R-410A
MODELS: PC090 Thru 240
PD180 Thru 240
7.5 - 20 Ton
60 Hertz
TABLE OF CONTENTS
Start-Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankcase Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Heating Sequence of Operation . . . . . . . . . . . . . . . . . . . . 20
LIST OF TABLES
1
5
PC090 - 240 and PD180 - 240 Physical Data. . . . . . . . . . 4
Electrical Data - Outdoor Unit - HP Without Powered
11 PD180 thru 240 Unit Control Board Flash Codes. . . . . . 22
6
Electrical Data - Outdoor Unit - HP With Powered
LIST OF FIGURES
3
9
Fan Orientation, Control Box End . . . . . . . . . . . . . . . . . 21
Typical Field Wiring Diagram - NC090 Air Handling Unit
Typical Field Wiring Diagram - NC120 thru 240 Evaporator
4
6
Typical Field Wiring Diagram - ND180 thru 240
PC/PD180 & PC/PD240 Unit Dimensions and Piping
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Safety Considerations
Reference
Installer should pay particular attention to the words: NOTE,
CAUTION, and WARNING. Notes are intended to clarify or
make the installation easier. Cautions are given to prevent
equipment damage. Warnings are given to alert installer that
personal injury and/or equipment damage may result if
installation procedure is not handled properly.
This instruction covers the installation and operation of the
basic condensing unit. For refrigerant piping installation
instructions refer to document 247077 “Application Data -
General Piping Recommendations for Split System Air
Conditioning and Heat Pumps”. For information on the
installation and operation of the evaporator blower units, refer
to Instruction Manual No. 508526.
All accessories come with a separate Installation Manual.
Renewal Parts
Improper installation may create a condition where the
operation of the product could cause personal injury or
property damage. Improper installation, adjustment,
alteration, service or maintenance can cause injury or
property damage. Refer to this manual for assistance or
for additional information, consult a qualified contractor,
installer or service agency.
Contact your local Source 1 Center for authorized replacement
parts.
Agency Approvals
Design certified by CSA as follows:
1. For use as a cooling/heating unit.
2. For outdoor installation only.
Before performing service or maintenance operations on
unit, turn off main power switch to unit. Electrical shock
could cause personal injury. Improper installation,
adjustment, alteration, service or maintenance can
cause injury or property damage. Refer to this manual.
For assistance or additional information consult a
qualified installer, service agency or the gas supplier.
Inspection
As soon as a unit is received, it should be inspected for possible
damage during transit. If damage is evident, the extent of the
damage should be noted on the carrier’s freight bill. A separate
request for inspection by the carrier’s agent should be made in
writing.
This product must be installed in strict compliance with
the enclosed installation instructions and any applicable
local, state and national codes including, but not limited
to, building, electrical, and mechanical codes.
This system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system. Gage sets, hoses, refrigerant
containers and recovery systems must be designed to
handle R-410A. If you are unsure, consult the
equipment manufacturer. Failure to use R-410A
compatible servicing equipment may result in property
damage or injury.
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Physical Data
Table 1: PC090 - 240 and PD180 - 240 Physical Data
Models
Component
PC090
PC120
10
PC180
15
PD180
15
PC240
20
PD240
20
Nominal Tonnage
REFRIGERANT
Refrigerant type
Holding charge (lb)
7.5
R-410A
1.0
R-410A
1.0
R-410A
1.0
R-410A
1.0
R-410A
1.0
R-410A
1.0
1
System #1
System #2
23.9
---
27.5
---
54.0
---
27.0
60.0
---
34.0
2
Operating Charge (lb)
27.0
34.0
DIMENSIONS (inches)
WEIGHTS (lb)
Length
Width
59.1
31.9
44.5
59.1
31.9
50.0
59.1
64.1
44.5
59.1
64.1
44.5
59.1
64.1
50.0
59.1
64.1
50.0
Height
Shipping
421
430
543
574
947
968
921
942
1116
1152
1090
1126
Operating
3
COMPRESSORS
Type
Single Scroll
1
Tandem Scroll Tandem Scroll
Single Scroll
2
Tandem Scroll
1
Single Scroll
2
Quantity
Cooling
1
1
System #1
System #2
System #1
System #2
7.5
---
1
10
---
2
15
---
2
7.5
7.5
1
20
---
2
10
10
1
Nominal Capacity (Tons)
Capacity Stages
---
---
---
1
---
1
Heating
Nominal Capacity (Tons)
Capacity Stages
System #1 & #2
System #1 & #2
7.5
1
10
1
15
1
15
1
20
1
20
1
SYSTEM DATA
No. Refrigeration Circuits
Suction Line OD (in.)
Liquid Line OD (in.)
1
1
1
2
1
2
1 1/8
5/8
1 3/8
7/8
1 5/8
7/8
1 3/8
5/8
1 5/8
7/8
1 3/8
7/8
OUTDOOR COIL DATA
Face area (Sq. Ft.)
23.8
2
29.0
2
47.5
2
47.5
2
58.1
2
58.1
2
Rows
Fins per inch
20
20
20
20
20
20
Tube diameter (in./MM)
Circuitry Type
Refrigerant Control
0.38 / 10
Interlaced
TXV
0.38 / 10
Interlaced
TXV
0.38 / 10
Interlaced
TXV
0.38 / 10
Interlaced
TXV
0.38 / 10
Interlaced
TXV
0.38 / 10
Interlaced
TXV
CONDENSER FAN DATA
No. Fans / Diameter (in.)
Type
2/24
Axial
Direct
1
2/24
Axial
Direct
1
4/24
Axial
Direct
1
4/24
Axial
Direct
1
4/24
Axial
Direct
1
4/24
Axial
Direct
1
Drive type
No. speeds
System #1
System #2
2
2
4
2
4
2
Number of motors
Motor HP (ea.)
---
---
---
2
---
2
1/3
3/4
1/3
1/3
3/4
3/4
4
Rotation
CW
850
7500
---
CW
1100
9800
---
CW
850
15000
---
CW
850
7500
7500
CW
1100
19600
---
CW
1100
9800
9800
RPM
System #1
System #2
Nominal CFM
1. Holding Charge is the amount in the unit as shipped from the factory.
2. Includes matched evaporator unit with 25 ft of piping.
3. All Compressors include crankcase heater.
4. When viewing the shaft end of the motor.
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3. The heat pump and the evaporator should be positioned to
minimize the number of bends in the refrigerant piping.
Table 2: Unit Application Data
208/230-3-60
187/252
432/504
540/630
4. The heat pump should be as close to the evaporator as
practical.
1
Voltage Variation
Min. / Max.
460-3-60
575-3-60
5. The heat pump should not be installed where normal
operating sounds may be objectionable.
Ambient Air on Condenser Coil
40°F/125°F
2
6. The evaporator should be located within the building, either
outside or inside the conditioned space.
Min. /Max.
Suction Pressure at Compressor and
Corresponding Temp. at Saturation
Min. / Max.
101.6 psig / 156.6 psig
32.0 ºF / 55.0 ºF
Rooftop Locations
Be careful not to damage the roof. Consult the building
contractor or architect if the roof is bonded. Choose a location
with adequate structural strength to support the unit.
1.Utilization range “A” in accordance with ARI Standard 110.
2.These units can operate in an ambient temperature of
125°F providing the wet bulb temperature of the air enter-
ing the evaporator coil does not exceed 67°F. Unit can
operate to 0°F if equipped with a low ambient kit.
The heat pump must be mounted on level supports. The
supports can be channel iron beams or wooden beams treated
to reduce deterioration.
Installation
Minimums of two (2) beams are required to support each unit.
The beams should: (1) be positioned perpendicular to the roof
joists. (2) Extend beyond the dimensions of the section to
distribute the load on the roof. (3) Be capable of adequately
supporting the concentrated loads at the corners. These beams
can usually be set directly on the roof. Flashing is not required.
Limitations
These units must be installed in accordance with all national
and local safety codes. If no local codes apply, installation must
conform to the appropriate national codes. Units are designed
to meet National Safety Code Standards. If components are to
be added to a unit to meet local codes, they are to be installed
at the dealer's and/or the customer's expense.
NOTE: On bonded roofs, check for special installation
requirements.
Ground Level Locations
Location
It is important that the units be installed on a substantial base
that will not settle, causing strain on the refrigerant lines and
possible leaks. A one-piece concrete slab with footers that
extend below the frost line is recommended. The slab should
not be tied to the building foundation, as noise will telegraph
through the slab.
Use the following guidelines to select a suitable location for
both the condensing unit and the evaporator.
1. The heat pump is designed for outdoor installation only.
2. The condenser fans are the propeller type and are not
suitable for use with ductwork in the condenser air stream.
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Table 3: Corner Weights & Center of Gravity
Weight (lbs.)
Model
Center of Gravity (in.)
4 Point Load Location (lbs.)
Shipping
421
Operating
430
X
Y
A
B
C
D
87
PC090
PC120
PC180
PD180
PC240
PD240
17.3
16.4
32.5
34
32.1
31.2
33
32.3
33
32.5
30.8
31.8
110
153
266
243
300
311
130
161
274
275
301
295
103
134
217
225
276
253
543
947
921
1116
1090
574
968
942
1152
1126
127
211
199
275
267
LEFT
A
D
LEFT
DIM X
A
B
D
C
CG
DIM X
CG
FRONT
FRONT
REAR
REAR
WIDTH
WIDTH
DIM Y
LENGTH
RIGHT
PC090, PC120
B
C
DIM Y
LENGTH
RIGHT
PC180, PD180,
PC240, PD240
Figure 1: Corner Weights & Center Of Gravity
NOTE: Front of unit is considered the side having the control
Holes are provided in the base rails for bolting the unit to its
foundation.
box.
Concrete piers can also support ground level units. These piers
should (1) extend below the frost line, (2) be located under each
of the section's four corners, and (3) be sized to carry the load
of the corner it supports.
For ground level installations, precautions should be taken to
protect the unit from tampering and unauthorized persons from
injury. Screws on access panels will prevent casual tampering.
Further safety precautions such as a fenced enclosure or
locking devices on the panels may be advisable. Check local
authorities for safety regulations.
On either rooftop or ground level installations, rubber padding
can be applied under the unit to lessen any transmission of
vibration.
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LENGTH OF FORKS MUST BE A MINIMUM OF 60 INCHES.
Clearances
The unit must be installed with sufficient clearance for air to
enter the condenser coils, for air discharge and for servicing
Spreaders, longer than the largest dimension across the
unit must be used across the top of the unit.
NOTE: Additional clearance is required to remove the
compressors out the back of the unit.
Table 4: Minimum Clearances
Clearance Description
Distance in Inches
Overhead (Top)
Front
120
36
36
30
30
0
Before lifting a unit, make sure that its weight is
distributed equally on the cables so that it will lift evenly.
Rear
Left Side
Right Side
1
Bottom
1.In all installations where snow accumulates and winter oper-
ation is expected, additional height must be provided to
insure normal condenser airflow.
Do not permit overhanging structures or shrubs to
obstruct condenser air discharge.
Rigging
Exercise care when moving the unit. Do not remove any
packaging until the unit is near the place of installation. Rig the
unit by attaching chain or cable slings to the lifting holes
provided in the base rails. Spreader bars, whose length
exceeds the largest dimension across the unit, MUST be used
across the top of the unit.
Figure 2: Typical Rigging
The unit may be moved or lifted with a forklift. Slotted openings
in the base rails are provided for this purpose.
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Power Wiring
Check the available power and the unit nameplate for correct
voltage. Run the necessary number of properly sized wires to
the unit. Provide a disconnect switch (if not included with the
unit) and fusing as required (Factory disconnect is a fused
disconnect /breaker). Route the conduit through the large
knockout located near the electrical box. See Table 5 for
Electrical Data.
Do not leave the system open to the atmosphere. Unit
damage could occur due to moisture being absorbed by
the POE oil in the system. This type of oil is highly
susceptible to moisture absorption
POE (polyolester) compressor lubricants are known to cause
long term damage to some synthetic roofing materials.
The disconnect switch may be bolted to the side of the unit but
not to any of the removable panels; which would interfere with
access to the unit. Make sure that no refrigerant lines will be
punctured when mounting the disconnect switch, and note that
it must be suitable for outdoor installation.
Exposure, even if immediately cleaned up, may cause
embrittlement (leading to cracking) to occur in one year
or more. When performing any service that may risk
exposure of compressor oil to the roof, take precautions
to protect roofing.
All power and control wiring must be in accordance
with National and Local electrical codes.
Procedures which risk oil leakage include, but are not limited to,
compressor replacement, repairing refrigerant leaks, replacing
refrigerant components such as filter drier, pressure switch,
metering device or coil.
Control Wiring
Route the necessary low voltage control wires from the
Simplicity™ control board to the thermostat and also between
the terminal blocks inside the heat pump and evaporator control
boxes. Refer to Figures 3 thru 6 for field wiring diagrams.
The unit is shipped with compressor mounting bolts which are
factory adjusted and ready for operation.
Compressors
The scroll compressors used in this product are specifically
designed to operate with R-410A Refrigerant and cannot be
interchanged.
Do not loosen compressor mounting bolts.
Phasing
Three-phase, scroll compressors operate in only one direction.
If the scroll is drawing low amperage, has similar suction and
discharge pressures, or is producing a high noise level, the
scroll is misphased. Change the incoming line connection
phasing to obtain the proper rotation.
This system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system.
The compressor also uses a polyolester (POE oil), Mobil 3MA
POE. This oil is extremely hydroscopic, meaning it absorbs
water readily. POE oil can absorb 15 times as much water as
other oils designed for HCFC and CFC refrigerants. Take all
necessary precautions to avoid exposure of the oil to the
atmosphere.
Scroll compressors require proper rotation to operate
properly. Failure to check and correct rotation may result
in property damage.
8
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Electrical Data
Table 5: Electrical Data - Outdoor Unit - HP Without Powered Convenience Outlet
Compressors
Outdoor Fan Motor
Pwr Conv Outlet
Minimum
Maximum
Fuse Size
(A)
Model
Circuit
Ampacity
Power
RLA
Qty
MCC
LRA
Power
FLA
(each)
1
2
HP Qty
FLA
Supply
(each) (each) (each)
Supply
208/230-1-60
460-1-60
208/230-3-60
460-3-60
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
25.0
12.2
9.0
39
19
164
100
78
1/3
1/3
1/3
3/4
3/4
3/4
1/3
1/3
1/3
1/3
1/3
1/3
3/4
3/4
3/4
3/4
3/4
3/4
2
2
2
2
2
2
4
4
4
4
4
4
4
4
4
4
4
4
2.1
1.2
0.9
3.0
1.6
1.4
2.1
1.2
0.9
2.1
1.2
0.9
3.0
1.6
1.4
3.0
1.6
1.4
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
35.5
17.6
13.1
46.8
23.5
18.0
64.7
32.2
24.0
64.7
32.2
24.0
79.8
44.0
32.9
79.8
44.0
32.9
45
25
20
60
30
20
80
40
30
80
40
30
100
60
45
100
60
45
PC090
575-3-60
14
575-1-60
208/230-3-60
460-3-60
18.1
9.0
28.3
14.0
10.6
39
137
62
208/230-1-60
460-1-60
PC120
PC180
PD180
PC240
PD240
575-3-60
6.8
50
575-1-60
208/230-3-60
460-3-60
25.0
12.2
9.0
164
100
78
208/230-1-60
460-1-60
19
575-3-60
14
575-1-60
208/230-3-60
460-3-60
25.0
12.2
9.0
39
164
100
78
208/230-1-60
460-1-60
19
575-3-60
14
575-1-60
208/230-3-60
460-3-60
30.1
16.7
12.2
30.1
16.7
12.2
47
225
114
80
208/230-1-60
460-1-60
26
575-3-60
19
575-1-60
208/230-3-60
460-3-60
47
225
114
80
208/230-1-60
460-1-60
26
575-3-60
19
575-1-60
1. Based on three, 75°C insulated copper conductors in conduit and ambient of 30°C.
2. Maximum fuse or maximum circuit breaker (HACR type per NEC).
Refer to NEC/NFPA No. 70, Articles 440-11, 12 for information on minimum disconnect sizing.
Table 6: Electrical Data - Outdoor Unit - HP With Powered Convenience Outlet
Compressors
Outdoor Fan Motor
Pwr Conv Outlet
FLA
Minimum
Circuit
Ampacity
Maximum
Fuse Size
(A)
Model
Power
RLA
Qty
MCC
LRA
Power
FLA
(each)
1
2
HP Qty
Supply
(each) (each) (each)
Supply
208/230-1-60
460-1-60
208/230-3-60
460-3-60
1
1
1
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
25.0
12.2
9.0
39
19
164
100
78
1/3
1/3
1/3
3/4
3/4
3/4
1/3
1/3
1/3
1/3
1/3
1/3
3/4
3/4
3/4
3/4
3/4
3/4
2
2
2
2
2
2
4
4
4
4
4
4
4
4
4
4
4
4
2.1
1.2
0.9
3.0
1.6
1.4
2.1
1.2
0.9
2.1
1.2
0.9
3.0
1.6
1.4
3.0
1.6
1.4
10.0
5.0
45.5
22.6
17.1
56.8
28.5
22.0
74.7
37.2
28.0
74.7
37.2
28.0
89.8
49.0
36.9
89.8
49.0
36.9
60
30
25
70
35
25
90
45
35
90
45
35
110
60
45
110
60
45
PC090
575-3-60
14
575-1-60
4.0
208/230-3-60
460-3-60
18.1
9.0
28.3
14.0
10.6
39
137
62
208/230-1-60
460-1-60
10.0
5.0
PC120
PC180
PD180
PC240
PD240
575-3-60
6.8
50
575-1-60
4.0
208/230-3-60
460-3-60
25.0
12.2
9.0
164
100
78
208/230-1-60
460-1-60
10.0
5.0
19
575-3-60
14
575-1-60
4.0
208/230-3-60
460-3-60
25.0
12.2
9.0
39
164
100
78
208/230-1-60
460-1-60
10.0
5.0
19
575-3-60
14
575-1-60
4.0
208/230-3-60
460-3-60
30.1
16.7
12.2
30.1
16.7
12.2
47
225
114
80
208/230-1-60
460-1-60
10.0
5.0
26
575-3-60
19
575-1-60
4.0
208/230-3-60
460-3-60
47
225
114
80
208/230-1-60
460-1-60
10.0
5.0
26
575-3-60
19
575-1-60
4.0
1. Based on three, 75°C insulated copper conductors in conduit and ambient of 30°C.
2. Maximum fuse or maximum circuit breaker (HACR type per NEC).
Refer to NEC/NFPA No. 70, Articles 440-11, 12 for information on minimum disconnect sizing.
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Take Adequate Precautions
Refrigerant Mains
Many service problems can be avoided by taking adequate
precautions to provide an internally clean and dry system and
by using procedures and materials that conform to established
standards.
This Split-System (Air Condensing / Heat Pump / Air
Handling) unit is one component of an entire system. As
such it requires specific application considerations with
regard to the rest of the system (air handling unit, duct
design, condensing unit, refrigerant piping and control
scheme).
Use hard drawn copper tubing where no appreciable amount of
bending around pipes or other obstructions is necessary. If soft
copper is used, care should be taken to avoid sharp bends that
may cause a restriction. Pack fiberglass insulation and a
sealing material such as permagum around refrigerant lines
where they penetrate a wall to reduce vibrations and to retain
some flexibility.
Failure to properly apply this equipment with the rest of
the system may result in premature failure and/or
reduced performance / increased costs. Warranty
coverage specifically excludes failures due to improper
application and Unitary Products specifically disclaims
any liability resulting from improper application.
Support all tubing at minimum intervals with suitable hangers,
brackets or clamps.
Braze all copper-to-copper joints with Silfos-5 or equivalent
brazing material. Do not use soft solder. Insulate all suction
lines with a minimum of 1/2" ARMAFLEX or equivalent that
meets local codes. Liquid lines exposed to direct sunlight and/
or high temperatures must also be insulated. Never solder
suction and liquid lines together. They can be taped together for
convenience and support purposes, but they must be
completely insulated from each other.
Please refer to the equipment Technical Guide,
Installation Manual and the piping applications bulletin
247077 or call the applications department for Unitary
Products @ 1-877-UPG-SERV for guidance.
Line Sizing
When sizing refrigerant pipe for a split-system air conditioner,
check the following:
The liquid and suction service ports on the condenser section
permit leak testing, evacuation, and partial charging of the field
piping and the evaporator without disturbing refrigerant stored
in the condenser during initial installation.
1. Suction line pressure drop due to friction.
2. Liquid line pressure drop due to friction.
3. Suction line velocity for oil return.
Before beginning installation of the main lines, be sure that the
evaporator section has not developed a leak in transit. Check
pressure at the Schrader valve located on the header of each
coil. If pressure still exists in the system, it can be assumed to
be leak free. If pressure DOES NOT exist the section will need
to be repaired before evacuation and charging is performed.
4. Liquid line pressure drop due to vertical rise. For certain
piping arrangements, different sizes of suction line pipe
may have to be used. The velocity of the refrigerant vapor
must always be great enough to carry the oil back to the
compressor.
A bi-flow solid core filter-drier MUST be field-installed in the
liquid line of every system to prevent dirt and moisture from
damaging the system. Properly sized filter-driers are shipped
with each condensing section.
5. Evaporator Located Below Condenser - On a split
system where the evaporator blower is located below the
condenser, the suction line must be sized for both pressure
drop and for oil return.
NOTE: Installing a filter-drier does not eliminate the need for
6. Condenser Located Below Evaporator - When the
condenser is located below the evaporator blower, the
liquid line must be designed for the pressure drop due to
both friction loss and vertical rise. If the pressure drop due
to vertical rise and friction exceeds 60 psi, some refrigerant
will flash before it reaches the thermal expansion valve.
the proper evacuation of a system before it is charged.
A field-installed moisture indicating sight-glass should be
installed in the liquid line(s) between the filter-drier and the
evaporator coil. The moisture indicating sight-glass can be used
to check for excess moisture in the system.
Flash gas:
Both condenser and evaporator sections have copper sealing
disks brazed over the end of liquid and suction connections.
The temperature required to make or break a brazed joint is
high enough to cause oxidation of the copper unless an inert
atmosphere is provided.
1. Increases the liquid line pressure loss due to friction that in
turn causes further flashing.
2. Reduces the capacity of the refrigerant control device
which starves the evaporator.
NOTE: Dry nitrogen should flow through the system at all times
when heat is being applied and until the joint has
cooled. The flow of nitrogen will prevent oxidation of the
copper lines during installation.
3. Erodes the seat of the refrigerant control device.
4. Causes erratic control of the refrigerant entering the
evaporator.
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Always punch a small hole in sealing disks before unbrazing to
prevent the pressure in the line from blowing them off. Do not
use a drill as copper shavings can enter system.
suction sealing disks and prepare the joints for connections of
the main lines.
Connect the main liquid line to the liquid line connection on the
evaporator section, while maintaining a flow of nitrogen.
NOTE: Solenoid and hot gas bypass valves (if used) should be
opened manually or electrically during brazing or
evacuating.
Make the suction line connection at the evaporator and run the
line to the heat pump. Connect the main suction line to the
suction line service valve connection, while maintaining a flow
of nitrogen. Cool the valve body and replace the Schrader valve
stem in the service port.
NOTE: Schrader valves located on unit service valves should
have their stems removed during brazing to prevent
damage to the valve and reduce system evacuation
time.
Once the brazing process is complete, leak testing should be
done on all interconnecting piping and the evaporator before
proper evacuation to below 500 microns is performed.
Start Installation
Start the installation of main lines at the heat pump. Verify
holding charge in unit by cracking open valve. If pressure is
present, close valve and proceed with installation. If no
pressure is present, check system for leaks.
Verify evacuation with micron guage or thermocouple. Once the
line set and evaporator section is properly evacuated, the
service valves can be opened and the heat pump is now ready
to charge with the appropriate weight of refrigerant. Calculate
the correct system charge for the outdoor unit, the indoor unit
and the field line set.
Verify all service valves are fully seated by screwing the stems
of both valves down into the valve bodies until they stop.
Remove the Schrader valve stem and connect a low-pressure
nitrogen source to the service port on the suction line valve
body. Punch a small hole in the sealing disk; the flow of
nitrogen will prevent any debris from entering the system. Wrap
the valve body with a wet rag to prevent overheating during the
brazing process. Overheating the valve will damage the valve
seals. Unbraze the sealing disk, cool the valve body and
prepare the joint for connections of the main lines. Repeat for
the liquid line valve body.
Charge the system by introducing liquid refrigerant into the
liquid line through the liquid port connection. Complete adding
the refrigerant in vapor form into the suction port when the
compressor is started.
The correct refrigerant pressures are indicated as shown in
This system uses R-410A Refrigerant which operates at
higher pressures than R-22. No other refrigerant may be
used in this system. Gage sets, hoses, refrigerant
containers and recovery systems must be designed to
handle R-410A. If you are unsure, consult the
equipment manufacturer. Failure to use R-410A
compatible servicing equipment may result in property
damage or injury.
Never remove a cap from an access port unless the
valve is fully back-seated with its valve stem in the
maximum counter-clockwise position because the
refrigerant charge will be lost. Always use a refrigeration
valve wrench to open and close these service valves.
Connect the main liquid line to the liquid line service valve
connection, while maintaining a flow of nitrogen. Cool the valve
body and replace the Schrader valve stem in the service port.
Install the liquid line from the heat pump to the evaporator liquid
connection, maintaining a flow of nitrogen during all brazing
operations.
Wear safety glasses and gloves when handling
refrigerants. Failure to follow this warning can cause
serious personal injury.
The filter-drier and sight glass must be located in the liquid line,
leaving the O.D. unit.
NOTE: This instruction covers the installation and operation of
the basic heat pump. For refrigerant piping installation
instructions refer to document 247077 "Application
Data - General Piping Recommendations for Split
System Air Conditioning and Heat Pumps".
Connect a low-pressure nitrogen source to the Schrader valve
located on the evaporator section coil headers. Punch a small
hole in the sealing disks, the flow of nitrogen will prevent any
debris from entering the system. Unbraze both liquid and
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NOTE: Do not use a heat pump thermostat.
Y1
G W1 W2
R
C
THERMOSTAT
SINGLE STAGE COOLING
TWO STAGE HEATING
NOTE: Liquid line solenoid is not included or required
on 7.5 Ton Single Stage Units.
Figure 3: Typical Field Wiring Diagram - NC090 Air Handling Unit With PC090 Heat Pump
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NOTE: Do not use a heat pump thermostat.
Y1
Y2
W1 W2
R
C
G
THERMOSTAT
TWO STAGE COOLING
TWO STAGE HEATING
NOTE: Liquid line solenoid is only activated during
second stage cooling operation.
Figure 4: Typical Field Wiring Diagram - NC120 thru 240 Evaporator Unit with PC120 thru 240 Heat Pump
VALVE SYS 2
218 / BR
219 / Y
BLK
1LLS
BLK
Figure 5: NC120 - 240 Liquid Line Solenoid Wiring
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NOTE: Do not use a heat pump thermostat.
Y1
Y2
W1 W2
R
C
G
THERMOSTAT
TWO STAGE COOLING
TWO STAGE HEATING
NOTE: Liquid line solenoid is not included or required
on any 4 pipe units.
Figure 6: Typical Field Wiring Diagram - ND180 thru 240 Evaporator Unit with PD180 thru 240 Heat Pump
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RIGHT
REAR
FRONT
LEFT
CONVENIENCE
OUTLET
A
2X (Ø 1.375)
KNOCKOUT
30.994
2X (Ø 0.875)
KNOCKOUT
12.126
9.876
4.751
3.883
23.000
37.000
7.000
7.000
10.000
7.000
7.000
3.664
2.933
1.664
24.000
31.758
58.500
RIGHT
FRONT
SYSTEM 2
2X (Ø 0.875)
KNOCKOUT
2X (Ø 1.375)
KNOCKOUT
15.53
12.70
12.000
10.000
SYSTEM 1
4.875
6.26
7.52
8.98
10.60
4.132
2.382
1.882
REAR
LEFT
Figure 7: PC090, PC120 Unit Dimensions
NOTE: Use System 1 piping dimensions when applying a PC090/120 model system.
Table 7: PC090, PC120 Unit Height Dimensions
MODEL
PC090
PC120
A
44.5
50.0
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REAR
RIGHT
LEFT
FRONT
A
SYSTEM 2
SYSTEM 1
2X (Ø 1.375)
KNOCKOUT
30.994
2X (Ø 0.875)
KNOCKOUT
11.375
9.125
4.750
4.132
23.000
37.000
7.000
7.000
23.000
37.000
7.000
7.000
3.913
3.181
1.913
64.000
59.000
FRONT
RIGHT
SYSTEM 2
SYSTEM 1
16.133
13.133
17.367
18.867
20.617
22.617
FRONT
(PIPING DETAIL)
Figure 8: PC/PD180 & PC/PD240 Unit Dimensions and Piping & Electrical Dimensions
NOTE: Use System 1 piping dimensions when applying a PC180/240 model system.
Table 8: PC/PD180 & PC/PD240 Unit Height Dimensions
MODEL
PC180
PD180
PC240
PD240
A
44.5
44.5
50.0
50.0
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Table 9: Piping and Electrical Connection Sizes
MODEL
No. Refrigeration Circuits
Suction Line OD (in.)
Liquid Line OD (in.)
PC090
PC120
1
PC180
1
PD180
2
PC240
1
PD240
2
1
1 1/8
5/8
1 3/8
7/8
1 5/8
7/8
1 3/8
5/8
1 5/8
7/8
1 3/8
7/8
Power Wiring Knockout
Control Wiring Knockout
1 3/8
7/8
1 3/8
7/8
1 3/8
7/8
1 3/8
7/8
1 3/8
7/8
1 3/8
7/8
5. Does the available power supply agree with the nameplate
data on the unit?
Piping And Electrical Connections
Piping connections are made from the rear of 7.5 thru 12.5 Ton
units and from the front of 15 thru 20 Ton units. Stubouts are
provided on the suction and liquid line service valves. Piping
can be routed to the unit from the left or right side.
6. Is the control circuit transformer set for the proper voltage?
7. Have the fuses, disconnect switch and power wire been
sized properly?
8. Are all compressor mounting bolts properly secured?
Electrical connections for power and control wiring are made
from the right or left side of the electrical control box. See Table
9 and Figures 7 and 8 for piping sizes and electrical knockout
details.
9. Are any refrigerant lines touching each other or any sheet
metal surface? Rubbing due to vibration could cause a
refrigerant leak.
10. Are there any visible signs of a refrigerant leak, such as oil
residue?
Start-Up
11. Has the refrigeration system been leak checked,
evacuated and had the correctly calculated charge
weighted in?
Crankcase Heaters
12. Is any electrical wire laying against a hot refrigerant line?
The crankcase heaters must be energized at least 8 hours
before starting the compressors. To energize the crankcase
heaters, the main disconnect switch must be closed. During this
8 hour period, the system switch on the room thermostat must
be “OFF” to prevent the compressor from starting. Make sure
that the bottom of the compressor is warm to the touch to prove
crankcase heater operation.
Initial Start-Up
1. Supply power to the unit through the disconnect switch at
least 8 hours prior to starting the compressor.
2. Move the system switch on the thermostat to the AUTO or
COOL position.
3. Reduce the setting of the room thermostat to energize the
compressor.
4. Check the operation of the evaporator unit per the
manufacturer’s recommendations.
Do not attempt to start the compressor without at least 8
hours of crankcase heat or compressor damage can
occur.
5. With an ammeter, check the compressor amps against the
unit data plate.
Pre-Start Check
6. Check for refrigerant leaks.
7. Check for any abnormal noises and/or vibrations, and
make the necessary adjustments to correct fan blade(s)
touching shroud, refrigerant lines hitting on sheet metal,
etc.
Before starting the unit, complete the following check list:
1. Have sufficient clearances been provided?
2. Has all foreign matter been removed from the interior of the
unit (tools, construction or shipping materials, etc.)?
8. After the unit has been operating for several minutes, shut
off the main power supply at the disconnect switch and
inspect all factory wiring connections and bolted surfaces
for tightness.
3. Have the condenser fans been rotated manually to check
for free rotation?
4. Are all wiring connections tight?
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Compressor Protection
Operation
In addition to the external pressure switches, the compressors
also have inherent (internal) protection. If there is an abnormal
temperature rise in a compressor, the protector will open to shut
down the compressor. The UCB incorporates features to
minimize compressor wear and damage. An Anti-Short Cycle
Delay (ASCD) is utilized to prevent operation of a compressor
too soon after its previous run. Additionally, a minimum run time
is imposed any time a compressor is energized.
Unit Control Overview
This series of heat pumps come factory equipped with
Simplicity™ controls to monitor all unit functionality and safety
controls.
Safety Controls
The Simplicity™ control board incorporates features to monitor
safety circuits as well as minimize compressor wear and
damage. An anti-short cycle delay (ASCD) is utilized to prevent
operation of a compressor too soon after its previous run. The
ASCD is initiated on unit start-up and on any compressor reset
or lockout.
The ASCD is initiated on unit start-up and on any compressor
reset or lock-out.
Flash Codes
The UCB will initiate a flash code associated with errors within
the system. Refer to UNIT CONTROL BOARD FLASH CODES
The Simplicity™ control board monitors the following inputs for
each cooling system:
• A high-pressure switch is factory installed to protect
against excessive discharge pressure due to a blocked
condenser coil or a condenser fan motor failure. During
cooling operation, if a high-pressure limit switch opens,
the Simplicity™ control board will de-energize the
associated compressors and initiate the 5-minute ASCD.
If the call for cool is still present at the end of the ASCD,
the control board will re-energize the halted compressor. If
a high-pressure switch opens three times within two hours
of operation, the Simplicity™ control board will lockout the
associated system compressors and will flash an error
Reset
Remove the call for cooling, by raising thermostat setting higher
than the conditioned space temperature. This resets any
pressure or freezestat flash codes. Simplicity™ only has
minimum run time in cool. Heat pump mode shuts off
immediately.
Sequence of Operation
Continuous Blower
By setting the room thermostat to “ON,” the low voltage control
circuit from the “R” to “G” is completed and the supply air blower
will operate continuously.
• A low-pressure switch to protect the unit against
excessively low suction pressure is standard on all
condensing units. If the low-pressure switch opens during
normal operation, the Simplicity™ control board will de-
energize the compressor, initiate the ASCD, and shut
down the condenser fans. On startup, if the low-pressure
switch opens, the Simplicity™ control board will monitor
the low-pressure switch to make sure it closes within one
minute. If it fails to close, the unit will shut down the
associated compressor and begin an ASCD. If the call for
cool is still present at the end of the anti-short cycle time
delay, the control board will re-energize the halted
compressor. If a low-pressure switch opens three times
within one hour of operation, the Simplicity™ control
board will lock-out the associated compressor and flash
Intermittent Blower
With the room thermostat fan switch set to “AUTO” and the
system switch set to either the “AUTO” or “HEAT” settings, the
blower is energized whenever a cooling or heating operation is
requested. The blower is energized after any specified delay
associated with the operation.
When energized, the indoor blower has a minimum run time of
30 seconds. Additionally, the indoor blower has a delay of 10
seconds between operations.
Cooling Sequence Of Operation
Single-Stage Heat Pump (PC090)
• An ambient air switch will lock out mechanical cooling at
40F. If the product was equipped from the factory with
the low ambient option the unit will operate down to 0F. If
the unit was not ordered with the factory low ambient
option a field installed low ambient kit is available.
A single stage thermostat is required to operate the heat pump
in cooling mode.
The reversing valve is energized during cooling mode. A
continuous 24V signal is passed through the normally closed
contacts of relay RY2 to the "O" terminal of the Defrost Control
Board (DC). The normally closed relay DR-2 within DC
energizes the solenoid (SOL) of the reversing valve.
The refrigerant systems are independently monitored and
controlled. On any fault, only the associated system will be
affected by any safety/preventive action. The other refrigerant
system will continue to operate unless it is affected by the fault
as well.
When the thermostat calls for cooling (Y1), the Simplicity
control board (UCB) closes the coils of relay RY1 and contactor
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M1 while sending a signal to one of the "CFAN" terminals on
DC.
• Relay RY2 has two functions. 1) control the crankcase
heater CCH2, 2) control the 24V output signal to S2 on
terminal block TB2.
• Relay RY1 controls the crankcase heater (CCH1). The
normally closed contacts allow CCH1 to operate during
unit shutdown.
• Contactor M2 controls compressor COMPR2.
If the initial call for cooling requires both stages (Y1 and Y2), the
UCB will delay the second stage by 30 seconds to avoid an
excessive power inrush.
• Contactor M1 controls compressor COMPR1.
The output signal from the remaining "CFAN" terminal on DC
closes the coil of contactor M3.
When the call for cooling (Y2) is satisfied, the UCB disables the
signal to RY2 and M2 as long as the specified minimum run
time (ASCD) has elapsed.
• Contactor M3 controls outdoor fans ODFAN1 & 2.
After completing the specified time for fan on-delay, UCB closes
the coil of relay BR1.
When the call for cooling (Y1) is satisfied, the UCB disables the
signal to RY1 and M1 as long as the specified minimum run
time (ASCD) has elapsed.
• Relay BR1 sends a 24V signal to G1 of terminal block
TB2. It may be used to control operation of an indoor
blower.
Dual Stage Heat Pump - 4 pipe (PD180-240)
A two stage thermostat is required to operate the heat pump in
cooling mode.
When the call for cooling (Y1) is satisfied, the UCB disables the
signal to RY1, M1 and DC as long as the specified minimum run
time (ASCD) has elapsed.
Both reversing valves are energized during cooling mode.
Continuous 24V signals are passed through the normally
closed contacts of relays RY2 and RY3 to the "O" terminals of
their respective Defrost Control Boards (DC1 and DC2). The
normally closed relays DR-2 within DC1 and DC2 energize the
solenoids (SOL1 and SOL2) of the reversing valves.
The UCB disables the signal to BR1 after completing the fan
off-delay period.
Dual Stage Heat Pump (PC120-240)
A two stage thermostat is required to operate the heat pump in
cooling mode.
When the thermostat calls for first-stage cooling (Y1), the
Simplicity control board (UCB) closes the coils of relay RY1 and
contactor M1 while sending a signal to one of the "CFAN"
terminals on DC1.
The reversing valve is energized during cooling mode. A
continuous 24V signal is passed through the normally closed
contacts of relay RY2 to the "O" terminal of the Defrost Control
Board (DC). The normally closed relay DR-2 within DC
energizes the solenoid (SOL) of the reversing valve.
• Relay RY1 has two functions. 1) control the crankcase
heater CCH1, 2) control the 24V output signal to S1 on
terminal block TB2.
When the thermostat calls for first-stage cooling (Y1), the
Simplicity control board (UCB) closes the coils of relay RY1 and
contactor M1 while sending a signal to one of the "CFAN"
terminals on DC.
• Contactor M1 controls compressor COMPR1.
The output signal from the remaining "CFAN" terminal on DC1
closes the coil of contactor M3.
• Contactor M3 controls outdoor fans ODFAN1 & 2.
• Relay RY1 has two functions. 1) control the crankcase
heater CCH1, 2) control the 24V output signal to S1 on
terminal block TB2.
After completing the specified time for fan on-delay, UCB closes
the coil of relay BR1.
• Contactor M1 controls compressor COMPR1.
• Relay BR1 sends a 24V signal to G1 of terminal block
TB2. It may be used to control operation of an indoor
blower.
The output signal from the remaining "CFAN" terminal on DC
closes the coil of contactor M3.
• Contactor M3 controls all outdoor fans.
When the thermostat calls for second-stage cooling (Y2), the
Simplicity control board (UCB) closes the coils of relay RY2 and
contactor M2 while sending a signal to one of the "CFAN"
terminals on DC2.
After completing the specified time for fan on-delay, UCB closes
the coil of relay BR1.
• Relay BR1 sends a 24V signal to G1 of terminal block
TB2. It may be used to control operation of an indoor
blower.
• Relay RY2 has two functions. 1) control the crankcase
heater CCH2, 2) control the 24V output signal to S2 on
terminal block TB2.
When the thermostat calls for second-stage cooling (Y2), the
Simplicity control board (UCB) closes the coil of relay RY2 and
contactor M2.
• Contactor M2 controls compressor COMPR2.
The output signal from the remaining "CFAN" terminal on DC2
closes the coil of contactor M4.
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• Contactor M4 controls outdoor fans ODFAN3 & 4.
• Relay RY1 has two functions: 1) control the operation of
crankcase heater CCH1, and 2) control the 24V output
signal to S1 on terminal block TB2.
If the initial call for cooling requires both stages (Y1 and Y2), the
UCB will delay the second stage by 30 seconds to avoid an
excessive power inrush.
• Contactor M1 controls compressor COMPR1.
• Relay RY3 (RY2 for PC090 model) toggles the 24V signal
from the "O" terminal of DC to the "Y" terminal assuring
the reversing valve cannot be energized except during
defrost.
When the call for cooling (Y2) is satisfied, the UCB disables the
signal to RY2 and M2 as long as the specified minimum run
time (ASCD) has elapsed.
When the call for cooling (Y1) is satisfied, the UCB disables the
signal to RY1 and M1 as long as the specified minimum run
time (ASCD) has elapsed.
• Concurrently, a 24V signal is sent to one of the "CFAN"
terminals of DC. The output signal from the remaining
"CFAN" terminal closes the coil of contactor M3.
• Contactor M3 controls outdoor fans ODFAN1 & 2 (all
models) and ODFAN3 & 4 (PC180-240).
Low Ambient Cooling
These units are factory equipped with low ambient switches
that work through the Simplicity control board to operate the
compressors and condenser fans normally to 40ºF ambient
temperature. The Electronic Low Ambient Controller
2LA04703000 Accessory is designed to assure safe operation
through condenser head pressure regulation down to 0ºF
ambient temperature.
(PC120-240; PD180-240 models)
• After a two second delay, the UCB energizes the contacts
of relay RY2 and contactor M2.
• Relay RY2 has two functions: 1) control the operation of
crankcase heater CCH2, and 2) control the 24V output
signal to S2 on terminal block TB2.
Low Ambient Control Operation
• Contactor M2 controls compressor COMPR2.
• A call for cooling closes contactor M3 which energizes all
condenser fans. The Low Ambient Control starts all fans
at full speed then adjusts according to the liquid line
temperature.
(PD180-240 models only)
• Concurrently, a 24V signal is sent to one of the "CFAN"
terminals of defrost control board DC2. The output signal
from the remaining "CFAN" terminal closes the coil of
contactor M4.
Refer to the appropriate 2LA low ambient kit instructions for
additional detail on the factory or field installed low ambient kit
and its operation.
• Contactor M4 controls outdoor fans ODFAN3 & 4.
Heating Sequence of Operation
General
Second Stage Heating Operation
When the thermostat calls for second stage heating (W2):
Heat pump models are to be matched with air handlers of
equivalent tonnage ratings. Twinning of heat pumps and air
handlers is not recommended.
• A 24V signal passes through UCB sending an input signal
to the "W" terminal of DC. This signal passes through DC
as an output signal to the "66" terminal of TB2 to be used
as a control signal for first stage electric heat.
A two stage thermostat is required to operate the heat pump in
heating mode.
Emergency Heating Operation
All reversing valves are de-energized during normal heating
mode. They are energized only during cooling and defrost
modes.
When the thermostat calls for emergency heating (EMER):
• The UCB de-energizes all compressor relays and
contactors.
The heat pump operates all compressors during a first stage
call for heating unless locked out by the Unit Control Board
(UCB).
• A 24V signal passes through UCB sending an input signal
to the "W" terminal of DC. This signal passes through DC
as an output signal to the "66" terminal of TB2 to be used
as a control signal for first stage electric heat.
First Stage Heating Operation
• The normally closed contacts of M1-AUX and M2-AUX
(PC120-240; PD180-240 models only) send a 24V output
signal to the "60" terminal of TB2 to be used as a control
signal for second stage electric heat.
When the thermostat calls for first stage heating (W1):
• The Simplicity control board (UCB) goes into a five minute
ASCD timer delay.
• When the ASCD time delay is satisfied, the UCB closes its
internal compressor relay contact, thus energizing the
contacts of relay RY1 and contactor M1.
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Defrost Operation
NOTE: The DC has two flash codes that only initiate if the
jumper between the two pressure switch terminals is
removed or broken.
The defrost control board (DC) utilizes a time/temperature
defrost scheme. The DC repeats normal heating run cycles,
which must be completed, until one of the following conditions
is met and the DC enters defrost mode:
Blower Operation
After completing the specified time for fan on-delay, UCB closes
the coil of relay BR1.
1. The DC satisfies its accumulated minimum run time. This
is factory set at 60 minutes, but is field adjustable to 30, 60
or 90 minutes.
• Relay BR1 sends a 24V signal to G1 of terminal block
TB2. It may be used to control operation of an indoor
blower.
2. The defrost switch(es) is closed. This normally open
switch is set to close at 28° F (+/-3°).
The UCB disables the signal to BR1 after completing the fan
off-delay period.
When the DC enters defrost mode, its on-board defrost relays
are powered. This energizes the reversing valve solenoid, de-
energizes the condenser fan motors and energizes the unit's
optional electric heater. The DC remains in defrost mode until
either of the following two conditions are met:
Rear
Rear
1. Both of the liquid line thermostats are open. Each is set to
open at 55 degrees (+/- 3).
2
2
4
3
2. The maximum defrost run time of 10 minutes is met.
The DC also contains a set of test pins. Placing a jumper
across these pins will result in the following actions:
• If the ASCD timer is active, it is now bypassed, allowing
the compressor to run.
1
1
• If the DC is in a lockout condition, the lockout is reset.
• If the compressor is running, the DC is forced into defrost
mode. The control will remain in defrost mode as long as
the jumper is in place. When the jumper is removed, the
control will terminate defrost mode.
Front
Front
Figure 9: Fan Orientation, Control Box End
Table 10: PC090 thru 240 Unit Control Board Flash Codes
GREEN
LED
16
RED
LED
8
RED
LED
4
RED
LED
2
RED
LED
1
FLASH CODE
DESCRIPTION
On Steady
1 Flash
This is a Control Failure
Not Applicable
-
-
-
-
-
-
-
-
-
-
Control waiting ASCD1
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
8 Flashes
10 Flashes
12 Flashes
13 Flashes
14 Flashes
OFF
Flashing
Off
Off
-
Off
Off
-
On
On
-
Off
On
-
HPS1 Compressor Lockout
Not Applicable
Off
-
LPS1 Compressor Lockout
Not Applicable
Off
Off
-
On
-
Off
-
On
-
-
Off
FS1 Compressor Lockout2
Not Applicable
Off
-
On
-
On
-
On
-
-
Compressors Locked Out on Low Outdoor Air Temperature1
Unit Locked Out due to Fan Overload Switch Failure
Flashing
Off
On
On
On
On
Off
Off
On
On
On
Off
On
Off
Off
On
Off
Off
Off
On
Off
Off
Compressor Held Off due to Low Voltage1
EEPROM Storage Failure
Flashing
Off
No Power or Control Failure
Off
1. Non-alarm condition.
2. Freeze - stat not applicable.
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Table 11: PD180 thru 240 Unit Control Board Flash Codes
GREEN
LED
16
RED
LED
8
RED
LED
4
RED
LED
2
RED
LED
1
FLASH CODE
DESCRIPTION
On Steady
1 Flash
This is a Control Failure
Not Applicable
-
-
-
-
-
-
-
-
-
-
Control waiting ASCD1
2 Flashes
3 Flashes
4 Flashes
5 Flashes
6 Flashes
7 Flashes
Flashing
Off
Off
Off
Off
Off
Off
Off
Off
Off
On
On
On
On
On
On
Off
Off
On
On
Off
On
Off
On
Off
On
HPS1 Compressor Lockout
HPS2 Compressor Lockout
LPS1 Compressor Lockout
LPS2 Compressor Lockout
Off
Off
Off
FS1 Compressor Lockout2
FS2 Compressor Lockout2
Off
8 Flashes
Off
On
Off
Off
Off
Compressors Locked Out on Low Outdoor Air Temperature1
Unit Locked Out due to Fan Overload Switch Failure
10 Flashes
12 Flashes
13 Flashes
14 Flashes
OFF
Flashing
Off
On
On
On
On
Off
Off
On
On
On
Off
On
Off
Off
On
Off
Off
Off
On
Off
Off
Compressor Held Off due to Low Voltage1
EEPROM Storage Failure
Flashing
Off
No Power or Control Failure
Off
1. Non-alarm condition.
2. Freeze - stat not applicable.
Check
Alarm
History
Reset All
ASCDs for
One Cycle
Non Alarm
Condition Green
LED Flashing
Current Alarm
Flashed
Red LED
Figure 10: Unit Control Board
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Flash Codes
Normal Maintenance
Various flash codes are utilized by the unit control board (UCB)
to aid in troubleshooting. Flash codes are distinguished by the
short on and off cycle used (approximately 200ms on and
200ms off). To show normal operation, the control board
flashes a 1 second on, 1 second off "heartbeat" during normal
operation. This is to verify that the UCB is functioning correctly.
Do not confuse this with an error flash code. To prevent
confusion, a 1-flash, flash code is not used.
Prior to any of the following maintenance procedures,
shut off all power to the unit, to avoid personal injury.
Periodic maintenance consists of changing or cleaning filters
and general cleaning of the outdoor coil.
Alarm condition codes are flashed on the UCB lower left Red
LED, See Figure Table 11. While the alarm code is being
flashed, it will also be shown by the other LEDs: lit continuously
while the alarm is being flashed. The total of the continuously lit
LEDs equates to the number of flashes, and is shown in the
table. Pressing and releasing the LAST ERROR button on the
UCB can check the alarm history. The UCB will cycle through
the last five (5) alarms, most recent to oldest, separating each
alarm flash code by approximately 2 seconds. In all cases, a
flashing Green LED will be used to indicate non-alarm
condition.
FILTERS - Inspect once a month. Replace Disposable or clean
Permanent Type as necessary. DO NOT replace Permanent
Type with Disposable.
MOTORS - Outdoor fan motors are permanently lubricated and
require no maintenance.
OUTDOOR COIL - Dirt should not be allowed to accumulate on
the outdoor coil surface or other parts in the air circuit. Cleaning
should be as often as necessary to keep the coil clean. Use a
brush, vacuum cleaner attachment, or other suitable means. Be
sure that the power to the unit is shut off prior to cleaning.
In some cases, it may be necessary to "zero" the ASCD for the
compressors in order to perform troubleshooting. To reset all
ASCDs for one cycle, press and release the UCB TEST/
RESET button once.
Flash codes that do and do not represent alarms are listed in
Exercise care when cleaning the coil so that the coil fins
are not damaged.
Do not permit the hot condenser air discharge to be
obstructed by overhanging structures or shrubs.
Unit Control Board Option Setup
Option Byte Setup
Troubleshooting
• Enter The Option Setup Mode By Pushing The Option
Setup / Store Button, And Holding It For At Least 2
Seconds.
• The Green Status Led (Option Byte) Will Be Turned On
And The Red Status Led (Heat Delay) Is Turned Off.
Troubleshooting of components necessarily requires
opening the electrical control box with the power
connected to the unit. Use extreme care when working
with live circuit! Check the unit nameplate for the correct
range before making any connections with line
terminals.
• The 4 Led Will Then Show The Status Of The Labeled
Option Low Ambient Lockout.
• Press The Up Or Down Button To Change The Led Status
To Correspond To The Desired Option Setup.
• To Save The Current Displayed Value, Push The Option
Setup / Store Button And Hold It For At Least 2 Seconds.
When The Value Is Saved, The Green Led Will Flash A
Few Times And Then Normal Display Will Resume.
NOTE: While in either Setup mode, if no buttons are pushed for
60 seconds, the display will revert to its normal display,
exiting the Option Setup mode. When saving, the
control board only saves the parameters for the
currently displayed mode (Option Byte or Heat
Delay). (Heat Delay not applicable on these units.)
The wire number or color and terminal designations
referred to may vary. Check the wiring label inside the
control box access panel for the correct wiring.
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Cooling Troubleshooting Guide
2. If M1 is pulled in and voltage is supplied at M1, lightly touch
the compressor housing. If it is hot, the compressor may be
off on inherent protection. Cancel any calls for cooling and
wait for the internal overload to reset. Test again when
cool.
On calls for cooling, if the compressors are operating but the
supply air blower motor does not energize after a short delay
(the room thermostat fan switch is in the “AUTO” position):
1. Turn the thermostat fan switch to the ON position. If the
supply air blower motor does not energize, go to Step 3.
3. If M1 is not pulled in, check for 24 volts at the M1 coil. If 24
volts are present and M1 is not pulled in, replace the
contactor.
2. If the blower motor runs with the fan switch in the ON
position but will not run after the first compressor has
energized when the fan switch is in the AUTO position,
check the room thermostat for contact between R and G in
the AUTO position during calls for cooling.
4. Failing the above, if voltage is supplied at M1, M1 is pulled
in, and the compressor still does not operate, replace the
compressor.
5. If 24 volts is not present at M1, check for 24 volts at the
UCB terminal, C1. If 24 volts is present, check for loose
wiring between C1 and the compressor contactor.
3. If the supply air blower motor does not energize when the
fan switch is set to ON, check that line voltage is being
supplied to the contacts of the M3, contactor, and that the
contactor is pulled in. Check for loose wiring between the
contactor and the supply air blower motor.
6. If 24 volts is not present at the C1 terminal, check for 24
volts from the room thermostat at the UCB Y1 terminal. If
24 volts is not present from the room thermostat, check for
the following:
4. If M3 is pulled in and voltage is supplied to M3, lightly touch
the supply air blower motor housing. If it is hot, the motor
may be off on internal protection. Cancel any thermostat
calls and set the fan switch to AUTO. Wait for the internal
overload to reset. Test again when cool.
a. 24 volts at the thermostat Y1 terminal
b. Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2, and
c. Loose wiring from the room thermostat to the UCB
5. If M3 is not pulled in, check for 24 volts at the M3 coil. If 24
volts are present at M3 but M3 is not pulled in, replace the
contactor.
7. If 24 volts is present at the UCB Y1 terminal, the
compressor may be out due to an open high-pressure
switch or low-pressure switch. Check for 24 volts at the
HPS1 and LPS1 terminals of the UCB. If a switch has
opened, there should be a voltage potential between the
UCB terminals, e.g. if LPS1 has opened, there will be a 24-
volt potential between the LPS1 terminals.
6. Failing the above, if there is line voltage supplied at M3, M3
is pulled in, and the supply air blower motor still does not
operate, replace the motor.
7. If 24 volts is not present at M3, check that 24 volts is
present at the UCB supply air blower motor terminal,
“FAN”. If 24 volts is present at the FAN, check for loose
wiring between the UCB and M3.
8. If 24 volts is present at the UCB Y1 terminal and none of
the protection switches have opened, the UCB may have
locked out the compressor for repeat trips. The UCB
should be flashing an alarm code. If not, press and release
the ALARMS button on the UCB. The UCB will flash the
last five alarms on the LED. If the compressor is locked
out, cancel any call for cooling. This will reset any
compressor lock outs.
8. If 24 volts is not present at the “FAN” terminal, check for 24
volts from the room thermostat. If 24 volts are not present
from the room thermostat, check for the following:
a. Proper operation of the room thermostat (contact
between R and G with the fan switch in the ON position
and in the AUTO position during operation calls).
NOTE: While the above step will reset any lockouts,
compressor #1 may be held off for the ASCD. See the
next step.
b. Proper wiring between the room thermostat and the
UCB, and
c. Loose wiring from the room thermostat to the UCB
9. If 24 volts is present at the UCB Y1 terminal and none of
the switches are open and the compressor is not locked
out, the UCB may have the compressor in an ASCD.
Check the LED for an indication of an ASCD cycle. The
ASCD should time out within 5 minutes. Press and release
the TEST button to reset all ASCDs.
9. If 24 volts is present at the room thermostat but not at the
UCB, check for proper wiring between the thermostat and
the UCB, i.e. that the thermostat G terminal is connected to
the G terminal of the UCB, and for loose wiring.
10. If the thermostat and UCB are properly wired, replace the
UCB.
10. If 24 volts is present at the UCB Y1 terminal and the
compressor is not out due to a protective switch trip, repeat
trip lock out, or ASCD, the economizer terminals of the
UCB may be improperly wired. Check for 24 volts at the Y1
“OUT” terminal of the UCB.
On calls for cooling, the supply air blower motor is operating but
compressor #1 is not (the room thermostat fan switch is in the
“AUTO” position):
1. If compressor #1 does not energize on a call for cooling,
check for line voltage at the compressor contactor, M1, and
that the contactor is pulled in. Check for loose wiring
between the contactor and the compressor.
11. If 24 volts is not present at the Y1 “OUT” terminal, the UCB
must be replaced. (If 24 volts is present at the Y1 OUT
terminal, check for 24 volts at the Y1 “ECON” terminal. If
24 volts is not present, check for loose wiring from the Y1
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“OUT” terminal to the Mate-N-Lock plug, the jumper in the
Mate-N-Lock plug, and in the wiring from the Mate-N-Lock
plug to the Y1 “ECON” terminal.)
remove any call for cooling at the thermostat or by
disconnecting the thermostat wiring at the Y2 UCB
terminal. This will reset any compressor lock outs.
12. If none of the above corrected the error, test the integrity of
the UCB. Disconnect the C1 terminal wire and jumper it to
the Y1 terminal. DO NOT jump the Y1 to C1 terminals. If
the compressor engages, the UCB has faulted.
NOTE: While the above step will reset any lock outs,
compressor #1 will be held off for the ASCD, and
compressor #2 may be held off for a portion of the
ASCD. See the next step.
13. If none of the above correct the error, replace the UCB.
9. If 24 volts is present at the UCB Y2 terminal and none of
the switches are open and the compressor is not locked
out, the UCB may have the compressor in an ASCD.
Check the LED for an indication of an ASCD cycle. The
ASCD should time out within 5 minutes. Press and release
the TEST button to reset all ASCDs.
For units with two stages of cooling: On calls for the second
stage of cooling, the supply air blower motor and compressor
#1 are operating but compressor #2 is not (the room thermostat
fan switch is in the “AUTO” position):
1. Compressor #2 will not energize simultaneously with
compressor #1 if a call for both stages of cooling is
received. The UCB delays compressor #2 by 30 seconds
to prevent a power surge. If after the delay compressor #2
does not energize on a second stage call for cooling, check
for line voltage at the compressor contactor, M2, and that
the contactor is pulled in. Check for loose wiring between
the contactor and the compressor.
10. If none of the above corrected the error, test the integrity of
the UCB. Disconnect the C2 terminal wire and jumper it to
the Y2 terminal. DO NOT jump the Y2 to C2 terminals. If
the compressor engages, the UCB has faulted.
11. If none of the above correct the error, replace the UCB.
On a call for cooling, the supply air blower motor and
compressor #2 are operating but compressor #1 is not (the
room thermostat fan switch is in the “AUTO” position):
2. If M2 is pulled in and voltage is supplied at M2, lightly touch
the compressor housing. If it is hot, the compressor may be
off on inherent protection. Cancel any calls for cooling and
wait for the internal overload to reset. Test again when cool.
1. Compressor #2 is energized in place of compressor #1
when compressor #1 is unavailable for cooling calls. Check
the UCB for alarms indicating that compressor #1 is locked
out. Press and release the ALARMS button if the LED is
not flashing an alarm.
3. If M2 is not pulled in, check for 24 volts at the M2 coil. If 24
volts is present and M2 is not pulled in, replace the
contactor.
2. Check for line voltage at the compressor contactor, M1,
and that the contactor is pulled in. Check for loose wiring
between the contactor and the compressor.
4. Failing the above, if voltage is supplied at M2, M2 is pulled
in, and the compressor still does not operate, replace the
compressor.
3. If M1 is pulled in and voltage is supplied at M1, lightly touch
the compressor housing. If it is hot, the compressor may be
off on inherent protection. Cancel any calls for cooling and
wait for the internal overload to reset. Test again when cool.
5. If 24 volts is not present at M2, check for 24 volts at the
UCB terminal, C2. If 24 volts are present, check for loose
wiring between C2 and the compressor contactor.
6. If 24 volts is not present at the C2 terminal, check for 24
volts from the room thermostat at the UCB Y2 terminal. If
24 volts is not present from the room thermostat, check for
the following:
4. If M1 is not pulled in, check for 24 volts at the M1 coil. If 24
volts is present and M1 is not pulled in, replace the
contactor.
5. Failing the above, if voltage is supplied at M1, M1 is pulled
in, and the compressor still does not operate, replace the
compressor.
a. 24 volts at the thermostat Y2 terminal
b. Proper wiring between the room thermostat and the
UCB, i.e. Y1 to Y1, Y2 to Y2, and
6. If 24 volts is not present at M1, check for 24 volts at the
UCB terminal, C1. If 24 volts is present, check for loose
wiring between C1 and the compressor contactor.
c. Loose wiring from the room thermostat to the UCB
7. If 24 volts is present at the UCB Y2 terminal, the
compressor may be out due to an open high-pressure
switch, low-pressure switch, or freezestat. Check for 24
volts at the HPS2, LPS2, and FS2 terminals of the UCB. If
a switch has opened, there should be a voltage potential
between the UCB terminals, e.g. if LPS2 has opened, there
will be 24 volts of potential between the LPS2 terminals.
7. If 24 volts is not present at the C1 terminal, check for 24
volts from the room thermostat at the UCB Y1 terminal. If
24 volts are not present at the UCB Y1 terminal, the UCB
may have faulted. Check for 24 volts at the Y1 ECON
terminal. If 24 volts is not present at Y1 “ECON”, the UCB
has faulted. The UCB should de-energize all compressors
on a loss of call for the first stage of cooling, i.e. a loss if 24
volts at the Y1 terminal.
8. If 24 volts is present at the UCB Y2 terminal and none of
the protection switches have opened, the UCB may have
locked out the compressor for repeat trips. The UCB
should be flashing a code. If not, press and release the
ALARMS button on the UCB. The UCB will flash the last
five alarms on the LED. If the compressor is locked out,
8. If 24 volts are present at the UCB Y1 terminal, the
compressor may be out due to an open high-pressure
switch or low-pressure switch. Check for 24 volts at the
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HPS1 and LPS1 terminals of the UCB. If a switch has
opened, there should be a voltage potential between the
UCB terminals, e.g. if LPS1 has opened, there will be a 24-
volt potential between the LPS1 terminals.
ASCD should time out within 5 minutes. Press and release
the TEST button to reset all ASCDs.
11. If 24 volts is present at the UCB Y1 terminal and the
compressor is not out due to a protective switch trip, repeat
trip lock out, or ASCD, the economizer terminals of the UCB
may be improperly wired. Check for 24 volts at the Y1 “OUT”
terminal of the UCB. If 24 volts is not present at the Y1
“OUT” terminal, the UCB must be replaced.
9. If 24 volts is present at the UCB Y1 terminal and none of
the protection switches have opened, the UCB may have
locked out the compressor for repeat trips. The UCB
should be flashing a code. If not, press and release the
ALARMS button on the UCB. The UCB will flash the last
five alarms on the LED. If the compressor is locked out,
remove any call for cooling. This will reset any compressor
lock outs.
12. If 24 volts is present at the Y1 “OUT” terminal, check for 24
volts at the Y1 “ECON” terminal. If 24 volts is not present,
check for loose wiring from the Y1 “OUT” terminal to the
Mate-N-Lock plug, the jumper in the Mate-N-Lock plug,
and in the wiring from the Mate-N-Lock plug to the Y1
“ECON” terminal.
NOTE: While the above step will reset any lock outs,
compressor #2 will be held off for the ASCD, and
compressor #1 may be held off for a portion of the
ASCD. See the next step.
13. If none of the above corrected the error, test the integrity of
the UCB. Disconnect the C1 terminal wire and jumper it to
the Y1 terminal. DO NOT jump the Y1 to C1 terminals. If
the compressor engages, the UCB has faulted.
10. If 24 volts is present at the UCB Y1 terminal and none of
the switches are open and the compressor is not locked
out, the UCB may have the compressor in an ASCD.
Check the LED for an indication of an ASCD cycle. The
14. If none of the above correct the error, replace the UCB.
26
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Cooling Charging Curves
PC090
600
500
400
300
200
115°
105°
95°
85°
75°
65°
120
130
140
150
160
170
180
Suction Pressure (psi)
1. Make sure that both condenser fans are running when charging.
2. This chart is applicable to unit with the TXV’s left to the factory setting. If the TXV’s have been
adjusted in the field, the charging chart may no longer apply.
Figure 11: PC090 Charging Chart
Cooling Charging Curves
PC120
600
500
400
300
115°
105°
95°
85°
75°
65°
200
120
130
140
150
160
170
180
Suction Pressure (psi)
1. Make sure that both condenser fans are running when charging.
2. This chart is applicable to unit with the TXV’s left to the factory setting. If the TXV’s have been
adjusted in the field, the charging chart may no longer apply.
Figure 12: PC120 Charging Chart
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Cooling Charging Curves
PC180
600
500
400
300
200
115°
105°
95°
85°
75°
65°
120
130
140
150
160
170
180
Suction Pressure (psi)
1. Make sure that all condenser fans are running when charging.
2. This chart is applicable to unit with the TXV’s left to the factory setting. If the TXV’s have been
adjusted in the field, the charging chart may no longer apply.
Figure 13: PC180 Charging Chart
Cooling Charging Curves
PD180
600
500
400
300
115°
105°
95°
85°
75°
65°
200
120
130
140
150
160
170
180
Suction Pressure (psi)
1. Make sure that all condenser fans are running when charging.
2. This chart is applicable to unit with the TXV’s left to the factory setting. If the TXV’s have been
adjusted in the field, the charging chart may no longer apply.
Figure 14: PD180 Charging Chart
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Cooling Charging Curves
PC240
600
500
400
300
200
115°
105°
95°
85°
75°
65°
120
130
140
150
160
170
180
Suction Pressure (psi)
1. Make sure that all condenser fans are running when charging.
2. This chart is applicable to unit with the TXV’s left to the factory setting. If the TXV’s have been
adjusted in the field, the charging chart may no longer apply.
Figure 15: PC240 Charging Chart
Cooling Charging Curves
PD240
600
500
400
300
115°
105°
95°
85°
75°
65°
200
120
130
140
150
160
170
180
Suction Pressure (psi)
1. Make sure that all condenser fans are running when charging.
2. This chart is applicable to unit with the TXV’s left to the factory setting. If the TXV’s have been
adjusted in the field, the charging chart may no longer apply.
Figure 16: PD240 Charging Chart
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Typical Wiring Diagrams
Figure 17: Typical PC090 Heat Pump Wiring Diagram
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Figure 18: Typical PC120 Heat Pump Wiring Diagram
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Figure 19: Typical PC180 - 240 Heat Pump Wiring Diagram
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Figure 20: Typical PD180 - 240 Heat Pump Wiring Diagram
Subject to change without notice. Printed in U.S.A.
430645-YIM-D-0610
Copyright © 2010 by Johnson Controls, Inc. All rights reserved.
Supersedes: 430645-YIM-C-0310
Johnson Controls Unitary Products
5005 York Drive
Norman, OK 73069
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