Lennox Xc14 Installation and operation manual

Page 1

Corp. 0704−L2 XC14

Service Literature Revised 07−2008

XC14 SERIES UNITS

The XC14 is a high efficiency residential split−system con-

densing unit, which features a scroll compressor and

R−410A refrigerant. XC14 units are available in sizes rang-

ing from 1 1/2 through 5 tons. The series is designed for use

with an expansion valve or RFC (approved for use with

R−410A) in the indoor unit. This manual is divided into sec-

tions which discuss the major components, refrigerant sys-

tem, charging procedure, maintenance and operation se-

quence.

Information contained in this manual is intended for use by

qualified service technicians only. All specifications are sub-

ject to change.

WARNING

Improper installation, adjustment, alteration, service

or maintenance can cause property damage, person-

al injury or loss of life. Installation and service must

be performed by a qualified installer or service

agency.

WARNING

Warranty will be voided if covered equipment is re-

moved from original installation site. Warranty will

not cover damage or defect resulting from:

Flood, wind, lightning, or installation and operation

in a corrosive atmosphere (chlorine, fluorine, salt,

recycled waste water, urine, fertilizers, or other dam-

aging chemicals).

DANGER

Shock Hazard

Remove all power at disconnect

before removing access panel.

Single phase XC14 units use single-

pole contactors. Potential

exists for electrical shock resulting

in injury or death.

Line voltage exist at all components

(even when unit is not in operation).

IMPORTANT

Operating pressures of this R−410A unit are higher

than pressures in R−22 units. Always use service

equipment rated for R410A.

TABLE OF CONTENTS

General Page 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications / Electrical Data Page 2. . . . . . . . .

I Application Page 4. . . . . . . . . . . . . . . . . . . . . . . . .

II Unit Components Page 4. . . . . . . . . . . . . . . . . .

III Refrigeration System Page 8. . . . . . . . . . . . . . .

IV Charging Page 9. . . . . . . . . . . . . . . . . . . . . . . . .

V Service and Recovery Page 21. . . . . . . . . . . . . .

VI Maintenance Page 21. . . . . . . . . . . . . . . . . . . . . .

VII Wiring and Sequence of Operation Page 22. .

Page 2

SPECIFICATIONS −1 units and 030 through 060 −2 units

General

Model No. XC14−018 XC14−024 XC14−030 XC14−036 XC14−042 XC14−048 XC14−060

Data Nominal Tonnage 1.5 2 2.5 3 3.5 4 5

Connections

(sweat)

Liquid line o.d. − in. 3/8 3/8 3/8 3/8 3/8 3/8 3/8

(sweat) Suction line o.d. − in. 3/4 3/4 3/4 7/8 7/8 7/8 1-1/8

1Refrigerant (R-410A) furnished 6 lbs. 12 oz. 7 lbs. 10 oz. 8 lbs. 0 oz. 8 lbs. 9 oz. 8 lbs. 10 oz. 10 lbs. 0 oz. 12 lbs. 0 oz.

Outdoor

Coil

Net face area -

sq ft

Outer coil 13.22 13.22 16.33 16.33 16.33 21.00 22.00

Coil sq. ft. Inner coil 12.60 12.60 15.71 15.71 15.71 20.25 21.33

Tube diameter − in. 5/16 5/16 5/16 5/16 5/16 5/16 5/16

Number of rows 2 2 2 2 2 2 2

Fins per inch 22 22 22 22 22 22 22

Outdoor

Fan

Diameter − in. 18 18 22 22 22 22 26

Fan Number of blades 4 4 4 4 4 4 4

Motor hp 1/5 1/5 1/6 1/6 1/4 1/4 1/3

Cfm 2400 2400 2900 2900 3500 3600 4400

Rpm 1100 1100 825 825 825 825 825

Watts 200 200 220 220 310 310 310

Shipping Data − lbs. 1 package 146 148 169 172 198 221 238

ELECTRICAL DATA

Line voltage data − 60 hz − 1ph 208/230V 208/230V 208/230V 208/230V 208/230V 208/230V 208/230V

2Maximum overcurrent protection (amps) 20 30 30 30 40 50 60

3Minimum circuit ampacity 12.3 17.9 17.2 18.7 24.1 29.0 34.8

Compressor Rated load amps 9.0 13.4 12.9 14.1 17.9 21.8 26.4

Power factor .96 .97 .98 .98 .94 .95 .98

Locked rotor amps 48 58 64 77 112 117 134

Condenser

Fan Motor

Full load amps 1.0 1.0 1.1 1.1 1.7 1.7 1.8

Fan Motor Locked rotor amps 1.9 1.9 2.1 2.1 3.1 3.1 2.9

OPTIONAL ACCESSORIES − must be ordered extra

Compressor Crankcase Heat-

93M05    

er 93M06 Factory Factory

Compressor Hard Start Kit 10J42 

88M91      

Compressor Low Ambient Cut−Off 45F08 

Compressor Time−Off Control 47J27 

Freezestat 3/8 in. tubing 93G35 

5/8 in. tubing 50A93       

Indoor Blower Off Delay Relay 58M81 

Loss of Charge Switch Kit 84M23 

Low Ambient Kit 34M72 

Refrigerant

Line Sets

L15−41−20, L15−41−30,

L15−41−40, L15−41−50

  

L15−65−30, L15−65−40,

L15−65−50

  

Field Fabricate 

NOTE  Extremes of operating range are plus 10% and minus 5% of line voltage.

1Refrigerant charge sufficient for 15 ft. length of refrigerant lines.

2HACR type circuit breaker or fuse.

3Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.

Page 3

SPECIFICATIONS 018, 024 −2 units & 030 through 060 −3 units

General

Model No. XC14−018 XC14−024 XC14−030 XC14−036 XC14−042 XC14−048 XC14−060

Data Nominal Tonnage 1.5 2 2.5 3 3.5 4 5

Connections

(sweat)

Liquid line o.d. − in. 3/8 3/8 3/8 3/8 3/8 3/8 3/8

(sweat) Suction line o.d. − in. 3/4 3/4 3/4 7/8 7/8 7/8 1-1/8

1Refrigerant (R-410A) furnished 5 lbs. 11 oz. 6 lbs. 8 oz. 6 lbs. 11 oz. 6 lbs. 11 oz. 8 lbs. 10 oz. 10 lbs. 0 oz. 12 lbs. 0 oz.

Outdoor

Coil

Net face area -

sq ft

Outer coil 13.22 18.67 21.00 21.00 16.33 21.00 22.00

Coil sq. ft. Inner coil − − − − − − − − − − − − 15.71 20.25 21.33

Tube diameter − in. 5/16 5/16 5/16 5/16 5/16 5/16 5/16

Number of rows 1 1 1 1 2 2 2

Fins per inch 26 26 26 26 22 22 22

Outdoor

Fan

Diameter − in. 18 22 22 22 22 22 26

Fan Number of blades 3 3 3 3 4 4 4

Motor hp 1/10 1/6 1/6 1/6 1/4 1/4 1/3

Cfm 2270 3160 3160 3160 3500 3600 4400

Rpm 1050 850 850 850 825 825 825

Watts 165 215 215 215 310 310 310

Shipping Data − lbs. 1 package 163 203 215 217 243 272 290

ELECTRICAL DATA

Line voltage data − 60 hz − 1ph 208/230V 208/230V 208/230V 208/230V 208/230V 208/230V 208/230V

2Maximum overcurrent protection (amps) 25 30 30 30 40 50 60

3Minimum circuit ampacity 15.7 17.9 17.2 18.7 24.1 29.0 34.8

Compressor Rated load amps 9.0 13.4 12.9 14.1 17.9 21.8 26.4

Power factor .93 .97 .98 .98 .94 .95 .98

Locked rotor amps 48 58 64 77 112 117 134

Condenser

Fan Motor

Full load amps 0.7 1.1 1.1 1.1 1.7 1.7 1.8

Fan Motor Locked rotor amps 1.4 2.1 2.1 2.1 3.1 3.1 2.9

OPTIONAL ACCESSORIES − must be ordered extra

Compressor Crankcase Heat-

93M04    

er 93M06 Factory Factory

Compressor Hard Start Kit 10J42 

88M91      

Compressor Low Ambient Cut−Off 45F08 

Compressor Time−Off Control 47J27 

Freezestat 3/8 in. tubing 93G35 

5/8 in. tubing 50A93       

Indoor Blower Off Delay Relay 58M81 

Loss of Charge Switch Kit 84M23 

Low Ambient Kit 34M72 

Refrigerant

Line Sets

L15−41−20, L15−41−30,

L15−41−40, L15−41−50

  

L15−65−30, L15−65−40,

L15−65−50

  

Field Fabricate 

NOTE  Extremes of operating range are plus 10% and minus 5% of line voltage.

1Refrigerant charge sufficient for 15 ft. length of refrigerant lines.

2HACR type circuit breaker or fuse.

3Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements.

Page 4

I − APPLICATION

XC14 condensing units are available in 1 1/2, 2, 2 -1/2, 3,

3 -1/2, 4 and 5 ton capacities. All major components (indoor

blower and coil) must be matched according to Lennox rec-

ommendations for the compressor to be covered under war-

ranty. Refer to the Engineering Handbook for approved sys-

tem matchups.

II − UNIT COMPONENTS

Unit components are illustrated in figure 1.

XC14 PARTS ARRANGEMENT

FIGURE 1

HR1

Crankcaseheater

(−048 & −060) S4 High

Presure

Switch

Vapor Line

Service Valve

Liquid Line

Service Valve

Muffler

Drier

S40

Crankcaseheater

Thermostat

(−048 & −060)

Discharge

Line

Thermostat

CAUTION

To prevent personal injury, or damage to panels, unit

or structure, be sure to observe the following:

While installing or servicing this unit, carefully stow

all removed panels out of the way, so that the panels

will not cause injury to personnel, nor cause damage

to objects or structures nearby, nor will the panels be

subjected to damage (e.g., being bent or scratched).

While handling or stowing the panels, consider any

weather conditions, especially windy conditions, that

may cause panels to be blown around and battered.

Detail

Detail C

Detail

FIGURE 2

Removing/Installing Louvered Panels

MAINTAIN MINIMUM PANEL ANGLE (AS CLOSE TO PARALLEL WITH THE UNIT

AS POSSIBLE) WHILE INSTALLING PANEL.

PREFERRED ANGLE

FOR INSTALLATION

Detail D

ROTATE IN THIS DIRECTION;

THEN DOWN TO REMOVE PANEL

SCREW

HOLES

ANGLE MAY BE TOO

EXTREME

HOLD DOOR FIRMLY TO THE HINGED

SIDE TO MAINTAIN

FULLY−ENGAGED TABS

LIP

IMPORTANT! Do not allow panels to hang on unit by top tab. Tab

is for alignment and not designed to support weight of panel.

Panel shown slightly rotated to allow top tab to exit (or enter) top

slot for removing (or installing) panel.

Remove the louvered panels as follows:

1.Remove 2 screws, allowing the panel to swing open slight-

ly (see figure 2).

2.Hold the panel firmly throughout this procedure. Ro-

tate bottom corner of panel away from hinge corner post

until lower 3 tabs clear the slots (see figure 2, Detail B).

Page 5

3.Move panel down until lip of upper tab clears the top slot

in corner post (see figure 2, Detail A).

Position and Install PanelPosition the panel almost par-

allel with the unit (figure 2, Detail D) with the screw side" as

close to the unit as possible. Then, in a continuous motion:

Slightly rotate and guide the lip of top tab inward (figure 2,

Details A and C); then upward into the top slot of the

hinge corner post.

Rotate panel to vertical to fully engage all tabs.

Holding the panel’s hinged side firmly in place, close the

right−hand side of the panel, aligning the screw holes.

When panel is correctly positioned and aligned, insert the

screws and tighten.

A − Control Box (Figure 3)

XC14 units are not equipped with a 24V transformer. All 24

VAC controls are powered by the indoor unit. Refer to wir-

ing diagram.

Electrical openings are provided under the control box cov-

er. Field thermostat wiring is made to color-coded pigtail

connections.

ELECTROSTATIC DISCHARGE (ESD)

Precautions and Procedures

CAUTION

Electrostatic discharge can affect electronic com-

ponents. Take precautions during unit installation

and service to protect the unit’s electronic controls.

Precautions will help to avoid control exposure to

electrostatic discharge by putting the unit, the con-

trol and the technician at the same electrostatic po-

tential. Neutralize electrostatic charge by touching

hand and all tools on an unpainted unit surface be-

fore performing any service procedure.

FIGURE 3

DUAL CAPACITOR

(C12)

COMPRESSOR

CONTACTOR

(K1)

CONTROL BOX

GROUNDING

LUG

1 − Compressor Contactor (K1)

The compressor is energized by a single−pole contactor lo-

cated in the control box. See figure 3. K1 is energized by the

indoor thermostat terminal Y1 (24V) when thermostat de-

mand is present.

2 − Dual Capacitor (C12)

The compressor and fan in XC14 series units use perma-

nent split capacitor motors. The capacitor is located in-

side the unit control box (see figure 3). A single dual" ca-

pacitor (C12) is used for both the fan motor and the com-

pressor (see unit wiring diagram). The fan side and the

compressor side of the capacitor have different MFD rat-

ings. See side of capacitor for ratings.

3 − Timed Off Control TOC (option) (A4)

The time delay is electrically connected between thermostat

terminal Y and the compressor contactor. Between cycles,

the compressor contactor is delayed for 5 minutes ±2 min-

utes but may last as long as 8 minutes. At the end of the

delay, the compressor is allowed to energize. When thermo-

stat demand is satisfied, the time delay opens the circuit to

the compressor contactor coil and the compressor is de−en-

ergized.

4 − Start Kit (option)

The start kit consist of a potential relay K31 and start capaci-

tor C7. The potential relay controls the operation of the start-

ing circuit. The relay is normally closed when contactor K1 is

de−energized. When K1 is energized, the compressor im-

mediately begins start up. K31 remains closed during com-

pressor start up and capacitor C7 remains in the circuit.

When compressor reaches approximately 75% of its speed,

K31 is energized. When K31 energizes, the contacts open

and start capacitor C7 is taken out of the circuit.

Page 6

B − Compressor (B1)

The scroll compressor used in all XC14 model units, is de-

signed for use with R410A refrigerant and operation at high

pressures. Compressors are shipped from the factory

charged with 3MA (32MMMA) P.O.E. oil. All XC14 compres-

sors are equipped with a factory installed sound cover made

of polyethylene containing a 2 inch thick batt of fiberglass in-

sulation. See figure 5.

See ELECTRICAL DATA table at the front of this manual or

compressor nameplate for compressor specifications.

The scroll compressor design is simple, efficient and requires

few moving parts. A cutaway diagram of the scroll compressor

is shown in figure 4. The scrolls are located in the top of the

compressor can and the motor is located just below. The oil lev-

el is immediately below the motor.

FIGURE 4

SCROLL COMPRESSOR

DISCHARGE

SUCTION

The scroll is a simple compression concept centered around

the unique spiral shape of the scroll and its inherent properties.

Figure 6 shows the basic scroll form. Two identical scrolls are

mated together forming concentric spiral shapes (figure 7). One

scroll remains stationary, while the other is allowed to "orbit" (fig-

ure 8). Note that the orbiting scroll does not rotate or turn but

merely orbits the stationary scroll.

NOTE − During operation, the head of a scroll compressor may

be hot since it is in constant contact with discharge gas.

FIGURE 5

SOUND COVER

COMPRESSOR

SOUND PAD

FIGURE 6

SCROLL FORM

FIGURE 7

STATIONARY SCROLL

ORBITING SCROLL

DISCHARGE

SUCTION

CROSS−SECTION OF SCROLLS

TIPS SEALED BY

DISCHARGE PRESSURE

DISCHARGE

PRESSURE

Page 7

SUCTION

POCKET

SUCTION

ORBITING SCROLL

STATIONARY SCROLL

SUCTION SUCTION

DISCHARGE

POCKET

SUCTION INTERMEDIATE PRESSURE

GAS

CRESCENT

SHAPED

GAS POCKET

HIGH PRESSURE GAS

FLANKS SEALED

BY CENTRIFUGAL

FORCE

MOVEMENT OF ORBIT

FIGURE 8

The counterclockwise orbiting scroll draws gas into the outer

crescent shaped gas pocket created by the two scrolls (figure 8

− 1). The centrifugal action of the orbiting scroll seals off the

flanks of the scrolls (figure 8 − 2). As the orbiting motion contin-

ues, the gas is forced toward the center of the scroll and the gas

pocket becomes compressed (figure 8 − 3). When the com-

pressed gas reaches the center, it is discharged vertically into a

chamber and discharge port in the top of the compressor (figure

6). The discharge pressure forcing down on the top scroll helps

seal off the upper and lower edges (tips) of the scrolls (figure 6).

During a single orbit, several pockets of gas are compressed

simultaneously providing smooth continuous compression.

The scroll compressor is tolerant to the effects of liquid return. If

liquid enters the scrolls, the orbiting scroll is allowed to separate

from the stationary scroll. The liquid is worked toward the center

of the scroll and is discharged. If the compressor is replaced,

conventional Lennox cleanup practices must be used.

Due to its efficiency, the scroll compressor is capable of draw-

ing a much deeper vacuum than reciprocating compressors.

Deep vacuum operation can cause internal fusite arcing

resulting in damaged internal parts and will result in com-

pressor failure. Never use a scroll compressor for eva-

cuating or pumping−down" the system. This type of dam-

age can be detected and will result in denial of warranty

claims.

The scroll compressor is quieter than a reciprocating com-

pressor, however, the two compressors have much different

sound characteristics. The sounds made by a scroll compres-

sor do not affect system reliability, performance, or indicate

damage.

C − Drier

A filter drier designed for all XC14 model units must be

installed in the liquid line. The field installed drier is designed

to remove moisture, which can lead to compressor failure.

Any time unit is exposed to open air due to service, drier

must be replaced. All replacement driers must be ap-

proved for R410A refrigerant.

D − Condenser Fan Motor (B4)

Make sure all power is disconnected before

beginning electrical service procedures.

DANGER

All units use single−phase PSC fan motors which require a run

capacitor. In all units, the condenser fan is controlled by

the compressor contactor.

ELECTRICAL DATA tables in this manual show specifi-

cations for condenser fans used in XC14’s.

Access to the condenser fan motor on all units is gained

by removing the four screws securing the fan assembly.

See figure 9. The grill fan assembly can be removed from

the cabinet as one piece. See figure 10. The condenser

fan motor is removed from the fan guard by removing the

four nuts found on top of the grill. See figure 10 if con-

denser fan motor replacement is necessary.

Page 8

FIGURE 9

Remove

screws

Remove

screws

FIGURE 10

E − Discharge Line Thermostat (S5)

The discharge line thermostat is NC, auto re−set and located

on the discharge line of the compressor. The switch opens

when discharge line temperatures exceeds the factory set-

ting of 220° + 5° F and shuts down the compressor.

F − High Pressure Switch (S4)

XC14 units are equipped with a high pressure switch that is

located in the liquid line of the compressor. The switch

(SPST, manual reset, normally closed) removes power from

the compressor contactor control circuit when discharge

pressure rises above factory setting at 590 + 10 psi.

G − Crankcase Heater (HR1) &

Thermostat (S40) 4 and 5 ton only

XC14−048 and −060 units are equipped with a 70 watt belly

band type crankcase heater. HR1 prevents liquid from accu-

mulating in the compressor. HR1 is controlled by a thermo-

stat located on the liquid line. When liquid line temperature

drops below 50° F the thermostat closes energizing HR1.

The thermostat will open, de−energizing HR1 once liquid line

temperature reaches 70° F.

H − Loss of Charge Switch (option) (S24)

The loss of charge switch is NC, auto re−set and located on

the suction line of the compressor.The switch opens when

suction line pressure drops to 25psi + 5 (shutting down the

compressor) and will close when suction line pressure rises

to 55psi + 5.

III − REFRIGERANT SYSTEM

A − Plumbing

Field refrigerant piping consists of liquid and suction lines

from the condensing unit (sweat connections) to the indoor

evaporator coil (sweat connections). Use Lennox L15

(sweat) series line sets as shown in table 1.

TABLE 1

Unit Liquid

Line

Suction

Line

L15 Line

Sets

018, −024,

−030,

3/8 in.

(10 mm)

3/4 in.

(19 mm)

L15−41

20 ft. − 50 ft.

(6 m − 15 m)

−036, −042,

−048

3/8 in.

(10 mm)

7/8 in.

(22 mm)

L15−65

30 ft. − 50 ft.

(9 m − 15 m)

−060 3/8 in.

(10 mm)

1−1/8 in.

(29 mm)

Field

Fabricated

The liquid line and vapor line service valves (figures 11 and

12) and gauge ports are accessible from the outside of the

unit. Use the service ports for leak testing, evacuating,

charging and checking charge.

Each valve is equipped with a service port which has a facto-

ry−installed Schrader valve. A service port cap protects the

Schrader valve from contamination and serves as the pri-

mary leak seal. Service valves are not rebuildable. If a valve

has failed, you must replace it.

To Access Schrader Port:

1 − Remove service port cap with an adjustable wrench.

2 − Connect gauge to the service port.

3 − When testing is complete, replace service port cap. Tight-

en finger tight, then an additional 1/6 turn.

To Open Service Valve:

1 − Remove the stem cap with an adjustable wrench.

2 − Using the adjustable wrench to keep the valve station-

ary, use a service wrench with a hex−head extension to

back the stem out counterclockwise as far as it will go.

NOTE − Use a 3/16" hex head extension for 3/8" line

sizes or a 5/16" extension for large line sizes.

3 − Replace the stem cap. Tighten finger tight, then tighten

an additional 1/6 turn.

Page 9

To Close Service Valve:

1 − Remove the stem cap with an adjustable wrench.

2 − Using the adjustable wrench to keep the valve station-

ary, use a service wrench with a hex−head extension to

turn the stem clockwise to seat the valve. Tighten the

stem firmly.

NOTE − Use a 3/16" hex head extension for 3/8" line

sizes or a 5/16" extension for large line sizes.

3 − Replace the stem cap. Tighten finger tight, then tighten an

additional 1/6 turn.

NOTE − Stem cap must be replaced to help prevent

valve leakage.

Service Valve

(Valve Closed)

Schrader valve open

to line set when valve is

closed (front seated)

service

port

service

port cap

stem cap

insert hex

wrench here

(valve front seated)

to outdoor coil

to indoor coil

Service Valve

(Valve Open)

Schrader

valve

service

port

service port

cap

insert hex

wrench here

to indoor coil

to outdoor coil

stem cap

FIGURE 11

Vapor Line Ball Valve – 5 Ton Units Only

Vapor line service valves function the same way as the other

valves, the difference is in the construction. A ball valve is

illustrated in figure 12.

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 assures a leak−free

seal.

Ball Valve (Valve Open)

FIGURE 12

Schrader valve

service port

cap

stem cap

stem

Use Adjustable Wrench

To open: rotate Stem Clockwise 90°.

To close: rotate Stem Counter-clockwise 90°.

ball

(shown open)

to outdoor coil

to indoor coil

IV − CHARGING

WARNING

R−410A refrigerant can be harmful if it is inhaled.

R−410A refrigerant must be used and recovered re-

sponsibly.

Failure to follow this warning may result in personal

injury or death.

A − Leak Testing

After the line set has been connected to the indoor and out-

door units, check the line set connections and indoor unit

for leaks.

IMPORTANT

The Clean Air Act of 1990 bans the intentional venting

of (CFC’s and HFC’s) as of July 1, 1992. Approved

methods of recovery, recycling or reclaiming must be

followed. Fines and/or incarceration my be levied for

noncompliance.

Page 10

WARNING

Fire, Explosion and Personal Safety

Hazard.

Failure to follow this warning could re-

sult in damage, personal injury or

death.

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 ex-

plosion, that could result in personal

injury or death.

WARNING

Danger of explosion!

When using a high pressure gas such

as dry nitrogen to pressurize a refriger-

ant or air conditioning system, use a

regulator that can control the pressure

down to 1 or 2 psig (6.9 to 13.8 kPa).

Using an Electronic Leak Detector

1 − Connect a cylinder of R−410A to the center port of the

manifold gauge set. Connect manifold gauge to service

valve port.

2 − With both manifold valves closed, open the valve on the

R−410A cylinder.

3 − Open the high pressure side of the manifold to allow the

R−410A into the line set and indoor unit. Weigh in a trace

amount of R−410A. [A trace amount is a maximum of 2

ounces (57 g) or 3 pounds (31 kPa) pressure.] Close the

valve on the R−410A cylinder and the valve on the high

pressure side of the manifold gauge set. Disconnect the

R−410A cylinder.

4 − Connect a cylinder of nitrogen with a pressure regulat-

ing valve to the center port of the manifold gauge set.

5 − Connect the manifold gauge set high pressure hose to

the vapor valve service port. (Normally, the high pres-

sure hose is connected to the liquid line port; however,

connecting it to the vapor port better protects the man-

ifold gauge set from high pressure damage.)

6 − Adjust the nitrogen pressure to 150 psig (1034 kPa).

Open the valve on the high side of the manifold gauge

set which will pressurize line set and indoor unit.

7 − After a few minutes, open a refrigerant port to ensure

the refrigerant you added is adequate to be detected.

(Amounts of refrigerant will vary with line lengths.)

Check all joints for leaks. Purge nitrogen and R−410A

mixture. Correct any leaks and recheck.

B − Evacuating

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 pip-

ing and compressor parts.

NOTE − This evacuation process is adequate for a new

installation with clean and dry lines. If excessive mois-

ture is present, the evacuation process may be required

more than once.

IMPORTANT

Use a thermocouple or thermistor electronic vacuum

gauge that is calibrated in microns. Use an instrument

that reads from 50 microns to at least 10,000 microns.

1 − Connect manifold gauge set to the service valve ports :

 low pressure gauge to vapor line service valve

 high pressure gauge to liquid line service valve

2 − 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 the vacuum

pump.

5 − Evacuate the line set and indoor unit to an absolute

pressure of 23,000 microns (29.01 inches of mercury).

During the early stages of evacuation, it is desirable to

close the manifold gauge valve at least once to deter-

mine if there is a rapid rise in absolute pressure. A rap-

id rise in pressure indicates a relatively large leak. If this

occurs, repeat the leak testing procedure.

NOTE − The term absolute pressure means the total

actual pressure within a given volume or system, above

the absolute zero of pressure. Absolute pressure in a

vacuum is equal to atmospheric pressure minus vacu-

um pressure.

6 − When the absolute pressure reaches 23,000 microns

(29.01 inches of mercury), close the manifold gauge

valves, turn off the vacuum pump and disconnect the

manifold gauge center port hose from vacuum pump.

Attach the manifold center port hose to a nitrogen cylin-

der with pressure regulator set to 150 psig (1034 kPa)

and purge the air from the hose with nitrogen. Open the

manifold gauge valves to break the vacuum in the line

set and indoor unit. Close the manifold gauge valves.

Page 11

CAUTION

Danger of Equipment Damage.

Avoid deep vacuum operation. Do not use compres-

sors to evacuate a system.

Extremely low vacuums can cause internal arcing and

compressor failure.

Damage caused by deep vacuum operation will void

warranty.

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 in-

door 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 the absolute pressure does not rise

above 500 microns (29.9 inches of mercury) within a

20−minute period after shutting off the vacuum pump

and closing the manifold gauge valves.

9 − When the absolute pressure requirement above has

been met, disconnect the manifold hose from the vacu-

um pump and connect it to an upright cylinder of R−410A

refrigerant. Open the manifold gauge valves to break the

vacuum from 1 to 2 psig positive pressure in the line set

and indoor unit. Close manifold gauge valves and shut

off the R−410A cylinder and remove the manifold gauge

set.

C − Charging −1 units and 030 through 060 −2

Polyol Ester Oil

IMPORTANT

Mineral oils are not compatible with R−410A. If oil

must be added, it must be a polyol ester oil.

The compressor is charged with sufficient polyol es-

ter oil. If oil must be added to the compressor in the

field, Copeland has approved Mobil EALtArctic

22CC and ICI EMKARATEtRL32CF.

This system uses R−410A refrigerant which operates at

much higher pressures than HCFC−22. The provided liquid

line filter drier is approved for use with R−410A. Do not re-

place it with components designed for use with HCFC−22.

This unit is NOT approved for use with coils which use capil-

lary tubes as a refrigerant metering device.

Factory Charge

Units are factory-charged with the amount of R−410A refrig-

erant indicated on the unit rating plate. This charge is based

on a matching indoor coil and outdoor coil with 15 ft. (4.6 m)

line set. For varying lengths of line set, refer to table 2 for re-

frigerant charge adjustment.

TABLE 2

Liquid Line Set

Diameter

Ounces per 5 feet (g per 1.5 m) adjust

from 15 feet (4.6 m) line set*

3/8 in. (9.5 mm) 3 ounce per 5 ft. (85 g per 1.5 m)

NOTE − *If line length is greater than 15 ft. (4.6 m), add this amount. If

line length is less than 15 ft. (4.6 m), subtract this amount.

Page 12

Units Delivered Void of Charge

If the system is void of refrigerant, clean the system using

the procedure described below.

1.Use 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.

3.Use nitrogen to break the vacuum and install the provided

filter drier in the system.

4.Evacuate the system again. Then, weigh the appropriate

amount of R−410A refrigerant (listed on unit nameplate)

into the system.

5.Monitor the system to determine the amount of moisture

remaining in the oil. Use test kit 10N46 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.

Pre−charge Airflow Check of Temperature Drop

across Evaporator Coil (Delta−T)

NOTE − Be sure that filters and indoor and outdoor coils are

clean before testing

Measure the entering air dry bulb (DB) and wet bulb (WB)

temperatures at the indoor coil. Find Delta−T in table 3. Mea-

sure evaporator coil’s leaving air DB and subtract that value

from the entering air DB. The measured difference should

be within +3ºF (+1.8ºC) of table value. If Delta−T is too low,

decrease the indoor fan speed (refer to indoor unit for infor-

mation). If the Delta−T is high, increase the indoor fan speed.

Repeat charging procedure and Delta−T (air flow adjust-

ment) procedure until both are correct.

Example:

Assume entering air DB − 72, WB − 64, leaving DB − 53.

Delta−T should be 15 (per table); delta across coil is 19 (72

minus 53) which is 4ºF higher than table value; therefore, in-

crease fan speed.

TABLE 3

80 24 24 24 23 23 22 22 22 20 19 18 17 16 15

Dry bulb

78 23 23 23 22 22 21 21 20 19 18 17 16 15 14

Dry

bulb

temperature 76 22 22 22 21 21 20 19 19 18 17 16 15 14 13

temperature

of air entering

indoor coil

74 21 21 21 20 19 19 18 17 16 16 15 14 13 12

indoor coil 72 20 20 19 18 17 17 16 15 15 14 13 12 11 10

70 19 19 18 18 17 17 16 15 15 14 13 12 11 10

57 58 59 60 61 62 63 64 65 66 67 68 69 70

Wet bulb temperature of air entering indoor coil

Page 13

WHEN TO CHARGE?

Warm weather best

Can charge in colder weather

CHARGE METHOD? Determine by:

Metering device type

Outdoor ambient temperature

REQUIREMENTS:

Sufficient heat load in structure

Indoor temperature between 70-80ºF (21−26ºC)

Manifold gauge set connected to unit

Thermometers:

− to measure outdoor ambient temperature

− to measure liquid line temperature

− to measure vapor line temperature

TXV RFC

APPROACH OR

SUBCOOLING

WEIGH-IN SUPERHEAT

Which

metering

device?

Below 65ºF

(18ºC)?

Above 40ºF

(4ºC)?

Above 65ºF

(18ºC)?

START: Determine how refrigerant is metered

FIGURE 13 When to charge, method to use, conditions & equipment required

IMPORTANT

Before attempting to charge any system, confirm proper airflow across the in-

door coil. Airflow over the indoor coil can be determined by measuring the stat-

ic pressure drop across the coil and comparing it with the factory table pro-

vided in the indoor coil installation instructions.

If value is greater than

shown, add refrigerant;

if less than shown,

remove refrigerant.

ABOVE

Outdoor

ambient 40ºF

(4ºC)?

START: Measure outdoor ambient temperature

BELOW

Check Liquid and Vapor line pressures

Compare unit pressures with Normal

Operating Pressures table 4, page 15.

(Table 4 is a general guide. Expect minor pressures

variations. Significant differences may mean improp-

er charge or other system problem.)

Use SUPERHEAT to correctly charge unit

or to verify the charge is correct.

NOTE − Do not at-

tempt to charge sys-

tem where a dash ap-

pears, system could

be overcharged. Su-

perheat is taken at va-

por line service port.

Vapor line superheat

must never be less

than 5ºF at the vapor

line service port.

USE WEIGH-IN METHOD

Weigh-in or remove refriger-

ant based upon line length

SHº (Superheat) Values (+/−5ºF)

Wet Bulb (air entering indoor coil)

ºF* 50 52 54 56 58 60 62 64 66 68 70 72 74 76

40 15 18 20 23 26 29 32 34 38 41 43 46 48 51

45 13 16 18 21 24 27 30 33 36 39 41 44 46 49

50 11 14 16 19 22 25 28 31 34 37 39 42 44 47

55 9 12141720232730333638404244

60 7 10121518212427303335384043

65 - 6 10 13 16 19 21 24 27 30 33 36 38 41

70 - - 7 1013161921242730333639

75 - - - 6 9 121518212428313437

80 - - - - 5 8 12 15 18 21 25 28 31 35

85 - - - - - - 8 11151922263033

90 - - - - - - 5 9 13 16 20 24 27 31

95 - - - - - - - 6 10 14 18 22 25 29

100 --------81216212428

105 - - - - - - - - 5 9 13 17 22 26

110 ---------611152025

115 ----------8141824

* Dry−bulb temperature (ºF) of entering outdoor ambient air.

If refrigerant added or

removed, retest to

confirm that unit is

properly charged

SUPERHEAT METHOD

Set thermostat to call for heat (must have a

cooling load between 70-80ºF (21−26ºC)

Connect gauge set

When heat demand is satisfied, set

thermostat to call for cooling

Allow temperatures and pressures to

stabilize

Record vapor line pressure; use value to

determine saturation temperature

(table 5 on page 15) SATº =

Record vapor line

temperature VAPº =

Subtract to determine superheat (SHº):

VAPº − SATº = SHº

Record the wet bulb temperature (air

entering indoor coil) WB =

Record outdoor ambient temperature

Compare results with table

FIGURE 14 Charging RFC units with Superheat Method

Page 14

ºF (ºC)* −018 −024 −030 −036 −042 −048 −060

65 (18) 3 (1.7) 5 (2.8) 4 (2.2) 5 (2.8) 6 (3.3) 7 (3.9) 8 (4.4)

75 (24) 5 (2.8) 6 (3.3) 5 (2.8) 5 (2.8) 8 (4.4) 8 (4.4) 9 (5.0)

85 (29) 6 (3.3) 6 (3.3) 6 (3.3) 6 (3.3) 8 (4.4) 8 (4.4) 9 (5.0)

95 (35) 6 (3.3) 7 (3.9) 6 (3.3) 6 (3.3) 8 (4.4) 8 (4.4) 9 (5.0)

105 (41) 6 (3.3) 6 (3.3) 6 (3.3) 5 (2.8) 8 (4.4) 8 (4.4) 9 (5.0)

115 (45) 6 (3.3) 6 (3.3) 6 (3.3) 6 (3.3) 8 (4.4) 9 (5.0) 9 (5.0)

*Temperature of air entering outdoor coil

APPROACH METHOD

Set thermostat to call for heat (must have a

cooling load between 70-80ºF (21−26ºC)

Connect gauge set

When heat demand is satisfied, set

thermostat to call for cooling

Allow temperatures and pressures to

stabilize

Record outdoor ambient

temperature AMBº =

Record line temp. LIQº =

Subtract to determine approach (APPº):

LIQº − AMBº = APPº

Compare results with table

DO NOT CHARGE UNIT

(Results of charging at low

temperatures not reliable)

ABOVE

START: Measure outdoor ambient temperature

BELOW

Check Liquid and Vapor line pressures

Compare unit pressures with Normal

Operating Pressures table 4, page 15.

(Table 4 is a general guide. Expect minor pressures

variations. Significant differences may mean improp-

er charge or other system problem.)

Use APPROACH to correctly charge unit or

to verify the charge is correct.

USE WEIGH-IN METHOD

Weigh-in or remove refriger-

ant based upon line length

APPº (Approach) Values(F:+/−1.0°; [C: +/−0.5°])

Above or

below 65ºF

(18ºC)?

If refrigerant added or

removed, retest to

confirm that unit is

properly charged

If value is greater than shown (high

approach), add refrigerant; if less

than shown (liquid temp too close to

ambient temp, low approach), remove

refrigerant.

FIGURE 15 Charging TXV units with Approach Method

DO NOT CHARGE UNIT

(Results of charging at low

temperatures not reliable)

ABOVE

START: Measure outdoor ambient temperature

BELOW

Check Liquid and Vapor line pressures

Compare unit pressures with Normal

Operating Pressures table 4, page 15.

(Table 4 is a general guide. Expect minor pressures

variations. Significant differences may mean improp-

er charge or other system problem.)

Use SUBCOOLING to correctly charge unit

or to verify the charge is correct.

USE WEIGH-IN METHOD

Weigh-in or remove refriger-

ant based upon line length

SUBCOOLING METHOD

Set thermostat to call for heat (must have a

cooling load between 70-80ºF (21−26ºC)

Connect gauge set

Measure outdoor ambient temperature

When heat demand is satisfied, set

thermostat to call for cooling

Allow temperatures and pressures to

stabilize [NOTE − IF NECESSARY, block

outdoor coil to maintain 325 − 375 psig]

Record line temp. LIQº =

Record liquid line pressure; use value to

determine saturation temperature

(table 5 on page 15) SATº =

Subtract to determine subcooling (SCº):

SATº − LIQº = SCº

Compare results with table

ºF (ºC)* −018 −024 −030 −036 −042 −048 −060

65 (18) 10 (5.6) 10 (5.6) 10 (5.6) 11 (6.1) 10 (5.6) 8 (4.4) 8 (4.4)

75 (24) 6 (3.3) 8 (4.4) 8 (4.4) 11 (6.1) 7 (3.9) 8 (4.4) 7 (3.9)

85 (29) 6 (3.3) 8 (4.4) 7 (3.9) 11 (6.1) 7 (3.9) 8 (4.4) 8 (4.4)

95 (35) 6 (3.3) 8 (4.4) 7 (3.9) 10 (5.6) 7 (3.9) 8 (4.4) 7 (3.9)

105 (41) 6 (3.3) 8 (4.4) 7 (3.9) 10 (5.6) 7 (3.9) 8 (4.4) 7 (3.9)

115 (45) 6 (3.3) 8 (4.4) 6 (3.3) 9 (5.0) 7 (3.9) 7 (3.9) 6 (3.3)

*Temperature of air entering outdoor coil

SCº (Subcooling) Values (F:+/−1.0°; [C: +/−0.5°])

Above or

below 65ºF

(18ºC)?

If refrigerant added or

removed, verify

charge using the

approach method

BLOCK OUTDOOR COIL

[sometimes necessary with lower temperatures]

Use cardboard or plastic sheet to restrict the

airflow through the outdoor coil to achieve pres-

sures from 325−375 psig (2240−2585 kPa).

Higher pressures are needed to check charge.

Block equal sections of air intake panels and

move coverings sideways until the liquid pres-

sure is in the above noted ranges.

If value is greater than

shown, remove

refrigerant; if less than

shown, add refrigerant

FIGURE 16 Charging TXV units with Subcooling Method

Page 15

TABLE 4 Normal Operating Pressures

IMPORTANT

Use this table to perform maintenance checks; it 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.

Model −018 −024 −030 −036 −042 −048 −060

Temp.

*Liquid Line Pressure / Vapor Line Pressure

**Temp

5F (5C) Liquid / Vapor Liquid / Vapor Liquid / Vapor Liquid / Vapor Liquid / Vapor Liquid / Vapor Liquid / Vapor

Expansion Valve (TXV)

65 (18) 222 / 140 233 / 138 230 / 136 240 / 137 236 / 138 238 / 136 239 / 133

70 (21) 241 / 141 250 / 138 247 / 137 259 / 138 253 / 140 256 / 138 258 / 135

75 (24) 259 / 143 271 / 140 265 / 139 278 / 139 273 / 141 277 / 139 278 / 136

80 (27) 279 / 144 291 / 141 287 / 140 299 / 139 296 / 142 299 / 140 300 / 137

85 (29) 301 / 145 313 / 143 308 / 141 321 / 140 318 / 143 320 / 139 323 / 138

90 (32) 319 / 145 335 / 143 331 / 142 344 / 141 341 / 144 343 / 140 346 / 139

95 (35) 346 / 146 361 / 145 355 / 144 368 / 142 366 / 146 369 / 141 370 / 140

100 (38) 370 / 147 384 / 146 380 / 145 393 / 143 392 / 147 395 / 142 396 / 142

105 (41) 396 / 148 412 / 147 405 / 146 419 / 144 417 / 148 422 / 144 415 / 143

110 (43) 422 / 150 436 / 148 432 / 147 446 / 145 445 / 149 450 / 146 449 / 145

115 (45) 451 / 151 468 / 149 461 / 148 477 / 146 475 / 151 481 / 148 476 / 147

Fixed Orifice (RFC)

65 (18) 223 / 123 230 / 121 231 / 123 234 / 130 248 / 135 240 / 126 244 / 125

70 (21) 239 / 127 251 / 128 249 / 127 247 / 134 266 / 138 260 / 129 263 / 128

75 (24) 253 / 131 272 / 133 270 / 132 270 / 136 285 / 141 281 / 133 281 / 131

80 (27) 278 / 136 289 / 135 291 / 136 290 / 138 305 / 143 301 / 135 303 / 134

85 (29) 299 / 139 312 / 140 314 / 140 313 / 141 327 / 145 324 / 138 324 / 136

90 (32) 320 / 142 335 / 142 337 / 142 336 / 143 349 / 147 346 / 140 347 / 139

95 (35) 343 / 145 361 / 144 359 / 144 358 / 145 372 / 149 371 / 142 370 / 141

100 (38) 367 / 147 383 / 147 383 / 146 361 / 148 396 / 150 395 / 144 394 / 143

105 (41) 392 / 149 409 / 149 408 / 147 409 / 150 421 / 152 420 / 146 418 / 145

110 (43) 417 / 152 441 / 151 433 / 149 430 / 151 447 / 153 447 / 148 444 / 146

115 (46) 445 / 154 467 / 152 467 / 151 463 / 152 476 / 154 473 / 150 471 / 147

*Values shown are typical pressures; indoor unit match up, indoor air quality equipment, and indoor load will cause the pressures to vary.

**Temperature of the air entering the outside coil.

TABLE 5 HFC−410A Temperature (°F) − Pressure (Psig)

°F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig °F Psig

32 100.8 48 137.1 63 178.5 79 231.6 94 290.8 110 365.0 125 445.9 141 545.6

33 102.9 49 139.6 64 181.6 80 235.3 95 295.1 111 370.0 126 451.8 142 552.3

34 105.0 50 142.2 65 184.3 81 239.0 96 299.4 112 375.1 127 457.6 143 559.1

35 107.1 51 144.8 66 187.7 82 242.7 97 303.8 113 380.2 128 463.5 144 565.9

36 109.2 52 147.4 67 190.9 83 246.5 98 308.2 114 385.4 129 469.5 145 572.8

37 111.4 53 150.1 68 194.1 84 250.3 99 312.7 115 390.7 130 475.6 146 579.8

38 113.6 54 152.8 69 197.3 85 254.1 100 317.2 116 396.0 131 481.6 147 586.8

39 115.8 55 155.5 70 200.6 86 258.0 101 321.8 117 401.3 132 487.8 148 593.8

40 118.0 56 158.2 71 203.9 87 262.0 102 326.4 118 406.7 133 494.0 149 601.0

41 120.3 57 161.0 72 207.2 88 266.0 103 331.0 119 412.2 134 500.2 150 608.1

42 122.6 58 163.9 73 210.6 89 270.0 104 335.7 120 417.7 135 506.5 151 615.4

43 125.0 59 166.7 74 214.0 90 274.1 105 340.5 121 423.2 136 512.9 152 622.7

44 127.3 60 169.6 75 217.4 91 278.2 106 345.3 122 428.8 137 519.3 153 630.1

45 129.7 61 172.6 76 220.9 92 282.3 107 350.1 123 434.5 138 525.8 154 637.5

46 132.2 62 175.4 77 224.4 93 286.5 108 355.0 124 440.2 139 532.4 155 645.0

47 134.6 78 228.0 109 360.0 140 539.0

Page 16

D − Charging 018, 024 −2 units & 030 through 060 −3 units

TO SUCTION

SERVICE VALVE

TO LIQUID

LINE SERVICE

VALVE

TEMPERATURE

SENSOR

QC RESTRICTOR

FITTING

REFRIGERANT

TANK

TEMPERATURE SENSOR

(LIQUID LINE)

MANIFOLD

GAUGE SET

AClose manifold gauge set valves and connect the center hose to an upright cylinder of R−410A.

BConnect the manifold gauge set’s low pressure side to the suction line service port.

CConnect the manifold gauge set’s high pressure side to the liquid line service port.

DPosition temperature sensor on liquid line near liquid line service port.

OUTDOOR UNIT

CHARGING SYSTEM

FIGURE 17

1. Determine the desired DTMeasure entering air temperature

using dry bulb (A) and wet bulb (B). DTis the intersecting value of A

and B in the table (see triangle).

2. Find temperature drop across coilMeasure the coil’s dry bulb

entering and leaving air temperatures (Aand C). Temperature Drop

Formula: (TDrop) = Aminus C.

3. Determine if fan needs adjustmentIf the difference between

the measured TDrop and the desired DT(TDrop–DT) is within +3º, no

adjustment is needed. See examples: Assume DT= 15 and Atemp.

= 72º, these C temperatures would necessitate stated actions:

Cº TDrop –DT=ºF ACTION

53º 19 – 15 =4Increase the airflow

58º 14 – 15 =−1 (within +3º range) no change

62º 10 – 15 =−5 Decrease the airflow

4. Adjust the fan speedSee indoor unit instructions to

increase/decrease fan speed.

Changing air flow affects all temperatures; recheck temperatures to

confirm that the temperature drop and DT are within +3º.

80 24 24 24 23 23 22 22 22 20 19 18 17 16 15

78 23 23 23 22 22 21 21 20 19 18 17 16 15 14

76 22 22 22 21 21 20 19 19 18 17 16 15 14 13

74 21 21 21 20 19 19 18 17 16 16 15 14 13 12

72 20 20 19 18 17 17 16 15 15 14 13 12 11 10

70 19 19 18 18 17 17 16 15 15 14 13 12 11 10

57 58 59 60 61 62 63 64 65 66 67 68 69 70

Temp.

of air

entering

indoor

coil ºF

INDOOR

COIL

DRY BULBDRY

BULB

WET

BULB

TDrop

19º

Dry−bulb

Wet−bulb ºF

72º

64º

53º

air flowair flow

All temperatures are

expressed in ºF

INDOOR COIL AIRFLOW CHECK

Check indoor coil airflow using the Delta−T (DT) process as illustrated.

FIGURE 18

Page 17

WHEN TO CHARGE?

Warm weather best

Can charge in colder weather

CHARGE METHOD? Determine by:

Metering device type

Outdoor ambient temperature

REQUIREMENTS:

Sufficient heat load in structure

Indoor temperature between 70-80ºF

(21−26ºC)

Manifold gauge set connected to unit

Thermometers:

− to measure outdoor ambient temperature

− to measure liquid line temperature

− to measure suction line temperature

TXV FIXED

ORIFICE

APPROACH OR

SUBCOOLING

WEIGH-IN

SUPERHEAT

65ºF

(18.3ºC) and

Above

START: Determine how refrigerant is metered

39ºF

(3.8ºC) and

Below

Which indoor

metering

device?

WEIGH-IN

64ºF

(17.7ºC) and

Below

40ºF

(4.4ºC) and

Above

DETERMINING CHARGE METHOD

ABCDE

FIGURE 19

START: Measure outdoor ambient temperature 1.. Connect gauge set as illustrated in figure

17.

2.. Check Liquid and suction line pressures

3.. Compare unit pressures with table 6,

Normal Operating Pressures.

4.. Weigh in the unit nameplate charge plus

any charge required for line set

differences over feet.

Liquid Line

Set Diameter

Ounces per 5 feet (g per 1.5 m)

adjust from 15 feet (4.6 m) line set*

3/8" (9.5 mm) 3 ounce per 5’ (85 g per 1.5 m)

NOTE − *If line length is greater than 15

ft. (4.6 m), add this amount. If line length

is less than 15 ft. (4.6 m), subtract this

amount.

Refrigerant

Charge per Line

Set Length

USE EITHER APPROACH

OR SUBCOOLING

METHOD

This nameplate is for illustration

purposes only. Go to actual

nameplate on outdoor unit for

charge information.

64ºF and

BELOW

65ºF

and

ABOVE

ABOVE or BE-

LOW

FIGURE 20

Once refrigerant charge is

correct, disconnect gauge set

and replace service port caps.

WEIGH IN TXV

Page 18

DO NOT CHARGE UNIT

(Results of charging at low

temperatures not reliable)

START: Measure outdoor ambient temperature

USE WEIGH-IN METHOD

Weigh-in or remove refrigerant

based upon line length

APPº (Approach) Values(F:+/−1.0° [C: +/−0.6°])

1.. Connect gauge set as illustrated in figure 17.

2.. Confirm proper airflow across coil using figure 18.

3.. Compare unit pressures with table 6, Normal

Operating Pressures.

4.. Set thermostat to call for heat (must have a cooling

load between 70-80ºF (21−26ºC).

5.. When heat demand is satisfied, set thermostat to call

for cooling.

6.. Allow temperatures and pressures to stabilize.

7.. Record outdoor ambient temperature:

AMBº =_________

8.. Record liquid line temperature:

LIQº = __________

9.. Subtract to determine approach (APPº):

LIQº_____ − AMBº _____ = APPº_____

10.. Compare results with table below.

FIGURE 21

64ºF and

BELOW

65ºF

and

ABOVE

ABOVE or BE-

LOW

If value is MORE

than shown, remove

refrigerant.

If value is LESS

than shown, add

refrigerant.

If refrigerant is added

or removed, verify

charge using the

Subcooling Method.

MORE or

LESS

ºF (ºC)* −018 −024 −030 −036 −042 −048 −060

65 (18) 4 (2.2) 2 (1.1) 2 (1.1) 2 (1.1 6 (3.3) 7 (3.9) 8 (4.4)

75 (24) 5 (2.8) 4 (2.2) 4 (2.2) 5 (2.8) 8 (4.4) 8 (4.4) 9 (5.0)

85 (29) 6 (3.3) 4 (2.2) 6 (3.3) 8 (4.4) 8 (4.4) 8 (4.4) 9 (5.0)

95 (35) 5 (2.8) 4 (2.2) 5 (2.8) 7 (3.9) 8 (4.4) 8 (4.4) 9 (5.0)

105 (41) 3 (1.7) 4 (2.2) 5 (2.8) 6 (3.3) 8 (4.4) 8 (4.4) 9 (5.0)

115 (45) 3 (1.7) 3 (1.7) 4 (2.2) 6 (3.3) 8 (4.4) 9 (5.0) 9 (5.0)

*Temperature of air entering outdoor coil

Once refrigerant charge is

correct, disconnect gauge set

and replace service port caps.

APPROACH TXV

DO NOT CHARGE UNIT

(Results of charging at low

temperatures not reliable)

START: Measure outdoor ambient temperature

USE WEIGH-IN METHOD

Weigh-in or remove refrigerant

based upon line length

SCº (Subcooling) Values (F:+/−1.0° [C: +/−0.6°])

BLOCK OUTDOOR COIL: [sometimes necessary with lower

temperatures] Use cardboard or plastic sheet to restrict the airflow

through the outdoor coil to achieve pressures from 325−375 psig

(2240−2585 kPa). Higher pressures are needed to check charge.

Block equal sections of air intake panels and move coverings

sideways until the liquid pressure is in the above noted ranges.

If value is MORE

than shown, remove

refrigerant.

1.. Connect gauge set as illustrated in figure 17.

2.. Confirm proper airflow across coil using figure 18.

3.. Compare unit pressures with table 6, Normal

Operating Pressures.

4.. Set thermostat to call for heat (must have a cooling

load between 70-80ºF (21−26ºC)

5.. Measure outdoor ambient temperature

6.. When heat demand is satisfied, set thermostat to

call for cooling

7.. Allow temperatures and pressures to stabilize.

NOTE − If necessary, block outdoor coil to maintain

325 − 375 psig.

8.. Record liquid line temperature:

LIQº = ______

9.. Measure liquid line pressure and use the value to

determine saturation temperature (see table 5):

SATº = ______

10.. Subtract to determine subcooling (SCº):

SATº_____ − LIQº _____ = SCº _____

11.. Compare results with table below.

FIGURE 22

MORE or

LESS

If refrigerant is added or

removed, verify charge

using the Approach

Method.

64ºF and

BELOW

65ºF

and

ABOVE

ABOVE or BE-

LOW

ºF (ºC)* −018 −024 −030 −036 −042 −048 −060

65 (18) 10 (5.6) 10 (5.6) 11 (6.1) 13 (7.2) 10 (5.6) 8 (4.4) 8 (4.4)

75 (24) 6 (3.3) 7 (3.9) 8 (4.4) 9 (5.0) 7 (3.9) 8 (4.4) 7 (3.9)

85 (29) 6 (3.3) 8 (4.4) 6 (3.3) 7 (3.9) 7 (3.9) 8 (4.4) 8 (4.4)

95 (35) 6 (3.3) 9 (5.0) 6 (3.3) 8 (4.4) 7 (3.9) 8 (4.4) 7 (3.9)

105 (41) 10 (5.6) 9 (5.0) 7 (3.9) 9 (5.0) 7 (3.9) 8 (4.4) 6 (3.3)

115 (45) 10 (5.6) 10 (5.6) 8 (4.4) 10 (5.6) 7 (3.9) 7 (3.9) 6 (3.3)

*Temperature of air entering outdoor coil

If value is LESS

than shown, add

refrigerant.

Once refrigerant charge is

correct, disconnect gauge set

and replace service port caps.

CARDBOARD OR

PLASTIC SHEETS

SUBCOOLING TXV

Page 19

START: Measure outdoor ambient temperature 1.. Connect gauge set as illustrated in figure

17.

2.. Check Liquid and suction line pressures

3.. Compare unit pressures with table 6,

Normal Operating Pressures.

4.. Weigh in the unit nameplate charge plus

any charge required for line set

differences over feet.

Liquid Line

Set Diameter

Ounces per 5 feet (g per 1.5 m)

adjust from 15 feet (4.6 m) line set*

3/8" (9.5 mm) 3 ounce per 5’ (85 g per 1.5 m)

NOTE − *If line length is greater than

15 ft. (4.6 m), add this amount. If line

length is less than 15 ft. (4.6 m),

subtract this amount.

Refrigerant Charge per Line Set Length

USE SUPERHEAT

This nameplate is for

illustration purposes only.

Go to actual nameplate on

outdoor unit for charge

information.

ABOVE or BE-

LOW

39ºF and

BELOW

40ºF

and

ABOVE

Once refrigerant charge is

correct, disconnect gauge set

and replace service port caps.

WEIGH IN FIXED ORIFICE

FIGURE 23

START: Measure outdoor ambient temperature

NOTE − Do not attempt to charge system where a

dash appears, system could be overcharged.

Superheat is taken at suction line service port.

Suction line superheat must never be less than 5ºF

at the suction line service port.

USE WEIGH-IN METHOD

Weigh-in or remove refrigerant

based upon line length

SHº (Superheat) Values (+/−5ºF)

Wet Bulb (air entering indoor coil)

ºF* 50 52 54 56 58 60 62 64 66 68 70 72 74 76

40 15 18 20 23 26 29 32 34 38 41 43 46 48 51

45 13 16 18 21 24 27 30 33 36 39 41 44 46 49

50 11 14 16 19 22 25 28 31 34 37 39 42 44 47

55 9 12141720232730333638404244

60 7 10121518212427303335384043

65 - 6 10 13 16 19 21 24 27 30 33 36 38 41

70 - - 7 1013161921242730333639

75 - - - 6 9 121518212428313437

80 - - - - 5 8 12 15 18 21 25 28 31 35

85 - - - - - - 8 11151922263033

90 - - - - - - 5 9 13 16 20 24 27 31

95 - - - - - - - 6 10 14 18 22 25 29

100 --------81216212428

105 - - - - - - - - 5 9 13 17 22 26

110 ---------611152025

115 ----------8141824

* Dry−bulb temperature (ºF) of entering outdoor ambient air.

1.. Connect gauge set as illustrated in figure 17.

2.. Confirm proper airflow across coil using figure

18.

3.. Compare unit pressures with table 6, Normal

Operating Pressures.

4.. Set thermostat to call for heat (must have a

cooling load between 70-80ºF (21−26ºC)

5.. When heat demand is satisfied, set thermostat to

call for cooling.

6.. Allow temperatures and pressures to stabilize.

7.. Measure the suction line pressure and use the

use value to determine saturation temperature

(table 5):

SATº =_________

8.. Record suction line temperature:

VAPº =_________

9.. Subtract to determine superheat (SHº):

VAPº − _____ SATº ______ = SHº______

10.. Record the wet bulb temperature (air entering

indoor coil):

WB =_______

11.. Record outdoor ambient temperature.

12.. Compare results with table to the left.

If value is MORE

than shown, remove

refrigerant.

If value is LESS

than shown, add

refrigerant.

If refrigerant is

added, retest to

confirm that unit is

properly charged.

MORE or

LESS

If refrigerant is

removed, retest to

confirm that unit is

properly charged.

ABOVE or BE-

LOW

39ºF and

BELOW

40ºF

and

ABOVE

Once refrigerant charge is

correct, disconnect gauge set

and replace service port caps.

Once refrigerant

charge is correct,

disconnect gauge

set and replace

service port caps.

SUPERHEAT FIXED ORIFICE

FIGURE 24

Page 20

TABLE 6

Normal Operating Pressures (Liquid +10 and Suction +5 psig)

IMPORTANT

Use this table to perform maintenance checks; it 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.

Model −018 −024 −030 −036 −042 −048 −060

**Temp.

5F (5C) Liquid / Vapor Liquid / Suction Liquid / Suction Liquid / Suction Liquid / Vapor Liquid / Vapor Liquid / Vapor

Expansion Valve (TXV)

65 (18) 230 / 138 225 / 135 226 / 129 238 / 132 236 / 138 238 / 136 239 / 133

70 (21) 244 / 139 242 / 137 241 / 131 254 / 135 253 / 140 256 / 138 258 / 135

75 (24) 265 / 140 260 / 138 259 / 134 273 / 138 273 / 141 277 / 139 278 / 136

80 (27) 286 / 140 282 / 140 281 / 138 293 / 140 296 / 142 299 / 140 300 / 137

85 (29) 307 / 142 304 / 141 301 / 140 316 / 142 318 / 143 320 / 139 323 / 138

90 (32) 330 / 143 326 / 142 324 / 141 340 / 143 341 / 144 343 / 140 346 / 139

95 (35) 351 / 144 351 / 142 348 / 142 366 / 144 366 / 146 369 / 141 370 / 140

100 (38) 380 / 144 376 / 144 372 / 143 392 / 145 392 / 147 395 / 142 396 / 142

105 (41) 407 / 145 403 / 145 399 / 144 420 / 147 417 / 148 422 / 144 415 / 143

110 (43) 436 / 146 433 / 145 428 / 145 449 / 148 445 / 149 450 / 146 449 / 145

115 (45) 466 / 147 463 / 147 456 / 146 480 / 149 475 / 151 481 / 148 476 / 147

Fixed Orifice (RFC)

65 (18) 232 / 124 228 / 125 229 / 128 241 / 131 248 / 135 240 / 126 244 / 125

70 (21) 248 / 127 244 / 127 243 / 129 258 / 134 266 / 138 260 / 129 263 / 128

75 (24) 267 / 131 261 / 131 261 / 132 277 / 136 285 / 141 281 / 133 281 / 131

80 (27) 286 / 135 284 / 134 284 / 135 298 / 139 305 / 143 301 / 135 303 / 134

85 (29) 307 / 138 303 / 137 305 / 138 321 / 141 327 / 145 324 / 138 324 / 136

90 (32) 328 / 141 325 / 140 327 / 140 342 / 143 349 / 147 346 / 140 347 / 139

95 (35) 351 / 143 347 / 142 349 / 142 366 / 145 372 / 149 371 / 142 370 / 141

100 (38) 375 / 146 370 / 144 372 / 144 392 / 147 396 / 150 395 / 144 394 / 143

105 (41) 400 / 148 394 / 146 396 / 146 416 / 149 421 / 152 420 / 146 418 / 145

110 (43) 426 / 150 420 / 148 422 / 148 446 / 151 447 / 153 447 / 148 444 / 146

115 (46) 457 / 153 447 / 150 449 / 150 480 / 152 476 / 154 473 / 150 471 / 147

*Values shown are typical pressures; indoor unit match up, indoor air quality equipment, and indoor load will cause the pressures to vary.

**Temperature of the air entering the outside coil.

TABLE 7

HFC−410A Temperature (°F) − Pressure (Psig)