installation, start-up and
service instructions
PACKAGED AIR
CONDITIONERS
564A
Sizes 024-060
764A
Sizes 024-060
Cancels: II 564A-24-1
II 564A-24-2
6/1/96
IMPORTANT — READ BEFORE INSTALLING
1. Read and become familiar with these installation in-
structions before installing this unit (Fig. 1). Retain these
instructions for future maintenance and repair.
2. Be sure the installation conforms to all applicable local
and national codes. Wear safety glasses and work gloves.
Use quenching cloth for unbrazing operations. Have fire
extinguisher available for all brazing operations.
CONTENTS
Page
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 1
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
I. Locate the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
II. Rig and Place Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 5
III. Unit Duct and Field Connections . . . . . . . . . . . . . . 5
Fig. 1 — Unit 564A and 764A (Size 036 Shown)
PRE-START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,12
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,13
I. Heating Section Start-Up and Adjustments . . . . 12
II. Cooling Section Start-Up and Adjustments . . . . 12
III. Indoor Airflow and Airflow Adjustments . . . . . . . 13
symbol
. Danger identifies the most serious hazards which
will result in severe personal injury or death. Warning indi-
cates
a
condition that could result in personal injury.
Caution is used to identify unsafe practices which would
result in minor personal injury or product and property
damage.
CARE AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 14
I. Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
II. Evaporator Fan and Motor . . . . . . . . . . . . . . . . . . 14
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-18
I. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
II. Evaporator Fan and Motor . . . . . . . . . . . . . . . . . . 15
III. Condenser Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
IV. Electrical Controls and Wiring . . . . . . . . . . . . . . . 16
V. Indoor Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
VI. Metering Device Servicing . . . . . . . . . . . . . . . . . . 16
VII. Liquid Line Strainer . . . . . . . . . . . . . . . . . . . . . . . . 16
VIII. Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . 16
IX. Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . 16
WARNING: Before performing service or main-
tenance operations on system, turn off main power
switches to unit. Turn off accessory heater power switch
if applicable. Electric shock can cause personal injury.
1. The power supply (volts, phase, and hertz) must corre-
spond to that specified on unit rating plate.
2. The electrical supply provided by the utility must be suf-
ficient to handle load imposed by this unit.
3. Refer to Installation, Locate the Unit section (page 5)
and Fig. 2-4 for locations of electrical inlets, condensate
drain, duct connections, and required clearances before
setting unit in place.
4. This installation must conform with local building codes
and with NEC (National Electrical Code) or NFPA
(National Fire Protection Association) 54 TIA-54-84-1.
Refer to provincial and local plumbing or wastewater codes
and other applicable local codes.
COOLING TROUBLESHOOTING CHART . . . . . . . . . . . . 19
START-UP CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . CL-1
SAFETY CONSIDERATIONS
WARNING: Improper installation, adjustment, alter-
ation, service, maintenance, or use can cause explo-
sion, fire, electric shock, or other occurrences which may
injure you or damage your property. Consult a quali-
fied installer or service agency for information or assis-
tance. The qualified installer or agency must use only
factory-authorized kits or accessories when modifying
this product.
5. Approved for outdoor installation on wood flooring or on
class A, B, or C roof covering materials.
INSTALLATION
All units can be connected into existing duct systems that are
sized properly and designed to handle the airflow shown in
the Air Delivery table and Indoor Airflow and Airflow Adjust-
ments section.
Recognize safety information. This is the safety-alert symbol
(
). When you see this symbol on the unit and in instruc-
tions or manuals, be alert to the potential for personal
injury.
NOTE: When installing any accessory item, see the manu-
facturer ’s installation instructions packaged with the acces-
sory. Use factory-authorized kits or accessories when
modifying this unit.
Understand the signal words — DANGER, WARNING, and
CAUTION. These words are used with the safety-alert
LEGEND
UNIT
WEIGHT
CENTER OF GRAVITY mm [in.]
UNIT
564A/764A
ELECTRICAL
CHARACTERISTICS
NEC
—
National Electrical Code
REQUIRED CLEARANCES TO COMBUSTIBLE
MATERIAL, mm [in.]
Top of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Duct Side of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Side Opposite Ducts . . . . . . . . . . . . . . . . . . . . . . . . 0
Bottom of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Lb Kg
X
Y
Z
042
048
208/230-1-60, 208/230-3-60 297 135 355.6 [14.00] 508.0 [20.00] 304.8 [12.00]
208/230-1-60, 208/230-3-60 310 114 355.6 [14.00] 508.0 [20.00] 304.8 [12.00]
NEC REQUIRED CLEARANCES, mm [in.]
Between Units, Power Entry Side . . . . . . . 1066.8 [42.00]
Unit and Ungrounded Surfaces,
Power Entry Side . . . . . . . . . . . . . . . . . 914.0 [36.00]
Unit and Block or Concrete Walls and Other
Grounded Surfaces, Power Entry Side . . . . 1066.8 [42.00]
REQUIRED CLEARANCES FOR SERVICING, mm [in.]
Condenser Coil Access Side . . . . . . . . . . . . 762.0 [30.00]
Power Entry Side
(Except for NEC Requirements) . . . . . . . . . 762.0 [30.00]
Unit Top . . . . . . . . . . . . . . . . . . . . . . . . 914.0 [36.00]
Side Opposite Ducts . . . . . . . . . . . . . . . . . 762.0 [30.00]
NOTES:
1. Clearances must be maintained to prevent recirculation of
air from condenser-fan discharge. With the exception of the
condenser coil (914 mm [36 in.]), a removable fence or bar-
ricade requires no clearance.
2. Dimensions are in millimeters. Dimensions in [ ] are in inches.
Fig. 3 — Base Unit Dimensions — 564A/764A042,048
—3—
LEGEND
UNIT
WEIGHT
CENTER OF GRAVITY mm [in.]
UNIT
ELECTRICAL
NEC
—
National Electrical Code
564A/764A CHARACTERISTICS
REQUIRED CLEARANCES TO COMBUSTIBLE
MATERIAL, mm [in.]
Top of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Duct Side of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Side Opposite Ducts . . . . . . . . . . . . . . . . . . . . . . . . 0
Bottom of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
Lb Kg
X
Y
Z
230-1-60, 208/230-3-60,
060
350 159 355.6 [14.00] 508.0 [20.00] 355.6 [14.00]
460-3-60
NEC REQUIRED CLEARANCES, mm [in.]
Between Units, Power Entry Side . . . . . . . 1066.8 [42.00]
Unit and Ungrounded Surfaces,
Power Entry Side . . . . . . . . . . . . . . . . . 914.0 [36.00]
Unit and Block or Concrete Walls and Other
Grounded Surfaces, Power Entry Side . . . . 1066.8 [42.00]
REQUIRED CLEARANCES FOR SERVICING, mm [in.]
Condenser Coil Access Side . . . . . . . . . . . . 762.0 [30.00]
Power Entry Side
(Except for NEC Requirements) . . . . . . . . . 762.0 [30.00]
Unit Top . . . . . . . . . . . . . . . . . . . . . . . . 914.0 [36.00]
Side Opposite Ducts . . . . . . . . . . . . . . . . . 762.0 [30.00]
NOTES:
1. Clearances must be maintained to prevent recirculation of
air from condenser-fan discharge. With the exception of the
condenser coil (914 mm [36 in.]), a removable fence or bar-
ricade requires no clearance.
2. Dimensions are in millimeters. Dimensions in [ ] are in inches.
Fig. 4 — Base Unit Dimensions — 564A/764A060
—4—
I. LOCATE THE UNIT
A. Clearance
Provide sufficient space for condenser airflow clearance, wir-
ing, and servicing unit. See Fig. 2-4. Locate unit where supply-
and return-air ducts can be conveniently brought out to unit
duct connections.
Un it m a y be p la ced w ith d u ct sid e a s close to bu ild in g
a s top r em ova l, d u ct con n ection s, a n d p ow er con n ec-
tion s p er m it. Position unit so water or ice from roof does
not drop directly on top of unit or in front of coil. Make pro-
visions for condensate drainage. Maintain a 4 ft clearance above
unit for vertical air discharge.
MAXIMUM ALLOWABLE
DIFFERENCE (in.)
A-B
B-C
A-C
1
1
1
⁄4
⁄
4
⁄4
Fig. 5 — Unit Leveling Tolerances
Roof installation method for units depends on building con-
struction and special requirements of local building codes.
Be sure that roof can support unit weight.
Maintain clearance around and above unit to provide proper
airflow and service access. See Fig. 2-4.
CAUTION: Do not restrict condenser airflow. An air
restriction at either the condenser air inlet (the entire
surface of the condenser coil) or the fan discharge can
be detrimental to compressor life.
The condenser fan discharges through the top of the unit.
Ensure that the fan discharge does not recirculate to the con-
denser coil. Do not locate the unit either in a corner or under
a complete overhead obstruction, and ensure the following clear-
ances are provided:
On roof overhangs, provide a minimum clearance of 48 in.
above the top of the unit for partial overhangs (such as a
normal house roof overhang). If there is a horizontal exten-
sion on the partial overhang, extension must not exceed
48 inches. For extended overhangs, provide a minimum clear-
ance of 36 in. between unit and overhang.
NOTES:
1. Extend a 24-in. gravel apron around pad.
2. Provide a 30-in. service clearance at front and rear sides of unit.
Provide a minimum clearance of 42 in. for the control box
side next to a block wall or any other grounded surface. Pro-
vide a minimum clearance of 36 in. between the control box
side of the unit and any electrically live parts.
Fig. 6 — Pad Dimensions
Unit may be installed on wood flooring, or on Class A, B, or C
roof covering materials.
III. UNIT DUCT AND FIELD CONNECTIONS
A. Condensate Disposal
Although unit is weatherproof, guard against water from higher
level runoff and overhangs.
Units should be at least 4 in. above the highest expected wa-
ter, flood, and runoff levels. Do not use the unit if it has been
under water.
NOTE: Ensure that condensate-water disposal methods com-
ply with local codes, restrictions, and practices.
3
Units remove condensate water through a
cated on the control box side of the unit.
⁄4-in. ID hole lo-
B. Ground-Level Installation
Mount unit on a solid, level pad. See Fig. 5 for unit leveling
tolerances. Construct pad as shown in Fig. 6. Side of unit with
condensate trap should be flush with pad for proper trap po-
sitioning (see Fig. 2-4). Extend a 24-in. gravel apron around
pad for condensate drainage.
Condensate water can be drained directly onto a gravel apron
in ground-level installations. Install a field-supplied conden-
sate trap at end of condensate connection to ensure proper
drainage. See Fig. 7. Make sure that the outlet of the trap is
at least 1 in. lower than the drain pan condensate connection
to prevent the pan from overflowing. See Fig. 8A and 8B. Prime
the trap with water. When using a gravel apron, make sure
it slopes away from the unit.
II. RIG AND PLACE UNIT
Inspect unit for transportation damage. File any claim with
transportation agency. Keep upright and do not drop. Level
by using unit frame as a reference. See Table 1 for additional
information. Weight is shown in Fig. 2-4. Unit can be moved
with handholds provided in the unit basepan.
—5—
Table 1 — Physical Data
UNIT 564A AND 764A
OPERATING WEIGHT (lb)
COMPRESSOR TYPE
024
030
036
042
048
060
222
236
250
297
310
350
Reciprocating
REFRIGERANT
Charge (lb)
R-22
2.8
3.9
4.7
4.4
6.1
7.5
REFRIGERANT METERING DEVICE
Acutrol™ System
CONDENSER COIL
Rows...Fins/in.
Total Face Area (sq ft)
Copper Tubes, Aluminum Plate Fins
1...17
6.7
1...17
7.9
2...17
6.2
1...17
11.1
2...17
8.6
2...17
10.7
CONDENSER-FAN MOTOR
Cfm
Propeller
1600
2000
2000
2600
2600
2800
Nominal Rpm
Motor Hp
825
1100
1100
1100
1100
1100
1
1
1
1
1
1
⁄
8
⁄
4
⁄
4
⁄
4
⁄
4
⁄
4
Diameter (in.)
20
20
20
20
20
20
EVAPORATOR COIL
Rows...Fins/in.
Total Face Area (sq ft)
Copper Tubes, Aluminum Plate Fins
2...15
2.8
3...15
2.8
3...15
3.1
3...15
3.9
3...15
4.3
4...15
4.9
EVAPORATOR-FAN MOTOR
Blower Motor Size (in.)
Nominal Cfm
Direct Drive
10 x 8
800
10 x 8
1000
10 x 8
1200
10 x 9
1400
10 x 9
1600
10 x 10
2000
950-1100
3*
Rpm Range
550-1000
3
550-1000
3
800-1050
3
800-1050
3
Med
1000-1100
2
Number of Speeds
Factory Speed Setting
Motor Hp
Low
Med
Low
Low
Low
1
1
1
1
3
⁄
4
⁄
4
⁄
2
⁄
2
⁄
4
1
CONNECTING DUCT SIZES
Supply Air (in.)
Return Air (in.)
Round
14
14
Square
13.9 x 13.9
13.9 x 27.8
FIELD-SUPPLIED RETURN AIR FILTER†
Throwaway (in.)
24 x 24
24 x 24
24 x 24
24 x 24
24 x 30
24 x 30
*460-v motors are 2-speed only.
†Required filter sizes shown are based on the ARI (Air Conditioning and Refrigeration Institute)
rated airflow at a velocity of 300 ft/min for throwaway type or 450 ft/min for high capacity type.
Recommended filters are 1-in. thick.
Fig. 8B — Condensate Trap (Using PVC Piping)
If the installation requires draining the condensate water
away from the unit, install a field-supplied 2-in. trap using
3
⁄
4-in. OD tubing or piping to ensure proper drainage. See
Fig. 8A and 8B. Make sure that the outlet of the trap is at
least one in. lower than the unit drain pan condensate con-
nection to prevent the pan from overflowing. Connect a drain
CONDENSATE DRAIN HOLE
3
3
3
tube using a minimum of ⁄4-in. PVC, ⁄4-in. CPVC, or
⁄4-in.
copper pipe (all field-supplied). Do not undersize the tube. Pitch
the drain tube downward at a slope of at least 1 inch in every
10 ft of horizontal run. Be sure to check the drain tube for
leaks. Prime trap at the beginning of cooling season start-up.
Allowable glues for condensate trap connection are: Stand-
ard ABS, CPVC, or PVC cement.
Fig. 7 — Condensate Connection Details
B. Field-Duct Connections
NOTE: The design and installation of the duct system must
be in accordance with the standards of NFPA for the instal-
lation of nonresidence-type air conditioning and ventilating
systems, NFPA 90A or residence-type, NFPA 90B, and/or
local codes and ordinances.
Units have duct flanges on the supply- and return-air open-
ings on the side of the unit. See Fig. 2-4 for connection sizes
and locations.
Fig. 8A — Condensate Trap (Using Tubing)
—6—
Install Flanges for Ductwork Connections (564A/764A060 only)
4. Install 2 hand-formed flanges onto return air opening
in holes provided to form rectangle around the return
air opening.
The size 060 units are shipped with flanges which must be
field-installed on the unit.
5. Install remaining 2 hand-formed flanges around dis-
charge air opening in holes provided.
To install unit flanges:
1. Five pieces of flange are shipped on the return air open-
ing of the unit. Remove the flanges from the shipping
position. See Fig. 9. Screws are field-supplied.
6. Ductwork can now be attached to flanges.
Adhere to the following criteria when selecting, sizing, and
installing the duct system:
2. One piece of flange is used as it is shipped (straight).
Bend the other 4 pieces at right angles.
1. Select and size ductwork, supply-air registers, and return-
air grilles according to ASHRAE (American Society of
Heating, Refrigeration, and Air Conditioning Engi-
neers) recommendations.
3. Install the straight flange on the right side of the re-
turn air opening in holes provided. See Fig. 10. Flanges
should stick out from unit to allow for connection of
ductwork.
CAUTION: When drilling the duct system fastening
holes into the side of the unit for duct flanges, do not
3
drill deeper than
⁄
4
in., and use extreme care not to
puncture the coil or coil tubes. See Fig. 11.
2. Use flexible transition between rigid ductwork and unit
to prevent transmission of vibration. The transition may
be screwed or bolted to duct flanges. Use suitable gas-
kets to ensure weathertight and airtight seal.
19.17″
3.92″
Fig. 9 — Shipping Location of Duct Flanges
(Size 060 Only)
3
Fig. 11 — Area Not To Be Drilled More Than ⁄4-in.
3. Size ductwork for cooling air quantity (cfm).
4. Adequately insulate and weatherproof all ductwork
located outdoors. Insulate ducts passing through un-
conditioned space, and use vapor barrier in accordance
with latest issue of SMACNA (Sheet Metal and Air
Conditioning Contractors National Association) and ACCA
(Air Conditioning Contractors of America) minimum
installation standards for heating and air conditioning
systems. Secure all ducts to building structure.
5. Flash, weatherproof, and vibration-isolate all openings
in building structure in accordance with local codes and
good building practices.
6. Air filters should be installed in return-air ductwork.
Return-air filter grille or filter tracks in duct may be used.
Figure 12 shows a typical duct system with unit installed.
Fig. 10 — Installation of Duct Flanges
(Size 060 Only)
—7—
CAUTION: Failure to follow these precautions could
result in damage to the unit being installed:
1. Make all electrical connections in accordance with
NEC ANSI/NFPA (latest edition) and local electrical
codes governing such wiring. In Canada, all elec-
trical connections must be in accordance with CSA
Standard C22.1 Canadian Electrical Code Part 1
and applicable local codes. Refer to unit wiring
diagram.
2. Use only copper conductor for connections between
field-supplied electrical disconnect switch and unit.
DO NOT USE ALUMINUM WIRE.
3. Be sure that high-voltage power to unit is within op-
erating voltage range indicated on unit rating plate.
On 3-phase units, ensure that phases are balanced
within 2%. Consult local power company for correc-
tion of improper voltage and/or phase imbalance.
LEGEND
4. Insulate low-voltage wires for highest voltage con-
tained within conduit when low-voltage control wires
are run in same conduit as high-voltage wires.
Outdoor Airflow
Indoor Airflow
NEC
—
National Electrical Code
Power Wiring
Control Wiring
5. Do not damage internal components when drilling
through any panel to mount electrical hardware, con-
duit, etc.
*Required for electric heater when single-point connection is not
used.
Fig. 12 — Typical Installation
High-Voltage Connections
The unit must have a separate electrical service with a field-
supplied, waterproof disconnect switch mounted at, or within
sight from the unit. Refer to the unit rating plate for maxi-
mum fuse/circuit breaker size and minimum circuit amps
(ampacity) for wire sizing. See Table 2 for electrical data.
C. Converting Horizontal Discharge Units to Downflow
(Vertical) Discharge
The field-supplied disconnect may be mounted on the unit over
the high-voltage inlet hole. See Fig. 2-4.
WARNING: Before performing service or mainte-
nance operations on system, turn off main power to unit.
Turn off accessory heater power switch if applicable. Elec-
trical shock can cause personal injury.
CAUTION: Operation of unit on improper line volt-
age constitutes abuse and may cause unit damage that
could affect warranty.
Units are dedicated side-supply products. Units are not con-
vertible to vertical air supply. A field-supplied plenum must
be used to convert to vertical air discharge.
Routing Power Leads Into Unit
Use only copper wire between disconnect and unit. The high-
voltage leads should be in a conduit until they enter the unit;
conduit termination at the unit must be watertight. Run the
high-voltage leads through the hole on the side of the unit
(see Fig. 13 for location). When the leads are inside the unit,
run leads to the control box (Fig. 14). For single-phase units,
connect leads to the black and yellow wires; for 3-phase units,
connect the leads to the black, yellow, and blue wires (see
Fig. 15).
D. Electrical Connections
WARNING: The unit cabinet must have an un-
interrupted, unbroken electrical ground to minimize the
possibility of personal injury if an electrical fault should
occur. This ground may consist of an electrical wire con-
nected to the unit ground in the control compartment,
or conduit approved for electrical ground when
installed in accordance with NEC, ANSI (American
National Standards Institute)/NFPA (latest edition)
(in Canada, Canadian Electrical Code CSA [Canadian
Standards Association] C22.1) and local electrical codes.
Failure to adhere to this warning could result in per-
sonal injury or death.
Connecting Ground Lead to Unit Ground
Refer to Fig. 14 and 15. Connect the ground lead to the chas-
sis using the unit ground screw in the control box.
Routing Control Power Wires
Form a drip-loop with the thermostat leads before routing
them into the unit. Route the thermostat leads through
grommeted hole provided in unit (see Fig. 13) into unit con-
trol box. Connect thermostat leads to unit control power leads
as shown in Fig. 16.
—8—
Route thermostat wires through grommet providing a drip
loop at the panel. Connect low-voltage leads to the thermo-
stat as shown in Fig. 16.
rewire transformer primary as described in Special Proce-
dures for 208-V Operation section on page 11.
Accessory Electric Heat Wiring
Refer to accessory electric heat installation instructions for
information on installing accessory electric heat. Accessory
electric heat wiring is shown in Fig. 17.
The unit transformer supplies 24-v power for complete
system including accessory electrical heater. Transformer is
factory wired for 230-v operation. If supply voltage is 208 v,
HIGH-VOLTAGE
POWER WIRING WIRING ENTRY
ENTRY HOLE HOLE
LOW-VOLTAGE
LEGEND
NEC
—
National Electrical Code
Field Control Wiring
Fig. 13 — Unit Electrical Connection Entry Holes
Field Splice
Fig. 15 — Line Power Connections
Fig. 16 — Control Connections
Fig. 14 — Control Box Wiring
—9—
Table 2 — Electrical Data
VOLTAGE
RANGE
DISCONNECT
SIZE
COMPRESSOR
OFM
FLA
IFM
ELECTRIC HEAT
POWER SUPPLY
NOMINAL
VOLTAGE
(V-Ph-Hz)
UNIT
564A/764A
Nominal
Min
Max
RLA
LRA
FLA
FLA
MCA
MOCP
FLA
LRA
kW*
—/—
—/—
16.9/ 16.9
25.6/ 29.0
48.1/ 55.1
20/ 20
30/ 30
50/ 60
16/ 16
24/ 27
44/ 51
024
030
208/230-1-60
208/230-1-60
187
187
254
254
10.9
61.0
0.9
1.5
2.4
2.4
3.8/ 5.0
7.5/10.0
18.1/20.8
36.1/41.7
68
—/—
—/—
22.9/ 22.9
25.6/ 29.0
48.1/ 55.1
70.7/ 81.1
30/ 30
30/ 30
50/ 60
80/ 90†
22/ 22
24/ 27
44/ 51
65/ 75
3.8/ 5.0
7.5/10.0
11.3/15.0
18.1/20.8
36.1/41.7
54.2/62.5
15.2
15.9
69.4
86.0
79
96
—/—
—/—
24.2/ 24.2
26.1/ 29.5
48.6/ 55.6
71.2/ 81.6
93.6/107.7
30/ 30
30/ 30
23/ 23
24/ 27
45/ 51
66/ 75
86/ 99
3.8/ 5.0
7.5/10.0
11.3/15.0
15.0/20.0
18.1/20.8
36.1/41.7
54.2/62.5
72.2/83.3
208/230-1-60
208/230-3-60
208/230-1-60
208/230-3-60
208/230-1-60
208/230-3-60
230-1-60
187
187
187
187
187
187
207
187
414
254
254
254
254
254
254
254
254
508
1.5
1.5
1.5
1.5
1.5
1.5
1.4
1.4
0.7
2.8
2.8
2.8
2.8
4.2
4.2
6.2
6.2
3.2
50/ 60
80/ 90†
100/110†
036
042
048
—/—
—/—
15.4/ 15.4
16.5/ 18.5
29.6/ 33.6
42.6/ 48.6
55.6/ 63.6
20/ 20
20/ 20
30/ 35
45/ 50
60/ 70†
15/ 15
15/ 17
27/ 31
39/ 45
51/ 59
3.8/ 5.0
7.5/10.0
11.3/15.0
15.0/20.0
10.4/12.0
20.8/24.1
31.3/36.1
41.7/48.1
8.9
18.5
10.9
21.3
12.3
26.9
17.7
9.0
64.5
97.6
74
107
83
—/—
—/—
27.4/ 27.4
27.4/ 29.5
48.6/ 55.6
71.2/ 81.6
93.8/107.7
35/ 35
35/ 35
26/ 26
26/ 27
45/ 51
66/ 75
86/ 99
3.8/ 5.0
7.5/10.0
11.3/15.0
15.0/20.0
18.1/20.8
36.1/41.7
54.2/62.5
72.2/83.3
50/ 60
80/ 90†
100/110†
—/—
—/—
17.9/ 17.9
17.9/ 18.5
29.6/ 33.6
42.6/ 48.6
55.6/ 63.6
25/ 25
25/ 25
30/ 35
45/ 50
60/ 70†
17/ 17
17/ 17
27/ 31
39/ 45
51/ 59
3.8/ 5.0
7.5/10.0
11.3/15.0
15.0/20.0
10.4/12.0
20.8/24.1
31.3/36.1
41.7/48.1
73.0
—/—
—/—
32.3/ 32.3
32.3/ 32.3
50.4/ 57.3
72.9/ 83.4
95.5/109.4
40/ 40
40/ 40
31/ 31
31/ 31
46/ 53
67/ 77
88/101
3.8/ 5.0
7.5/10.0
11.3/15.0
15.0/20.0
18.1/20.8
36.1/41.7
54.2/62.5
72.2/83.3
107.0
73.0
60/ 60
121
87
80/ 90†
100/110†
—/—
—/—
21.1/ 21.1
21.1/ 21.1
31.3/ 35.3
44.3/ 50.4
57.4/ 65.4
25/ 25
25/ 25
35/ 40
45/ 60
60/ 70†
21/ 21
21/ 21
29/ 32
41/ 46
53/ 60
3.8/ 5.0
7.5/10.0
11.3/15.0
15.0/20.0
10.4/12.0
20.8/24.1
31.3/36.1
41.7/48.1
—
5.0
10.0
15.0
20.0
—
41.2
41.2
59.8
85.9
111.9
50
50
60
90†
125†
40
40
20.8
41.7
62.5
83.3
128.0
128.0
63.0
55
141
146
71
79
103
—/—
—/—
29.7/ 29.7
29.7/ 29.7
33.8/ 37.8
46.8/ 52.9
59.9/ 67.9
35/ 35
35/ 35
35/ 40
50/ 60
60/ 70†
29/ 29
29/ 29
31/ 35
43/ 49
55/ 62
3.8/ 5.0
7.5/10.0
11.3/15.0
15.0/20.0
10.4/12.0
20.8/24.1
31.3/36.1
41.7/48.1
060
208/230-3-60
—
5.0
10.0
15.0
20.0
—
6.0
12.0
18.0
24.1
15.2
15.2
19.0
26.6
34.1
20
20
20
30
35
15
15
18
24
31
460-3-60
EXAMPLE: Supply voltage is 460-3-60
LEGEND
FLA
—
—
Full Load Amps
AB = 452 v
BC = 464 v
AC = 455 v
HACR
Heating, Air Conditioning and
Refrigeration
IFM
—
—
—
—
—
—
—
Indoor (Evaporator) Fan Motor
Locked Rotor Amps
452 + 464 + 455
LRA
MCA
MOCP
NEC
OFM
RLA
Average voltage =
=
3
Minimum Circuit Amps
Maximum Overcurrent Protection
National Electrical Code
457
Outdoor (Condenser) Fan Motor
Rated Load Amps
Determine maximum deviation from average voltage:
(AB) 457 − 452 = 5 v
(BC) 464 − 457 = 7 v
(AC) 457 − 455 = 2 v
*Heater capacity (kW) is based on heater voltage of 208 v, 240 v, or
480 v. If power distribution voltage to unit varies from rated heater voltage, heater
kW will vary accordingly.
†Fuse or HACR circuit breaker.
Maximum deviation is 7 v.
NOTES:
Determine percentage of voltage imbalance:
1. In compliance with NEC requirements for multimotor and combination load and
equipment (refer to NEC Articles 430 and 440), the overcurrent protective de-
vice for the unit shall be fuse or HACR breaker.
7
% Voltage imbalance = 100 x
457
2. Unbalanced 3-Phase Supply Voltage
= 1.53%
Never operate a motor where a phase imbalance in supply voltage is greater
than 2%. Use the following formula to determine the percentage of voltage
imbalance.
This amount of phase imbalance is satisfactory as it is below the maximum
allowable 2%.
% Voltage Imbalance
IMPORTANT: If the supply voltage phase imbalance is more than 2% contact
your local electric utility company immediately.
max voltage deviation from average voltage
= 100 x
average voltage
—10—
Fig. 17 — Electric Heater Wiring
Special Procedures for 208-V Operation
PRE-START-UP
WARNING: Failure to observe the following warn-
ings could result in serious personal injury:
WARNING: Make sure that the power supply to the
unit is switched OFF before making any wiring changes.
Electrical shock can cause personal injury or death.
1. Follow recognized safety practices and wear protec-
tive goggles when checking or servicing refrigerant
system.
1. Disconnect the orange transformer-primary lead from
the contactor. See unit wiring label.
2. Remove the wirenut from the terminal on the end of the
red transformer-primary lead.
2. Do not operate compressor or provide any electric
power to unit unless compressor terminal cover is in
place and secured.
3. Do not remove compressor terminal cover until all
electrical sources have been disconnected.
3. Save the wirenut.
4. Connect the red lead to the contactor terminal from which
the orange lead was disconnected.
5. Using the wirenut removed from the red lead, insulate
the loose terminal on the orange lead.
6. Wrap the wirenut with electrical tape so that the metal
terminal cannot be seen.
4. Relieve and reclaim all pressure from both high- and
low-pressure sides of the system before touching or
disturbing anything inside terminal box if refriger-
ant leak is suspected around compressor terminals.
5. Never attempt to repair soldered connection while
refrigerant system is under pressure.
Indoor blower-motor speeds may need to be changed for 208-v
operation. Refer to Indoor Airflow and Airflow Adjustments
section on page 13.
6. Do not use torch to remove any component. System
contains oil and refrigerant under pressure. To re-
move a component, wear protective goggles and pro-
ceed as follows:
a. Turn off electrical power to unit.
Heat Anticipator Setting
b. Relieve and reclaim all pressure from system.
The room thermostat heat anticipator must be adjusted prop-
erly to ensure proper heating performance. Set anticipator
settings for room thermostat according to separate Accessory
Electric Heater Installation Instructions.
c. Cut component connecting tubing with tubing cut-
ter and remove component from unit.
d. Carefully unsweat remaining tubing stubs when
necessary. Oil can ignite when exposed to torch
flame.
Failure to make a proper heat anticipator adjustment will
result in improper operation, discomfort to the occupants of
the conditioned space, and inefficient energy utilization; how-
ever, the required setting may be changed slightly to provide
a greater degree of comfort for a particular installation.
For unit compressors equipped with accessory crankcase heat-
ers, heaters are energized as long as there is power to the
unit. Energize crankcase heater 24 hours prior to unit start-
up. To energize heater only, set thermostat at OFF position
and turn on unit main power at disconnect switch.
E. Accessory Installation
At this time, any required accessories should be installed
on the unit. Refer to separate accessory installation
instructions.
—11—
Proceed as follows to inspect and prepare the unit for initial
start-up:
4. After the call for heat has been satisfied, the evaporator
fan will stop. For units equipped with time-delay relay,
evaporator fan will stop after a 30-second time delay.
1. Remove all access panels.
To shut off unit, set system selector switch at OFF position
or set heating set point lever below room temperature.
2. Read and follow instructions on all WARNING, CAU-
TION, and INFORMATION labels attached to, or shipped
with, unit.
B. Heating Sequence of Operation
3. Make the following inspections:
When power is supplied to unit, transformer (TRAN) is
energized.
a. Inspect for shipping and handling damages such as
broken lines, loose parts, disconnected wires, etc.
With thermostat set to call for heating, sequence of operation
is as follows:
b. Inspect for oil at all refrigerant tubing connections
and on unit base. Detecting oil generally indicates a
refrigerant leak. Leak-test all refrigerant tubing con-
nections using electronic leak detector, halide torch,
or liquid-soap solution. If refrigerant leak is de-
tected, see Repairing Refrigerant Leaks section on
page 15.
On a call for heat, circuit R-W and R-G are made through
first-stage thermostat bulb. If accessory electric heaters are
used, a relay is energized, bringing on first stage of supple-
mental electric heat and fan. When thermostat is satisfied,
contacts open, deenergizing relay (on all units) and time-
delay relay (on units equipped with time-delay relay). Heat-
ers deenergize, and evaporator fan stops after a 30-second
time delay (on units equipped with time-delay relay).
c. Inspect all field- and factory-wiring connections. Be
sure that connections are completed and tight.
d. Inspect coil fins. If damaged during shipping and han-
dling, carefully straighten fins with a fin comb.
II. COOLING SECTION START-UP AND ADJUSTMENTS
4. Verify the following conditions:
CAUTION: Complete the required procedures given
a. Make sure that condenser fan blade is correctly po-
sitioned in fan orifice. Top edge of blade should be
3.125 in. from condenser outlet grille.
in Pre-Start-Up section, page 11, before starting the unit.
Do not jumper any safety devices when operating the
unit.
Do not operate the compressor when the outdoor tem-
perature is below 40 F (unless accessory low ambient
kit is installed).
b. Make sure that air filter(s) is in place.
c. Make sure that condensate drain pan and trap are
filled with water to ensure proper drainage.
Do not rapid-cycle the compressor.
d. Make sure that all tools and miscellaneous loose parts
have been removed.
5. Compressors are internally spring mounted. Do not loosen
or remove compressor holddown bolts.
A. Checking Cooling Control Operation
Start and check the unit for proper cooling control operation
as follows:
6. Each unit system has 2 Schrader-type ports, one low-
side Schrader fitting located on the suction line, and one
high-side Schrader fitting located on the compressor dis-
charge line. Be sure that caps on the ports are tight.
1. Place room thermostat SYSTEM switch in OFF posi-
tion. Observe that evaporator-fan motor starts when FAN
switch is placed in ON position and shuts down after a
30-second time delay when FAN switch is placed in AUTO.
position.
See Start-Up Checklist in back of book. Unit is now ready for
initial start-up.
2. Place SYSTEM switch in COOL position and FAN switch
in AUTO. position. Set cooling control below room tem-
perature. Observe that compressor, condenser fan, and
evaporator-fan motors start. Observe that cooling cycle
shuts down when control setting is satisfied. Evaporator-
fan motor has off-delay (on units equipped with time-
delay relay) of approximately 30 seconds on shutdown.
START-UP
I. HEATING SECTION START-UP AND ADJUSTMENTS
(For units with accessory electric heaters.)
CAUTION: Complete the required procedures given
3. When using an auto. changeover room thermostat, place
both SYSTEM and FAN switches in AUTO. positions.
Observe that unit operates in Heating mode when tem-
perature control is set to ‘‘call for heating’’ (above room
temperature) and operates in Cooling mode when tem-
perature control is set to ‘‘call for cooling’’ (below room
temperature).
in Pre-Start-Up section on this page before starting unit.
Do not jumper any safety devices when operating the unit.
A. Checking Heating Control Operation
Start and check the unit for proper heating control operation
as follows:
1. Turn on unit electrical supply.
B. Checking and Adjusting Refrigerant Charge
2. Set system switch selector at HEAT position and fan switch
at AUTO. or ON position. Set heating temperature
lever above room temperature.
The refrigerant system is fully charged with R-22 refriger-
ant, and is tested and factory-sealed.
3. The evaporator fan and first-stage heat will start im-
mediately. If unit is equipped with 2-stage heaters, second-
stage heat will energize upon a call from W2. Check for
heating effect at supply diffusers.
NOTE: Adjustment of the refrigerant charge is not required
unless the unit is suspected of not having the proper R-22
charge. See Refrigerant Charge section on page 16 for fur-
ther details.
—12—
C. Unit Controls
Table 3 — Dry Coil Air Delivery —
Horizontal Discharge
Compressor
High-Pressure Relief Valve — Valve is located in compressor.
Relief valve opens at a pressure differential of approximately
450 psi between suction (low side) and discharge (high side)
to allow pressure equalization.
UNIT
IFM SPEED
SETTING
AIRFLOW
(Cfm)
ESP
POWER
(Watts)
564A/764A
(in. wg)
Low
Med
High
Low*
Med
High
Low
Med
High
Low*
Med
High
Low
—
800
800
0.30
0.65
0.80
—
282
349
439
—
024
030
036
042
048†
060
800
Internal Current and Temperature Sensing Overload
—
1000
1000
1000
1200
1200
1200
1400
1400
1400
1600
—
Device resets automatically when internal compressor motor
temperature drops to a safe level. When an internal overload
is suspected of being open, check by using an ohmmeter or
continuity tester.
0.35
0.65
0.30
0.50
0.65
—
370
460
445
480
530
—
D. Cooling Sequence of Operation
NOTE: With the FAN switch in the ON position, 24 v is sup-
plied to the time-delay relay (TDR) through the G terminal
on the thermostat. This voltage energizes the coil of the re-
lay, closing the normally-open set of contacts which provide
continuous power to the indoor (evaporator) fan motor (IFM).
Moving the FAN switch back to the AUTO. position (provid-
ing there is not a call for cooling) deenergizes the TDR (when
applicable) which deenergizes the IFM after a 30-second de-
lay. The FAN switch in AUTO. position cycles upon a call for
cooling.
0.30
0.60
0.50
—
495
571
650
—
High
Low
Med**
High
1600
2000
2000
2000
0.65
0.15
0.60
0.65
720
900
850
945
LEGEND
On a call for cooling, 24 v is supplied to the compressor con-
tactor (C) and TDR simultaneously through the Y and G ter-
minals of the thermostat, respectively. On units with a com-
pressor TDR, there is a built-in, 5-minute (±45 seconds) delay
between compressor starts. Energizing the contactor closes
the normally-open set of contacts supplying power to both the
compressor and outdoor (condenser) fan motor (OFM). Ener-
gizing the TDR closes the normally-open set of contacts pro-
viding power to the IFM. On the loss of the call for cooling,
24 v is removed from both the Y and G terminals of the ther-
mostat (providing the FAN switch is in the AUTO. position),
deenergizing both the compressor and TDR and opening both
the contacts supplying power to compressor and OFM. IFM
has a 30-second delay.
ESP
IFM
—
—
External Static Pressure
Indoor (Evaporator) Fan Motor
*Unit is factory set on medium speed, this airflow is not obtainable at
low speed.
†Size 048 has low and high speed only.
**460 volt motors do not have a medium speed.
NOTE: Values for 208/230-v motors are at 230 v; deduct 10% for 208 v.
A. For 208/230-v Blower Motors:
The motor leads are color-coded as follows:
3-SPEED
2-SPEED
black
blue
red
=
=
=
high speed
medium speed
low speed
black
red
=
=
high speed
low speed
III. INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS
To change the speed of the blower motor, remove the fan mo-
tor speed leg lead from the indoor (evaporator) fan relay (IFR)
and replace with lead for desired blower motor speed. Insu-
late the removed lead to avoid contact with chassis parts.
CAUTION: For cooling operation, the recommended
airflow is 350 to 450 cfm per each 12,000 Btuh of rated
cooling capacity.
Table 3 shows dry coil air delivery for horizontal discharge
units.
B. For 460-v (2-Speed) Blower Motors:
The motor leads are color coded as follows:
WARNING: Disconnect electrical power to the unit be-
fore changing blower speed. Electrical shock can cause
personal injury or death.
black
yellow
purple
red
=
=
=
=
high
jumper
jumper
low
Airflow can be changed by changing the lead connections of
the blower motor.
To change the speed of the blower motor from low speed to
high speed, remove the red lead from the indoor fan relay
(IFR). Insulate the red lead to avoid contact with any chassis
parts. Separate the black lead from the purple jumper. Con-
nect the black lead to the IFR. Insulate the purple lead to
avoid contact with any chassis parts.
Units 564A/764A024, 036, 048, and 060 blower motors are
factory wired for low speed operation. Units 564A/764A030
and 042 are factory wired for medium speed operation.
—13—
CARE AND MAINTENANCE
I. AIR FILTER
CAUTION: Never operate the unit without a suit-
NOTE: The following steps should be performed by a quali-
fied service person.
able air filter in the return-air duct system. Always re-
place the filter with the same dimensional size and type
as originally installed. See Tables 1 and 2 for recom-
mended filter sizes.
WARNING: Before installing or servicing unit, turn
off main power to system to avoid shock hazard or in-
jury from rotating parts. There may be more than one
disconnect switch. Turn off accessory heater power if ap-
plicable. Electrical shock can cause personal injury or
death.
Inspect air filter(s) at least once each month and replace
(throwaway-type) or clean (permanent-type) at least twice dur-
ing each cooling season or whenever the filter(s) becomes clogged
with dust and lint.
To ensure continuing high performance, and to reduce the pos-
sibility of premature equipment failure, periodic main-
tenance must be performed on this equipment. Unit should
be inspected at least once each year by a qualified service
person.
II. EVAPORATOR FAN AND MOTOR
NOTE: Motors without oilers are permanently lubricated. Do
not attempt to lubricate these motors.
NOTE TO EQUIPMENT OWNER: Consult your local dealer
about the availability of a maintenance contract.
For longer life, operating economy, and continued efficiency,
clean accumulated dirt and grease from the evaporator-fan
wheel and motor annually.
WARNING: The ability to properly perform mainte-
nance on this equipment requires certain expertise,
mechanical skills, tools, and equipment. If you do not
possess these, do not attempt to perform any mainte-
nance on this equipment other than those procedures
recommended in the User’s Manual. FAILURE TO HEED
THIS WARNING COULD RESULT IN SERIOUS PER-
SONAL INJ URY AND POSSIBLE DAMAGE TO THIS
EQUIPMENT.
Lubricate the motor every 5 years if the motor is used inter-
mittently (thermostat FAN switch in AUTO. position), or
every 2 years if the motor is used continuously (thermostat
FAN switch in ON position).
WARNING: Disconnect and tag all electrical power to
the unit before cleaning the evaporator-fan and wheel.
Failure to adhere to this warning could cause personal
injury or death.
The minimum maintenance requirements for this equipment
are as follows:
To clean the blower wheel:
1. Inspect air filter(s) each month. Clean or replace when
necessary.
1. Access the blower assembly as follows:
a. Remove top access panel.
2. Inspect condensing coil, drain pan, and condensate drain
each cooling season for cleanliness. Clean when
necessary.
b. Remove 3 screws that hold blower orifice ring to blower
housing. Save screws.
c. Loosen set screw(s) which secure wheel to motor shaft.
2. Remove and clean blower wheel as follows:
3. Inspect evaporator-fan motor and wheel for cleanliness
each heating and cooling season. Clean when necessary.
For first heating season, inspect evaporator-fan motor
bimonthly to determine proper cleaning frequency.
a. Lift wheel from housing. When handling and/or clean-
ing blower wheel, be sure not to disturb balance weights
(clips) on blower wheel vanes.
4. Check electrical connections for tightness and controls
for proper operation each heating and cooling season.
Service when necessary.
b. Remove caked-on dirt from wheel and housing with
a brush. Remove lint and/or dirt accumulations from
wheel and housing with vacuum cleaner, using a soft
brush attachment. Remove grease and oil with a mild
solvent.
5. Check the drain channel in the top cover periodically
for blockage (leaves, insects). Clean as needed.
c. Reassemble blower into housing. Place upper orifice
ring on blower to judge location of the blower wheel.
Blower wheel should be approximately .2 in. below
bottom of orifice ring when centered correctly. Be sure
set screws are tightened on motor and are not on round
part of shaft.
WARNING: Failure to follow these warnings could re-
sult in serious personal injury:
1. Turn off all electrical power to the unit before per-
forming any maintenance or service on the unit.
2. Use extreme caution when removing panels and parts.
As with any mechanical equipment, personal injury
can result from sharp edges, etc.
d. Set upper orifice ring in place with 3 screws removed
in Step 1.
3. Never place anything combustible either on, or in con-
tact with, the unit.
e. Replace top access panel.
4. Should overheating occur, shut off all of the electri-
cal supply(s).
—14—
SERVICE
Inspect the condenser coil, evaporator coil, and condensate
drain pan at least once each year. Proper inspection and clean-
ing requires the removal of the unit top. See Unit Top
Removal section above.
NOTE: The following steps should be performed by a quali-
fied service person.
The coils are easily cleaned when dry; therefore, inspect and
clean the coils either before or after each cooling season.
Remove all obstructions (including weeds and shrubs) that
interfere with the airflow through the condenser coil. Straighten
bent fins with a fin comb. If coated with dirt or lint, clean the
coils with a vacuum cleaner, using a soft brush attachment.
Be careful not to bend the fins. If coated with oil or grease,
clean the coils with a mild detergent-and-water solution. Rinse
coils with clear water, using a garden hose. Be careful not to
splash water on motors, insulation, wiring, or air filter(s). For
best results, spray condenser-coil fins from inside to outside
the unit. On units with an outer and inner condenser coil, be
sure to clean between the coils. Be sure to flush all dirt and
debris from the unit base.
WARNING: Before installing or servicing unit, turn
off main power to system to avoid shock hazard or in-
jury from rotating parts. There may be more than one
disconnect switch. Turn off accessory heater power if
applicable. Electrical shock can cause personal injury
or death.
I. CLEANING
Inspect unit interior at the beginning of each heating and cool-
ing season or as operating conditions require. To inspect and
clean, the unit top must be removed.
A. Unit Top Removal
NOTE: When performing maintenance or service procedures
that require removal of the unit top, be sure to perform all of
the routine maintenance procedures that require top re-
moval, including: coil inspection and cleaning, and conden-
sate drain pan inspection and cleaning.
Inspect the drain pan and condensate drain line when
inspecting the coils. Clean the drain pan and condensate drain
by removing all foreign matter from the pan. Flush the pan
and drain tube with clear water. Do not splash water on the
insulation, motor, wiring, or air filter(s). If the drain tube is
restricted, clear it with a ‘‘plumbers snake’’ or similar probe
device. Ensure that the auxiliary drain port above the drain
tube is also clear.
Only qualified service personnel should perform mainte-
nance and service procedures that require unit top removal.
Refer to the following top removal procedures:
1. Remove 7 screws on unit top cover surface. Save all screws.
2. Remove 2 screws that secure unit top cover flange. Save
all screws.
II. EVAPORATOR FAN AND MOTOR
Refer to Care and Maintenance section for procedure.
3. Lift top from unit carefully. Set top on edge and ensure
that top is supported by unit side that is opposite duct
side.
III. CONDENSER FAN
When maintenance and/or service procedures are concluded,
carefully replace and secure unit top to unit, using screws re-
moved in Steps 1 and 2.
CAUTION: Keep the condenser fan free from all
obstructions to ensure proper cooling operation. Never
place articles on top of the unit. Damage to unit may
result.
B. Repairing Refrigerant Leaks
Proceed as follows to repair a refrigerant leak and to charge
the unit.
1. Shut off unit power supply.
1. Locate leak and ensure that refrigerant system pres-
sure has been relieved and recovered from both high-
and low-pressure ports.
2. Remove condenser-fan assembly (grille, motor, motor cover,
and fan) by removing screws and flipping assembly onto
unit top cover.
2. Repair leak following accepted practices.
3. Loosen fan hub setscrews.
4. Adjust fan height as shown in Fig. 18.
5. Tighten setscrews.
NOTE: Install a filter drier whenever the system has been
opened for repair.
3. Add a small charge of nitrogen vapor to system and leak-
test unit.
6. Replace condenser-fan assembly.
4. Evacuate refrigerant system if additional leaks are not
found.
5. Charge unit with R-22 refrigerant, using a volumetric-
charging cylinder or accurate scale. Refer to unit rating
plate for required charge. Be sure to add extra refrig-
erant to compensate for internal volume of filter drier.
NOTE: See Adjusting Refrigerant Charge on page 16.
C. Condenser Coil, Evaporator Coil, and Condensate
Drain Pan
Fig. 18 — Condenser-Fan Adjustment
WARNING: Be careful! Coil fins are sharp. Protect
hands with gloves when cleaning or handling coil.
—15—
IV. ELECTRICAL CONTROLS AND WIRING
A. Adjusting Refrigerant Charge
Inspect and check the electrical controls and wiring an-
nually. Be sure to turn off all electrical power to the unit.
Amount of refrigerant charge is listed on unit nameplate (also
refer to Table 1). Refer to Carrier Refrigerant Service Tech-
niques Manual, Refrigerants section.
Remove the control, evaporator fan, and compressor compart-
ment access panels to locate all the electrical controls and
wiring. Check all electrical connections for tightness. Tighten
all screw connections. If any smoky or burned connections are
noticed, disassemble the connection and clean all the parts.
Then restrip the wire end, and reassemble the connection prop-
erly and securely.
Unit panels must be in place when unit is operating during
charging procedure.
No Charge
Use standard evacuating techniques. After evacuating
system, weigh in the specified amount of refrigerant (refer to
Table 1).
After inspecting the electrical controls and wiring, replace all
the panels. Start the unit, and observe at least one complete
heating cycle (if accessory electric heaters are field installed
in unit) and one complete cooling cycle to ensure proper
operation. If discrepancies are observed in either or both
operating cycles, or if a suspected malfunction has occurred,
check each electrical component with the proper electrical
instrumentation. Refer to unit wiring label when performing
these checkouts.
Low Charge Cooling
Use Cooling Charging Charts, Fig. 19-24. Vary refrigerant un-
til the conditions of the appropriate chart are met. Note that
charging charts are different from the type normally used.
Charts are based on charging the units to the correct super-
heat for the various operating conditions. Accurate pressure
gage and temperature sensing device are required.
NOTE: Refer to the Cooling Sequence of Operation on
page 13 as an aid in determining proper control operation.
To measure suction pressure, perform the following:
V. INDOOR AIRFLOW
1. Connect the pressure gage to the service port on the suc-
tion line.
The airflow does not require checking unless improper per-
formance is suspected. If a problem exists, be sure that all
supply- and return-air grilles are open and free from obstruc-
tions, and that the air filter is clean. When necessary, refer
to Indoor Airflow and Airflow Adjustments section on
page 13 to check the system airflow.
2. Mount the temperature sensing device on the suction
line and insulate it so that outdoor ambient tempera-
ture does not affect the reading. Indoor-air cfm must be
within the normal operating range of the unit.
To Use Cooling Charging Charts
VI. METERING DEVICE SERVICING
1. Take the outdoor ambient temperature and read the suc-
tion pressure gage.
Refrigerant metering devices are fixed orifices and are lo-
cated in the inlet header to the evaporator coil.
2. Refer to appropriate chart to determine what the suc-
tion temperature should be.
VII. LIQUID LINE STRAINER
Strainer is made of wire mesh and is located in the liquid
line on inlet side. Remove strainer by cutting it from the liq-
uid line. Braze a new strainer into liquid line with nitrogen
gas flowing through the refrigerant system.
3. If suction temperature is high, add refrigerant. If suc-
tion temperature is low, carefully recover some of the
charge.
4. Recheck the suction pressure as charge is adjusted.
VIII. REFRIGERANT CHARGE
EXAMPLE: (Fig. 19)
Outdoor Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 F
Suction Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 psig
WARNING: Avoid contact with hot gas discharge line
to prevent a burn when working on compressor.
Suction Temperature should be . . . . . . . . . . . . . . . . . . . 70 F
(Suction Temperature may vary ± 5° F.)
CAUTION: To prevent personal injury, wear safety
glasses and gloves when handling refrigerant.
If Chargemaster charging device is used, temperature and
pressure readings must be accomplished using the charging
chart.
Do not overcharge system. An overcharge can cause com-
pressor damage.
IX. REPLACEMENT PARTS
Unit refrigerant system is factory charged. When recharging
is necessary, weigh in total charge indicated on unit name-
plate. Remove and recover any refrigerant remaining in
system before recharging. If system has lost complete charge,
evacuate system to 500 microns (29.90-in. Hg vacuum) be-
fore recharging. Schrader fitting connections are provided on
unit suction and discharge lines for evacuation and charg-
ing. Dial-a-Charge charging cylinder is an accurate device used
to charge systems by weight; these cylinders are available at
refrigeration supply firms.
A complete list of replacement parts may be obtained from
your distributor upon request.
—16—
Fig. 19 — Cooling Charging Chart — 564A/764A024
Fig. 21 — Cooling Charging Chart — 564A/764A036
Fig. 20 — Cooling Charging Chart 564A/764A030
Fig. 22 — Cooling Charging Chart — 564A/764A042
—17—
Fig. 24 — Cooling Charging Chart — 564A/764A060
Fig. 23 — Cooling Charging Chart — 564A/764A048
—18—
COOLING TROUBLESHOOTING CHART
CAUSE
SYMPTOM
REMEDY
Compressor and con-
denser fan will not
start.
Power failure
Call power company.
Fuse blown or circuit breaker tripped
Replace fuse or reset circuit breaker.
Replace component.
Defective thermostat, contactor, transformer,
or control relay
Insufficient line voltage
Incorrect or faulty wiring
Thermostat setting too high
Determine cause and correct.
Check wiring diagram and rewire correctly.
Lower thermostat setting below room temperature.
Check wiring and repair or replace.
Compressor will not
start but condenser
fan runs.
Faulty wiring or loose connections in
compressor circuit
Compressor motor burned out, seized, or
internal overload open
Determine cause. Replace compressor.
Determine cause and replace.
Defective run/start capacitor, overload, or
start relay
One leg of 3-phase power dead
Replace fuse or reset circuit breaker.
Determine cause.
Compressor cycles
(other than normally
satisfying thermostat).
Refrigerant overcharge or undercharge
Recover refrigerant, evacuate system, and recharge
to capacities shown on nameplate.
Defective compressor
Insufficient line voltage
Blocked condenser
Replace and determine cause.
Determine cause and correct.
Determine cause and correct.
Determine cause and replace.
Defective run/start capacitor, overload,
or start relay
Defective thermostat
Replace thermostat.
Faulty condenser-fan motor or capacitor
Restriction in refrigerant system
Dirty air filter
Replace.
Locate restriction and remove.
Replace filter.
Compressor operates
continuously.
Unit undersized for load
Thermostat set too low
Low refrigerant charge
Leaking valves in compressor
Air in system
Decrease load or increase unit size.
Reset thermostat.
Locate leak, repair, and recharge.
Replace compressor.
Recover refrigerant, evacuate system, and recharge.
Clean coil or remove restriction.
Replace filter.
Condenser coil dirty or restricted
Dirty air filter
Excessive head
pressure.
Dirty condenser coil
Clean coil.
Refrigerant overcharged
Air in system
Recover excess refrigerant.
Recover refrigerant, evacuate system, and recharge.
Determine cause and correct.
Check for leaks, repair and recharge.
Replace compressor.
Condenser air restricted or air short-cycling
Low refrigerant charge
Compressor valves leaking
Restriction in liquid tube
High heat load
Head pressure too low.
Remove restriction.
Excessive suction
pressure.
Check for source and eliminate.
Replace compressor.
Compressor valves leaking
Refrigerant overcharged
Dirty air filter
Recover excess refrigerant.
Replace filter.
Suction pressure too
low.
Low refrigerant charge
Metering device or low side restricted
Insufficient evaporator airflow
Check for leaks, repair, and recharge.
Remove source of restriction.
Increase air quantity. Check filter, and replace if
necessary.
Temperature too low in conditioned area
Outdoor ambient below 40 F
Reset thermostat.
Install low-ambient kit.
Replace.
Field-installed filter-drier restricted
—19—
PACKAGED SERVICE TRAINING
Our packaged service training programs provide an excellent way to increase your knowledge of the
equipment discussed in this manual. Product programs cover:
•
•
Maintenance
Operating Sequence
•
•
Unit Familiarization
Installation Overview
A large selection of product, theory, and skills programs is available. All programs include a video
cassette and/or slides and a companion booklet. Use these for self teaching or to conduct full training
sessions.
For a free Service Training Material Catalog (STM), call 1-800-962-9212. Ordering instructions are
included.
Copyright 1996 Carrier Corporation
CATALOG NO. BDP-3356-403
START-UP CHECKLIST
(Remove and Store in Job File)
I. PRELIMINARY INFORMATION
MODEL NO.:
DATE:
SERIAL NO.:
TECHNICIAN:
II. PRE-START-UP (insert checkmark in box as each item is completed)
Ⅺ VERIFY THAT ALL PACKING MATERIALS HAVE BEEN REMOVED FROM UNIT
Ⅺ VERIFY THAT CONDENSATE CONNECTION IS INSTALLED PER INSTALLATION INSTRUCTIONS
Ⅺ CHECK ALL ELECTRICAL CONNECTIONS AND TERMINALS FOR TIGHTNESS
Ⅺ VERIFY THAT UNIT INSTALLATION IS LEVEL
Ⅺ CHECK FAN WHEEL AND PROPELLER FOR LOCATION IN HOUSING/ORIFICE AND SETSCREW
TIGHTNESS
III. START-UP
ELECTRICAL
SUPPLY VOLTAGE
L1-L2
L2-L3
L2
L3-L1
L3
COMPRESSOR AMPS L1
EVAPORATOR-FAN AMPS
TEMPERATURES
OUTDOOR-AIR TEMPERATURE
RETURN-AIR TEMPERATURE
DB
DB
WB
PRESSURES
REFRIGERANT SUCTION
REFRIGERANT DISCHARGE
PSIG
PSIG
Ⅺ VERIFY REFRIGERANT CHARGE USING CHARGING TABLES
Copyright 1996 Carrier Corporation
CL-1
CATALOG NO. BDP-3356-403
|