oz. per 5 ft. adjust  
from 15 ft. line set*  
If unit is equipped with a crankcase heater, it  
should be energized 24 hours before unit  
start-up to prevent compressor damage as a  
result of slugging.  
3/8 in.  
3 oz. per 5 ft.  
* If line length is greater than 15 ft., add this amount.  
If line length is less than 15 ft., remove this amount.  
1. Rotate fan to check for frozen bearings or binding.  
Table 4  
2. Inspect all factory and field-installed wiring for loose  
connections.  
IMPORTANT  
3. After evacuation is complete, open liquid line and  
suction line service valves to release refrigerant  
charge (contained in outdoor unit) into system.  
Mineral oils are not compatible with R410A. If  
oil must be added, it must be a polyol ester oil.  
4. Replace the stem caps and secure finger tight, then  
tighten an additional 1/6 of a turn.  
If the system is void of refrigerant, clean the system using  
the procedure described below.  
5. Check voltage supply at the disconnect switch. The  
voltage must be within the range listed on the unit  
nameplate. If not, do not start equipment until the  
power company has been consulted and the voltage  
condition corrected.  
1. Use dry nitrogen to pressurize the system and check  
for leaks. Repair leaks, if possible.  
2. Evacuate the system to remove as much of the  
moisture as possible.  
6. Set thermostat for cooling demand, turn on power to  
indoor blower and close the outdoor unit disconnect  
switch to start the unit.  
3. Use dry nitrogen to break the vacuum.  
4. Evacuate the system again.  
7. Recheck unit voltage with unit running. Power must be  
within range shown on unit nameplate.  
5. Weigh the appropriate amount of R410A refrigerant  
(listed on unit nameplate) into the system.  
Refrigerant Charging  
6. Monitor the system to determine the amount of  
moisture remaining in the oil. Use a test kit to verify  
that the moisture content is within the kit’s dry color  
range. It may be necessary to replace the filter drier  
several times to achieve the required dryness level. If  
system dryness is not verified, the compressor  
will fail in the future.  
This system is charged with R410A refrigerant which  
operates at much higher pressures than R22. The liquid line  
drier provided with the unit is approved for use with R410A.  
Do not replace it with one designed for use with R22. This  
unit is NOT approved for use with coils which use  
capillary tubes as a refrigerant metering device.  
The outdoor unit should be charged during warm weather.  
However, applications arise in which charging must occur  
in the colder months. The method of charging is deter-  
mined by the outdoor ambient temperature.  
R410A refrigerant cylinders are rose colored. Refriger-  
ant should be added through the vapor valve in the  
liquid state.  
Certain R410A cylinders are identified as being  
equipped with a dip tube. These allow liquid refriger-  
ant to be drawn from the bottom of the cylinder  
without inverting the cylinder. Do not turn this type of  
cylinder upside down to draw refrigerant.  
Measure the liquid line temperature and the outdoor  
ambient temperature as outlined below:  
1. Connect the manifold gauge set to the service valve  
ports as follows:  
Units are factory charged with the amount of R410A  
refrigerant indicated on the unit rating plate. This charge is  
based on a matching indoor coil and outdoor coil with 15'  
line set. For varying lengths of line set, refer to Table 4 for  
refrigerant charge adjustment.  
Low pressure gauge to suction line service valve  
High pressure gauge to liquid line service valve  
506467-01  
Issue 1008  
Page 12  
2. Close manifold gauge set valves. Connect the center  
manifold hose to an upright cylinder of R410A.  
Blocking Outdoor Coil  
Outdoor coil should be  
3. If room temperature is below 70°F, set the room thermo-  
stat to call for heat. This will create the necessary load  
for properly charging the system in the cooling cycle.  
blocked one side at a time  
with cardboard or plastic  
sheet until proper testing  
pressures are reached.  
4. Use a digital thermometer to record the outdoor  
ambient temperature.  
Cardboard or Plastic Sheet  
5. When the heating demand has been satisfied, switch  
the thermostat to cooling mode with a set point of  
68°F. When pressures have stabilized, use a digital  
thermometer to record the liquid and suction line  
temperatures.  
Figure 12  
4. Subtract the liquid line temperature from the satura-  
tion temperature (according to the chart) to determine  
subcooling.  
6. The outdoor temperature will determine which charg-  
ing method to use. Proceed with the appropriate  
charging method.  
_____ ° Saturation Temperature °F  
Charge Using Weigh-In Method  
_____ ° Liquid Line Temperature °F  
=
_____ ° Subcooling Value °F  
If the system is void of refrigerant, or if the outdoor ambient  
temperature is cool, first locate and repair any leaks then  
use the weigh-in method to charge the unit.  
5. Compare the subcooling value with those shown in  
Table 6 on page 14. If subcooling is greater than  
shown, recover some refrigerant. If subcooling is less  
than shown, add some refrigerant.  
1. Recover the refrigerant from the unit.  
2. Conduct a leak check, then evacuate as previously  
outlined.  
Charge Using Approach Method –  
Outdoor Temperatures 65°F or Above  
3. Weigh in the charge according to the total amount  
shown on the unit nameplate.  
The following procedure is intended as a general guide  
and is for use on expansion valve systems only. For best  
results, indoor temperature should 70°F to 80°F. Monitor  
system pressures while charging.  
If weighing facilities are not available, use one of the  
following procedures to charge the unit.  
Charge Using Subcooling Method –  
Outdoor Temperatures Below 65°F  
1. Record outdoor ambient temperature using a digital  
thermometer.  
When the outdoor ambient temperature is below 65°F, the  
subcooling method can be used to charge the unit. It may  
be necessary to restrict the air flow through the outdoor  
coil to achieve pressures in the 200-250 psig range.  
These higher pressures are necessary for checking the  
charge. Block equal sections of air intake panels and  
move obstructions sideways until the liquid pressure is in  
the 200-250 psig range (see Figure 12).  
2. Attach high pressure gauge set and operate unit for  
several minutes to allow system pressures to stabilize.  
3. Compare stabilized pressures with those provided in  
Table 8 on page 15. Minor variations in these pres-  
sures may be expected due to differences in installa-  
tions. Significant differences could mean that the  
system is not properly charged or that a problem  
exists with some component in the system.  
Pressures higher than those listed indicate that the  
system is overcharged. Pressures lower than those  
listed indicate that the system is undercharged. Verify  
adjusted charge using the approach method.  
1. With the manifold gauge hose on the liquid service  
port and the unit operating stably, use a digital ther-  
mometer to record the liquid line temperature.  
2. At the same time, record the liquid line pressure reading.  
4. Use the same digital thermometer to check liquid line  
temperature.  
3. Use the temperature/pressure chart (Table 5 on page 14)  
to determine the saturation temperature for the liquid line  
pressure reading.  
5. Subtract the outdoor ambient temperature from the  
liquid line temperature to determine the approach  
temperature.  
506467-01  
Issue 1008  
Page 13  
R410A Temperature/Pressure Chart  
Subcooling Values  
Temp.  
(F  
Pressure  
Psig  
Temp.  
(F  
Pressure  
Psig  
Temp.  
(F  
Pressure  
Psig  
32  
33  
100.8  
102.9  
74  
75  
214.0  
217.4  
116  
117  
396.0  
401.3  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
105.0  
107.1  
109.2  
111.4  
113.6  
115.8  
118.0  
120.3  
122.6  
125.0  
127.3  
129.7  
132.2  
134.6  
137.1  
139.6  
142.2  
144.8  
147.4  
150.1  
152.8  
155.5  
158.2  
161.0  
163.9  
166.7  
169.6  
172.6  
175.5  
178.5  
181.6  
184.3  
187.7  
190.9  
194.1  
197.3  
200.6  
203.9  
207.2  
210.6  
76  
77  
220.9  
224.4  
228.0  
231.6  
235.3  
239.0  
242.7  
246.5  
250.3  
254.1  
258.0  
262.0  
266.0  
270.0  
274.1  
278.2  
282.3  
286.5  
290.3  
295.1  
299.4  
303.8  
308.2  
312.7  
317.2  
321.8  
326.4  
331.0  
335.7  
340.5  
345.3  
350.1  
355.0  
360.0  
365.0  
370.0  
375.1  
380.2  
385.4  
390.7  
118  
119  
120  
121  
122  
123  
124  
125  
126  
127  
128  
129  
130  
131  
132  
133  
134  
135  
136  
137  
138  
139  
140  
141  
142  
143  
144  
145  
146  
147  
148  
149  
150  
151  
152  
153  
154  
155  
406.7  
412.2  
417.7  
423.2  
428.8  
434.5  
440.2  
445.9  
451.8  
457.6  
463.5  
469.5  
475.6  
481.6  
487.8  
494.0  
500.2  
506.5  
512.9  
519.3  
525.8  
532.4  
539.0  
545.6  
552.3  
559.1  
565.9  
572.8  
579.8  
586.8  
593.8  
601.0  
608.1  
615.4  
622.7  
630.1  
637.5  
645.0  
Table 6  
78  
79  
80  
81  
°
°
°
Liquid Line Temperature °F  
Outdoor Ambient Temperature °F  
Approach Temperature °F  
_
82  
83  
=
84  
85  
86  
6. Compare the approach value with those shown in Table  
7. If the values do not agree with those provided in Table 7,  
add refrigerant to lower the approach temperature or recover  
refrigerant from the system to increase the approach  
temperature.  
87  
88  
89  
90  
91  
92  
93  
94  
Check Charge Using Normal Operating Pressures  
Use Table 8 to perform maintenance checks. Table 8 is not  
a procedure for charging the system. Minor variations in  
these pressures may be due to differences in installations.  
Significant deviations could mean that the system is not  
properly charged or that a problem exists with some  
component in the system.  
95  
96  
97  
98  
99  
100  
101  
102  
103  
104  
105  
106  
107  
108  
109  
110  
111  
112  
113  
114  
115  
Approach Values for TXV Systems  
Approach value is the liquid line temperature minus  
the outdoor ambient temperature (± 1°F).  
Note: For best results, use the same digital  
thermometer to check both outdoor ambient and  
liquid temperatures.  
Table 7  
72  
73  
207.2  
210.6  
114  
115  
385.4  
390.7  
Table 5  
506467-01  
Issue 1008  
Page 14  
Normal Operating Pressures  
L = Liquid S = Suction  
Values provided above are typical pressures. Indoor unit matchup, indoor air quality, and indoor load  
will cause pressures to vary.  
Table 8  
506467-01  
Issue 1008  
Page 15  
Thermostat Demand Wiring  
OPERATION  
Outdoor unit and indoor blower cycle on demand from the  
room thermostat. When the thermostat blower switch is  
moved to the ON position, the indoor blower operates  
continuously.  
The diagnostic module requires a thermostat demand  
signal to operate properly. The thermostat demand signal  
input, labeled Y on the module, should always be con-  
nected to the compressor contactor coil so that when the  
coil is energized, the demand signal input is 24VAC. When  
the coil is not energized, the demand signal input should be  
less than 0.5VAC.  
System Diagnostic Module  
4AC16LT units contain a diagnostic module for trouble-  
shooting air conditioning system failures. By monitoring  
and analyzing data from the compressor and thermostat  
demand, the module can accurately detect the cause of  
electrical and system related failure without any sensors.  
If a system problem occurs, a flashing LED indicator  
communicates the failure code.  
Miswired Module Codes  
Depending on the system configuration, some ALERT  
flash codes may not be active. The presence of safety  
switches affects how the system alerts are displayed by  
the module.  
LED Description  
Miswiring the diagnostic module will cause false LED  
codes. Table 11 on page 19 describes LED operation  
when the module is miswired and what troubleshooting  
action is required to correct the problem.  
POWER LED (Green) indicates voltage is present at the  
power connection of the module.  
ALERT LED (Yellow) communicates an abnormal system  
condition through a unique flash code. The ALERT LED  
will flash a number of times consecutively, pause, and  
then repeat the process. The number of consecutive  
flashes correlates to a particular abnormal condition.  
TRIP LED (Red) indicates there is a demand signal from  
the thermostat but no current to the compressor is de-  
tected by the module. The TRIP LED typically indicates  
the compressor protector is open or may indicate missing  
supply power to the compressor.  
Interpreting the Diagnostic LEDs  
When an abnormal system condition occurs, the diagnostic  
module displays the appropriate ALERT and/or TRIP LED.  
The yellow ALERT LED will flash a number of times  
consecutively, pause, and then repeat the process. To  
identify a flash code number, count the number of consecu-  
tive flashes. Refer to Table 9 on page 17 and Table 10 on  
page 18 for information on the flash codes.  
Every time the module powers up, the last ALERT LED  
flash code that occurred prior to shutdown is displayed for  
60 seconds. The module will continue to display the  
previous flash code until the condition returns to normal or  
24VAC is removed from the module. TRIP and ALERT  
LEDs flashing at the same time means control circuit  
voltage is too low for operation.  
24VAC Power Wiring  
The diagnostic module requires a constant nominal 24VAC  
power supply. The wiring to the module’s R and C terminals  
must be directly from the indoor unit or thermostat.  
506467-01  
Issue 1008  
Page 16  
Flash Codes  
LED  
Status  
Fault Description  
Troubleshooting Information  
POWER  
(Green)  
Module has power  
Supply voltage is present at module terminals  
1. Compressor protector is open  
* Check for high head pressure  
Thermostat demand  
signal Y1 is present,  
but the compressor  
is not running  
* Check compressor supply voltage  
TRIP  
(Red)  
2. Outdoor unit power disconnect is open  
3. Compressor circuit breaker or fuse(s) is open  
4. Broken wire or connector is not making contact  
5. Low pressure switch open if present in system  
6. Compressor contactor has failed open  
1. Low refrigerant charge  
2. Evaporator blower is not running  
* Check blower relay coil and contacts  
* Check blower motor capacitor  
* Check blower motor for failure or blockage  
* Check evaporator blower wiring and connector  
* Check indoor blower control board  
* Check thermostat wiring for open circuit  
3. Evaporator coil is frozen  
* Check for low suction pressure  
* Check for excessively low thermostat setting  
* Check evaporator airflow (coil blockages or return air filter)  
* Check ductwork or registers for blockage  
4. Faulty metering device  
Long Run Time  
Compressor is  
running  
extremely long run  
cycles  
ALERT  
(Yellow)  
Flash  
Code 1  
* Check TXV bulb installation (size, location, and contact)  
* Check if TXV/fixed orifice is stuck closed or defective  
5. Condenser coil is dirty  
6. Liquid line restriction (filter drier blocked if present in system)  
7. Thermostat is malfunctioning  
* Check thermostat sub-base or wiring for short circuit  
* Check thermostat installation (location, level)  
1. High head pressure  
* Check high pressure switch if present in system  
* Check if system is overcharged with refrigerant  
* Check for non-condensable in system  
2. Condenser coil poor air circulation (dirty, blocked, damaged)  
3. Condenser fan is not running  
System  
Pressure Trip  
Discharge or suction  
pressure  
ALERT  
(Yellow)  
Flash  
out of limits or  
compressor  
* Check fan capacitor  
* Check fan wiring and connectors  
Code 2  
overloaded  
* Check fan motor for failure or blockage  
4. Return air duct has substantial leakage  
5. If low pressure switch present in system, check Flash Code 1 info  
Table 9  
506467-01  
Issue 1008  
Page 17  
Flash Codes (cont.)  
LED  
Status  
Fault Description  
Troubleshooting Information  
1. Thermostat demand signal is intermittent  
2. Time delay relay or control board defective  
3. If high pressure switch present, go to Flash Code 2 info  
4. If low pressure switch present, go to Flash Code 1 info  
ALERT  
(Yellow)  
Flash  
Short Cycling  
Compressor is  
running  
Code 3  
only briefly  
1. Run capacitor has failed  
ALERT  
(Yellow)  
Flash  
2. Low line voltage (contact utility if voltage at disconnect is low)  
* Check wiring connections  
3. Excessive liquid refrigerant in compressor  
4. Compressor bearings are seized  
*Measure compressor oil level  
Locked Rotor  
Code 4  
1. Outdoor unit power disconnect is open  
2. Compressor circuit breaker or fuse(s) is open  
3. Compressor contactor has failed open  
* Check compressor contactor wiring and connectors  
* Check for compressor contactor failure (burned, pitted, or open)  
* Check wiring and connectors between supply and compressor  
* Check for low pilot voltage at compressor contactor coil  
4. High pressure switch is open and requires manual reset  
5. Open circuit in compressor supply wiring or connections  
6. Unusually long compressor protector reset time due to extreme ambient temperature  
7. Compressor windings are damaged  
ALERT  
(Yellow)  
Flash  
Open Circuit  
Code 5  
* Check compressor motor winding resistance  
1. Run capacitor has failed  
ALERT  
(Yellow)  
Flash  
Open Start Circuit  
Current only in run  
circuit  
2. Open circuit in compressor start wiring or connections  
* Check wiring and connectors between supply and the compressor S terminal  
3. Compressor start winding is damaged  
Code 6  
* Check compressor motor winding resistance  
ALERT  
(Yellow)  
Flash  
1. Open circuit in compressor run wiring or connections  
* Check wiring and connectors between supply and the compressor R terminal  
2. Compressor run winding is damaged  
Open Run Circuit  
Current only in start  
circuit  
Code 7  
* Check compressor motor winding resistance  
ALERT  
(Yellow)  
Flash  
Welded Contactor  
Compressor always  
runs  
1. Compressor contactor has failed closed  
2. Thermostat demand signal not connected to module  
Code 8  
ALERT  
(Yellow)  
Flash  
Low Voltage  
Control circuit less  
than 17VAC  
1. Control circuit transformer is overloaded  
2. Low line voltage (contact utility if voltage at disconnect is low)  
* Check wiring conditions  
Code 9  
Table 10  
506467-01  
Issue 1008  
Page 18  
Miswired Module Troubleshooting  
Miswired Module Indication  
Recommended Troubleshooting Action  
Determine if both R and C module terminals are connected. Verify voltage is present  
at module's R and C terminals. Review 24VAC Power Wiring section on page 16 for  
R and C wiring.  
Green LED is not on,  
module does not power up.  
Green LED intermittent,  
module powers up only  
when compressor runs.  
Determine if R and Y terminals are wired in reverse. Verify module's R and C  
terminals have a constant source. Review 24VAC Power Wiring section on page 16  
for R and C wiring.  
TRIP LED is on but system  
and compressor check OK.  
Verify Y terminal is connected to 24VAC at contactor coil. Verify voltage at contactor  
coils falls below 0.5VAC when off.  
TRIP LED and ALERT LED  
flashing together.  
Verify R and C terminals are supplied with 19-28VAC.  
ALERT Flash Code 3  
(Compressor Short Cycling)  
displayed incorrectly.  
Verify Y terminal is connected to 24VAC at contactor coil. Verify voltage at contactor  
coil falls below 0.5VAC when off.  
ALERT Flash Code 5, 6, or 7  
(Open Circuit, Open Start  
Circuit, or Open Run Circuit)  
displayed incorrectly.  
Check that compressor run and start wires are through module's current sensing  
holes. Verify Y terminal is connected to 24VAC at contactor coil. Verify voltage at  
contactor coil falls below 0.5VAC when off.  
ALERT Flash Code 6  
(Open Start Circuit)  
displayed for Code 7  
(Open Run Circuit  
or vice versa.  
Check that compressor run and start wires are routed through correct module  
sensing holes.  
Determine if module's Y terminal is connected. Verify Y terminal is connected to 24VAC at  
contactor coil. Verify 24VAC is present across Y and C when thermostat demand signal is  
present. If not, R and C are reverse wired. Verify voltage at contactor coil falls below  
0.5VAC when off. Review Thermostat Demand Wiring on page 16 for Y and C wiring.  
ALERT Flash Code 8  
(Welded Contactor)  
displayed incorrectly.  
Table 11  
506467-01  
Issue 1008  
Page 19  
4. Check all wiring for loose connections.  
5. Check for correct voltage at unit (with unit operating).  
6. Check amp-draw on blower motor.  
MAINTENANCE  
WARNING  
Before performing maintenance operations on  
system, turn the electric power to unit OFF at  
disconnect switch(es). Unit may have multiple  
power supplies. Electrical shock could cause  
personal injury or death.  
Unit nameplate _________ Actual _________  
Maintenance and service must be performed by a quali-  
fied installer or service agency.  
At the beginning of each cooling season, the system  
should be checked as follows:  
1. Clean and inspect condenser coil. Coil may be  
flushed with a water hose. Be sure the power is off  
before using water to clean the coil.  
2. Outdoor fan motor is pre-lubricated and sealed. No  
further lubrication is needed.  
3. Visually inspect connecting lines and coils for evi-  
dence of oil leaks.  
4. Check wiring for loose connections.  
5. Check for correct voltage at unit (with unit operating).  
6. Check amp-draw outdoor fan motor.  
Unit nameplate _________ Actual _________  
NOTE – If owner complains of insufficient cooling, the  
unit should be gauged and refrigerant charge checked.  
Refer to the Refrigerant Charging section on page 12.  
Indoor Coil  
1. Clean coil, if necessary.  
2. Check connecting lines and coils for evidence of oil  
leaks.  
3. Check condensate pan line and clean, if necessary.  
Indoor Unit  
1. Clean or change filters.  
2. Adjust blower speed for cooling. Measure the pressure  
drop over the coil to determine the correct blower CFM.  
3. Belt drive blowers: Check belt for wear and proper  
tension.  
506467-01  
Issue 1008  
Page 20  
Start-Up and Performance Checklist  
Job Name _______________________________  
Job No. ________________  
City ___________________  
City ___________________  
Date ______________  
State ______________  
State ______________  
Job Location _____________________________  
Installer _________________________________  
Unit Model No.______________  
Serial No. ___________________  
Service Technician ________________________________________  
Nameplate Voltage ______________  
Outdoor Fan ___________________  
Rated Load Ampacity ________  
Compressor _______________  
Maximum Fuse or Circuit Breaker________________________  
Electrical Connections Tight?  
Indoor Filter Clean?  
Supply Voltage (Unit Off) ________________  
Indoor Blower RPM _____________  
S.P. Drop Over Indoor (Dry) ____________  
Voltage with Compressor Operating _____________  
Vapor Pressure ____________  
Outdoor Coil Entering Air Temperature _____________  
Discharge Pressure___________  
Refrigerant Charge Checked?  
Refrigerant Lines: Leak Checked?  
Service Valves: Fully Opened?  
Outdoor Fan Checked?  
Properly Insulated?  
Caps Tight?  
Thermostat: Calibrated?  
Properly Set?  
Level?  
506467-01  
Issue 1008  
Page 21  
LT BLUE  
OUTDOOR  
FAN  
DUAL  
CAPACITOR  
PURPLE  
BLACK  
TO 24 VAC  
POWER SOURCE  
20 VA MINIMUM  
NEC CLASS 2  
F
C
H
ORANGE  
Y2  
YELLOW  
R
C
Y1  
RED  
BLUE  
R
C
L
Y2  
BLACK  
Y1  
R
S
C
COMPRESSOR  
CRANKCASE HEATER  
(IF USED)  
L2  
L1  
GROUND  
LUG  
208-230/60/1  
GROUND  
B1  
S
R
C
1
BLACK  
L1  
S4 HIGH  
PRESSURE  
SWITCH  
S24 LOSS  
OF CHARGE  
SWITCH  
K1-1  
A132  
Y2  
Y1  
L
R
C
208-230/60/1  
L2  
YELLOW  
RED  
ORANGE  
BLACK  
S24  
S4  
HR1  
K1  
H
C
C12  
F
EQUIPMENT  
GROUND  
R
B4  
PURPLE  
C
Y2 Y1  
TO 24 VAC  
POWER SOURCE  
20 VA MINIMUM  
NEC CLASS 2  
FOR USE WITH COPPER CONDUCTORS ONLY. REFER TO UNIT RATING  
PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT  
PROTECTION SIZE.  
1
DESCRIPTION  
WARNING--  
KEY  
A4  
A132  
B1  
COMPONENT  
ELECTRIC SHOCK HAZARD, CAN CAUSE INJURY OR DEATH.  
UNIT MUST BE GROUNDED IN ACCORDANCE WITH NATIONAL  
AND LOCAL CODES.  
CONTROL - TIMED OFF  
DIAGNOSTIC MODULE  
COMPRESSOR  
B4  
C12  
HR1  
K1-1  
S4  
S24  
MOTOR - OUTDOOR FAN  
CAPACITOR - DUAL  
HEATER - COMPRESSOR  
CONTACTOR - COMPRESSOR  
SWITCH - HIGH PRESSURE  
SWITCH - LOSS OF CHARGE  
LINE VOLTAGE FACTORY INSTALLED  
LINE VOLTAGE FIELD INSTALLED  
24 VOLT FACTORY INSTALLED  
CLASS II VOLTAGE FIELD INSTALLED  
Wiring Diagram P/N 48440-002  
Figure 13  
506467-01  
Issue 1008  
Page 22  

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