INSTALLATION MANUAL

PPU PACKAGED UNIT

L AIR COOLED L

QUALITY FLEXIBILITY VISION

INDUSTRIES

PPU096 - 480 Single Packaged Unit Side Discharge Step 2- Protect Unit From Damage To maintain warranty, protect unit against adverse weather conditions, theft or vandalism on the jobsite. Step 3 - Provide Unit Support Refer to Table 1 for unit weight. If desired, construct a stand or frame of I-beams or angle iron that adequately supports the unit. The floor and floor joists of existing buildings may require reinforcement; follow applicable codes. Step 4 - Rig and Place Unit Provide space around unit for service, filter access and overhead clearance. Move and install unit. Refer to Fig. 4 for rigging details. Unit should be level. Refer to Fig. 2 for unit leveling tolerance. Step 5 - Field Fabricate Ductwork Connect supply and return ducts to flanges on unit using a flexible connection. Attach ductwork to building structure and insulate with fiberglass and vapor barrier to reduce sound transmission and prevent vapor condensation. Insulate and weatherproof all external ductwork, joints, and openings with counter flashing and mastic in accordance with applicable codes. Ducts passing through an unconditioned space must be insulated and covered with a vapor barrier.

Installation, Start-Up and Service Instructions

CONTENTS SAFETY CONSIDERATIONS.............................................................1 INSTALLATION..........................................................................1-8 Step 1--Receive and Inspect..............................................................1 Step 2--Protect Unit from Damage.....................................................1 Step 3--Provide Unit Support.............................................................1 Step 4--Rig and Place Unit.................................................................1 Step 5--Field Fabricate Ductwork......................................................1 Step 6--Install Condensate Drain Line and External Trap ...........................................................................................................2 Step 7--Make Electrical Connections................................................2 Step 8--Adjust Evaporator-Fan Speed...............................................4 PRE-START-UP..................................................................................9 START-UP..........................................................................................9 SERVICE..........................................................................................10 TROUBLESHOOTING.....................................................................11 APPENDIX A START-UP CHECKLIST

SAFETY CONSIDERATIONS Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical components.Only trained and qualified service personnel should install, repair or service air conditioning equipment. Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All other operations should be performed by trained personnel.When working on air conditioning equipment, observe the precautions stated in the literature, tags and labels attached to the unit and any other safety precautions that may apply. Follow all safety codes. Wear safety glasses and work gloves. Use quencher cloth for brazing and unbrazing operations. Have a fire extinguisher available during brazing operations.
WARNING! BEFORE PERFORMINGSERVICE OR MAINTENANCE OPERATIONS ON UNIT, TURN OFFMAIN POWER SWITCH TO UNIT. ELECTRICAL SHOCK COULD CAUSE PERSONALINJURY OR DEATH!

Step 1-- Receive and Inspect Unit Check unit against shipping order. Inspect carefully for concealed shipping damage. If shipping is damaged or incomplete, file claim with transportation company and advise Peake immediately.

Maximum Allowable Difference

A- B 0.5

B- C 1.0

A- C 1.0

Fig. 2 -- Unit Leveling Tolerance

Step 6--Install Condensate Drain Line and External Trap Condensate drain connections are located at both sides of the unit. All units must have an external trap for condensate drainage. Install a trap at least 4-in. deep and protect against freezeup. See Fig.3 . If drain line is installed downstream from the external trap, pitch the line away from the unit at 1 in. per 10 ft. of run. Do not use a pipe size smaller than the unit connection.

CAUTION
All panels must be in place when rigging. Step 7--Make Electrical Connections WARNING! Unit cabinet list have an uninterrupted unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. This ground may consist of electrical wire connected to unit ground lug in control compartment, or conduit approved for electrical ground when installed in accordance with NEC (National Electrical Code) ANSI (American National Standards Institute) /NFPA (National Fire Protection Association) 70-1987 and local electrical codes. Failure to follow this warning could result in the installer being liable for personal injury of others. FIELD POWER SUPPLY -- All units are factory-wired for the voltage shown on the unit nameplate. Refer to unit label diagram for additional information.

NOTE: Trap should be deep enough to offset maximum unit static difference. A 4-in. trap is recommended. Fig. 3--External Trap Condensate Drain

When installing units, provide a disconnect per the NEC. All field wiring must comply with the NEC and local requirements. In Canada, electrical connections must be made in accordance with CSA (Canadian Standards Association) C22. I Canadian Electrical Code Part One. Install field wiring as follows: 1. Install conduit through side panel openings. Install power lines to terminal connections as shown in electrical schematic, located on inside of control box cover. During operation, voltage to compressor terminals must be within range indicted on unit nameplate (see Table 2). On 3-phase units, voltages between phases must be balanced within 2 %, and the current within 10%. Use the formula shown in Table 2. Note 2 on page 6 to determine the percentage of voltage imbalance. Operation on improper line voltage or excessive phrase imbalance constitutes abuse and may cause damage to electrical components. Such operation would invalidate any applicable PEAKE warranty.

Fig. 4- Rigging Detail Notes Hook rigging shackles through holes in skids. Use wooden top skid when riging to prevent rigging straps from damaging unit.

T able 1 PH Y SICA L D AT A BASE UN IT N OM IN AL C APA C ITY (ton s) C O M PRESSOR Q TY REFRIG ERA NT TY PE O peratin g C h arge(lbs) C O ND ENSER C OILS Face A rea (sq. ft) Rows...Fin s/in . EV APORATO R C OIL Face A rea (sq. ft) Rows...Fin s/in . O UTD OO R AIR FAN S Q ty...Diam eter (in .) N om in al Cfm M otor Hp Rpm IND OO R AIR FAN S Size (in ) Q ty D rive Type N om in al Cfm M otor Pulley Pitch D iam eter A /B (in ) Fan Pulley Pitch Diam eter (in ) Belts- Qty..Type..Len gth (in ) Full Load Efficien cy % M otor Hp BASE UN IT N OM IN AL C APA C ITY (ton s) C O M PRESSOR Q TY REFRIG ERA NT TY PE O peratin g C h arge(lbs) Sys1/Sys2 C O ND ENSER C OILS Face A rea (sq. ft) Rows...Fin s/in . EV APORATO R C OIL Face A rea (sq. ft) Rows...Fin s/in . O UTD OO R AIR FAN S Q ty...Diam eter (in .) N om in al Cfm M otor Hp Rpm IND OO R AIR FAN S Size (in ) Q ty D rive Type N om in al Cfm M otor Pulley Pitch D iam eter A /B (in ) Fan Pulley Pitch Diam eter (in ) Belts- Qty..Type..Len gth (in ) Full Load Efficien cy % M otor Hp PPU096 7.5 1 16 15.9 3...14 PPU120 10 1 R-22 18 26 28 25.7 4...14 17.7 4...14 2...24 8800 1/2 1075 15.5x15 2 5800 4.3/5.3 11.4 2..B..62 84.1 3 PPU480 40 2 36/36 PPU144 12 1 PPU180 15 2

18.9 25.7 3...14 3...14 A lum in um Fin s with Copper Tubin g 7 10 17.7 3...14 4...14 3...14 Propeller 1...24 1...24 2...24 5000 6000 8800 1/2 1/2 1/2 1075 1075 1075 C en trifugal 12.12x12 15.5x15 15.5x15 1 1 2 Belt 3000 4000 4600 3.4/4.4 2.8/3.8 4.3/5.3 11.0 11.0 11.4 1..A ...50 1..A ..54 2..B..60 81.2 83.4 84.1 2 2 3 PPU240 20 2 32/32 37.2 3...14 19.7 4...12 2...24 8800 1/2 1075 15.5x15 2 8000 4.3/5.3 11.4 2..B..75 84.3 5
3

PPU300 25 2 R-22 25/25

PPU360 30 2 25/25

40.6 49.2 63.7 3...14 3...14 3...14 A lum in um Fin s with Copper Tubin g 23.6 23.1 30.2 4...14 4...12 4...14 Propeller 4...24 4...24 5...24 17500 20000 24000 1/2 1/2 1/2 1075 1075 1075 C en trifugal 15.5x15 18.62x18 18.62x18 2 2 2 Belt 10000 12000 16000 4.9/5.9 4.9/5.9 4.9/5.9 11.4 11.0 11.0 2..B..71 2..B..84 2..B..84 84.8 87.4 87.5 7.5 10 15

FIELD CONTROL WIRING -- Install a PEAKE approved accessory thermostat assembly according to installation instructions included with accessory. Locate thermostat assembly on a solid wall in the conditioned space to sense average temperature in accordance with thermostat instructions. Route thermostat cable or equivalent single leads of colored wire from subbase terminals to low voltage connections on unit (Refer to Appendix A) as described in steps 1-3 below. NOTE: For wire runs up to 50 ft, use no. 18 AWG(American Wire Gage) insulated wire(35C minimum). For 51 to 75 ft, use no. 14 AWG insulated wire(35C minimum). All wire larger than no. 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat. 1. Pass control wires through the hole provided on unit, located on condenser side corner post. 2. Feed wire into the control box to terminal block no. 2(TB2), located in control box. 3. Connect thermostat wires to terminals of the terminal block no.2. Step 8-- Adjust Evaporator Fan Speed Adjust evaporator fan speed to meet job site conditions. Table 1 shows evaporator fan motor data. Refer to Fan Performance Data (pages 7&8) to determine fan speed settings. Fan motor pulleys are factory set for speed shown in Table 1. To change fan speeds: 1. Shut off unit power supply. 2. Loosen belt by loosening fan motor mounting nuts. 3. Loosen movable pulley flange setscrew (see diagram) 4. Screw movable flange toward fixed flange to increase speed or away from fixed flange to decrease speed. Increasing fan speed increases load on motor. Do not exceed maximum speed specified in Table 1. 5. Set movable flange at nearest keyway of pulley hub and tighten setscrew. (See table 1 for speed change for each full turn of pulley flange.)

To align fan and motor pulleys: 1. Loosen fan pulley setscrews. 2. Slide fan pulley along fan shaft. 3. Make angular alignment by loosening motor from mounting plate. To adjust belt tension: 1. Loosen fan motor mounting nuts. 2. Slide motor mounting plate away from fan scroll for proper belt tension (1/2-in. deflection with one finger) and tighten mounting nuts 3. Adjust bolt and nut on mounting plate to secure motor evaporator in fixed position.

STRAIGHT EDGE MUST BE PARALLEL WITH BELT MOVABLE FLANGE

PULLEYS

MOTORS AND FAN SHAFTS MUST BE PARALLEL SET SCREWS

FIXED FLANGE SINGLE GROOVE

Fig.5 Evaporator Fan Pulley Adjustment

Tab le 2
(6 0 H z)
U N IT P P U 096 P P U 120 P P U 144 P P U 180 P P U 240 P P U 300 P P U 360 P P U 480 P P U 096 P P U 120 P P U 144 P P U 180 P P U 240 P P U 300 P P U 360 P P U 480 N O M IN A L V O LTA GE 208/230 (3-phase) 208/230 (3-phase) 208/230 (3-phase) 208/230 (3-phase) 208/230 (3-phase) 208/230 (3-phase) 208/230 (3-phase) 208/230 (3-phase) 460 (3-phase) 460 (3-phase) 460 (3-phase) 460 (3-phase) 460 (3-phase) 460 (3-phase) 460 (3-phase) 460 (3-phase) 414-506 414-506 414-506 414-506 414-506 414-506 414-506 414-506 187-254 187-254 187-254 187-254 187-254 187-254 187-254 V O LTA GE R A N GE 187-254

EL EC TR IC A L D A TA
C O M P R ESSO R R LA 25.0 34.5 41.0 50.0 69.0 82.0 135.0 177.0 12.4 17.0 17.0 24.8 34.0 34.0 67.5 88.5 LR A 185.0 239.0 269.0 370.0 478.0 538.0 565.0 856.0 89.0 119.0 119.0 178.0 238.0 238.0 283.0 856.0 O FM FLA 3.9 3.9 7.8 7.8 7.8 15.6 15.6 19.5 2.0 2.0 4.0 4.0 4.0 8.0 8.0 10.0 IFM FLA 6.4 6.4 9.0 9.0 14.4 21.0 25.0 38.0 3.2 3.2 4.5 4.5 7.2 10.5 12.5 19.0 P O W ER SU P P LY MCA 44.0 56.0 72.2 83.5 91.2 148.2 219.5 293.1 22.0 27.7 31.9 41.6 56.5 65.6 110.0 146.9 MOCP* 70 90 110 120 130 160 350 430 40 50 50 60 70 80 150 175

L E GE N D FL A IFM LRA M CA

Full Loa d A mps Indoor Fa n motor Locke d R otor A mps M inimum C ircuit A mps

LRA M CA RLA HACR NEC

Loc ke d R otor A mps M inimum C irc uit A mps R a te d Loa d A mps H e a ting, A ir-C onditioning a nd R e frige ration N a tional Ele ctric al C ode

*Fuse or H A C R c ircuit brea ke r

N O TES: 1. In complianc e w ith N EC requireme nts for miltimotor and c ombination load a nd equipme nt(re fer to N EC A rtic le s 430 and 440), the overc urre nt protec tive de vice for the unit shall be fuse or H A C R bre aker. 2. U nba lance d 3-P hase Supply V oltage N e ve r o p e ra te a mo to r w h e re a p h a se imb a la n ce in su p p ly vo lta g e is g rea ter th a n 2 % . U se the follow ing formula to de termine the pe rce ntage of voltage imbalance . % V olta ge Imba la nc e = 100 x max volta ge devia tion from avera ge voltage a ve rage volta ge

Exa mple : Supply voltage is 230 -3-60 A ve rage V olta ge = (252 + 261 + 255)/3 A B =252 V = 768/3 B C =261 V = 256 A C =255 V D e termine ma ximum de viation from a ve rage volta ge : (A B ) 256 - 252 = 4 V (B C ) 261 - 256 = 5 V (A C ) 256 - 255 = 1 V M aximum devia tion is 5 V D e termine pe rce nta ge of volta ge imbalance : % V oltage imbalance = 100 x 5/256 = 1.95 % This a mount of pha se is sa tisfac tory a s it is be low the maximum a llow able 2% IM PO R T A N T : If the s upply v o ltag e phas e im balance is m o re than 2 % c o ntact yo ur lo cal e le c tric utility co mpany imm e diate ly

Fan Pe rformance Data

P P U-0 9 6 AIRFLOW (Cfm ) 2000 2250 2500 2700 3000 3200 3500 3750 4000 0 .2 Rpm 500 511 555 581 629 663 713 755 796 EXTERNAL STATIC P RESSURE (in.wg) 0 .6 1 .0 1 .4 Rpm Bhp Rpm Bhp Rpm 770 1 .3 8 884 650 0 .9 2 659 0 .9 5 778 1 .4 3 885 690 1 .1 4 806 1 .6 4 904 717 1 .3 1 828 1 .8 3 925 760 1 .5 9 864 2 .1 5 960 786 1 .8 0 887 2 .4 1 980 825 2 .1 4 928 2 .8 4 1014 864 2 .4 9 964 3 .2 3 864 2 .4 9 1 .8 Rpm 910 947 1004 1012 1040 -

Bhp 0 .5 0 0 .5 2 0 .6 7 0 .8 1 1 .0 6 1 .2 5 1 .5 7 1 .8 9 2 .2 3

Bhp 1 .9 5 1 .9 7 2 .1 8 2 .4 2 2 .7 8 3 .0 4 3 .4 8 -

Bhp 2 .6 4 2 .6 6 2 .8 4 3 .0 1 3 .4 1 -

P P U-1 2 0 AIRFLOW (Cfm ) 3000 3200 3500 3700 4000 4300 4500 4700 5000 P P U-1 4 4 ,1 8 0 AIRFLOW (Cfm ) 3700 4000 4300 4500 4700 5000 5200 5500 5800 P P U-2 4 0 AIRFLOW (Cfm ) 6000 7000 8000 9000 10000

0 .2 Rpm 532 558 597 622 662 702 728 756 797

Bhp 0 .6 4 0 .7 5 0 .9 4 1 .0 9 1 .3 3 1 .6 1 1 .8 3 2 .0 6 2 .4 4

EXTERNAL STATIC P RESSURE (in.wg) 0 .6 1 .0 1 .4 Rpm Bhp Rpm Bhp Rpm 778 1 .2 8 874 670 0 .9 7 692 1 .1 0 798 1 .4 4 888 722 1 .3 3 826 1 .7 1 915 745 1 .5 0 846 1 .9 1 935 778 1 .7 8 879 2 .2 2 960 815 2 .1 1 908 2 .5 8 994 836 2 .3 5 930 2 .8 5 1017 862 2 .6 1 952 3 .1 2 899 3 .0 4 EXTERNAL STATIC P RESSURE (in.wg) 0 .6 1 .0 1 .4 Rpm Bhp Rpm Bhp Rpm 952 768 1 .5 0 860 1 .8 5 978 805 1 .8 0 895 2 .1 6 931 2 .5 4 1012 847 2 .1 2 956 2 .8 2 1034 872 2 .3 7 982 3 .1 1 1056 899 2 .6 3 938 3 .0 8 1020 3 .6 0 1092 962 3 .4 0 1046 3 .9 3 1116 1005 3 .9 2 1084 4 .4 7 1152 1045 4 .5 0 1124 5 .0 7 1191 EXTERNAL STATIC P RESSURE (in.wg) 0 .6 1 .0 1 .4 Rpm Bhp Rpm Bhp Rpm 835 2 .9 0 902 759 2 .4 0 836 3 .3 0 920 3 .8 0 993 902 4 .5 0 992 5 .0 0 1072 968 5 .8 0 1 0 6 4 .8 6 .5 1150 1023 7 .6 1 1 2 5 .3 8 .6 1 2 1 5 .3
7

Bhp 1 .6 0 1 .7 7 2 .0 7 2 .2 8 2 .6 3 3 .0 5 3 .3 3 -

1 .8 Rpm 974 988 998 1013 1043 1069 -

Bhp 2 .1 1 2 .1 8 2 .4 3 2 .6 7 3 .0 6 3 .4 8 -

0 .2 Rpm 654 697 740 770 800 843 873 918 963

Bhp 1 .1 2 1 .3 7 1 .6 6 1 .8 9 2 .1 3 2 .5 2 2 .8 2 3 .3 0 3 .8 3

Bhp 2 .2 7 2 .6 2 2 .9 7 3 .2 3 3 .5 2 4 .0 5 4 .4 2 5 .0 3 5 .6 9

1 .8 Rpm 1031 1060 1088 1108 1129 1162 1183 1217 -

Bhp 2 .6 5 3 .0 4 3 .4 6 3 .7 6 4 .0 7 4 .5 3 4 .8 8 5 .5 1 -

0 .2 Rpm 690 760 820 880 930

Bhp 1 .8 0 2 .7 0 3 .8 0 5 .2 0 6 .7

Bhp 3 .6 0 4 .5 0 5 .7 0 7 .6 9 .6

1 .8 Rpm 974 1073 1 1 5 7 .3 1242 1 3 1 2 .5

Bhp 4 .0 0 5 .2 0 6 .6 8 .6 1 0 .5

P P U-300 AIRFLOW (Cfm) 7 00 0 8 00 0 9 00 0 100 00

11000

0.2 Rpm 58 8 64 5 70 0 75 0 80 0

Bhp 2 .3 0 3 .1 0 4 .4 0 5 .7 0 7 .0 0

EXTERNAL STATIC P RESSURE (in.wg) 0 .6 1.0 1.4 Rpm Bhp Rpm Bhp Rpm 819 6 64 2.80 73 8 3 .3 0 80 9 4 .5 0 898 7 29 3.80 87 8 5 .6 0 975 7 91 4.90 8 48 6.30 94 1 7 .2 0 10 44.2 9 04 8.00 1 00 3.4 9 11 13.8

Bhp 3 .9 0 5 .0 0 6 .2 0 8.4 10

1 .8 Rpm 8 84 9 70 105 3 112 7.7 120 2.9

Bhp 4.60 5.70 7.20 9 .6 11 .1

P P U-360 AIRFLOW (Cfm) 8 00 0 9 00 0 100 00

11000 12000

0.2 Rpm 66 7 72 0 77 2 82 3 87 0

Bhp 2 .8 0 3 .5 0 4 .9 0 6 .1 0 7.3

EXTERNAL STATIC P RESSURE (in.wg) 0 .6 1.0 1.4 Rpm Bhp Rpm Bhp Rpm 7 40 3.20 82 2 3 .8 0 879 7 99 4.20 88 7 4 .8 0 949 8 57 5.40 95 1 6 .1 0 10 18 9 14 6.70 1 014 7.7 10 85 9 65 .7 8.5 1 07 1.9 9.4 11 47 EXTERNAL STATIC P RESSURE (in.wg) 0 .6 1.0 1.4 Rpm Bhp Rpm Bhp Rpm 888 7 48 2.27 83 0 2 .7 7 958 8 07 2.98 89 6 3 .5 0 8 65 3.83 96 1 4 .4 5 10 27 9 23 4.76 1 024 5 .6 2 10 95 9 75 6.04 1 083 6 .8 6 11 57.7

4.20
5 .4 0 6 .6 0 8.9 1 0.4

Bhp

1 .8 Rpm 9 41 101 6 108 9 116 0.9 122 7.2

Bhp 5.00 6.10 7 .6 10 .1 11 .5

P P U-480 AIRFLOW (Cfm) 120 00 130 00

14000 15000 16000

0.2 Rpm 68 7 74 2 79 5 84 8 89 6

Bhp 2 .0 2 2 .5 2 3 .5 3 4 .3 9 5 .2 6

Bhp 2 .9 8 3 .8 3 4 .6 9 6 .3 2 7 .3 84

1 .8 Rpm 9 50 102 5 109 9 117 1.8 123 8.7

Bhp 3.65 4.45 5.55 7.37 3 8.39 5

LEG END Bhp - Brake Horsepower Rpm - Revolutions per minute NOTES: 1. Boldface indicates field-supplied drive required. 2. Shading indicates alternate moto r required. 3. Shading indicates field-supplied motor and drive required. 4. Use of a field-supplied mo to r may affect wire sizing. Co ntact your P eake dealer to verify. 5. Values include lo sses for filters, unit casing and wet coils. 6. Conversion - Bhp to W atts Bhp x .746 W atts = M otor Efficiency See P hysical Data Tables for motor efficiency.

PRE-START-UP WARNING! Failure to observe the following warnings could result in serious personal injury: 1. Follow recognized safety practices and wear protective goggles when checking or servicing refrigerant system. 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 are disconnected. 4. Relieve all pressure from system before touching or disturbing anything inside terminal box if refrigerant leak is suspected around compressor terminals. Use accepted methods to recover refrigerant. 5. Never attempt to repair soldered connection while refrigerant system is under pressure. 6. Do not use torch to remove any component. System contains oil and refrigerant under pressure. To remove a component, wear protective goggles and proceed as follows: a. b. c. d. Shut off electrical power to unit. Relieve all pressure from system using both high and lowpressure ports. Use accepted methods to recover refrigerant. Cut component connection tubing with tubing cutter, and remove component from unit. Carefully unsweat remaining tubing stubs when necessary. Oil can ignite when exposed to torch flame . d Make sure that all tools and miscellaneous loose parts have been removed.

START-UP Unit Preparation -- Make sure that unit has been installed in accordance with these installation instructions and applicable codes. Return-Air Filters-- Make sure correct filters are field installed in unit. Do not operate unit without return-air filters. Compressor Mounting-- Compressors are internally spring mounted. Do not loosen or remove compressor holddown bolts. Internal Wiring -- Check all electrical connections in unit control boxes; tighten as required. Refrigerant Service Ports -- Each refrigerant system has 2 Schrader-type service gage ports: one on the suction line, one on the liquid line. Be sure that caps on the ports are tight. Cooling-- To start unit, turn on main power supply. Set system selector switch at COOL position and fan switch at AUTO position. Adjust thermostaht to a setting below room temperature. Compressor starts on closure of contactor. Reset thermostat at a position above room temperature. Compressor will shut off. TO SHUT OFF UNIT-- Set system selector switch at OFF position. Resetting thermostat to a position above room temperature shuts unit off temporarily until space temperature exceeds thermostat setting. Compressor restart is accomplished by manual reset at the thermostat by turning the selector switch to OFF position and then ON position. Ventilation (Continuous Fan)-- Set fan and system selector switches at ON and OFF positions, respectively. Evaporator fan operates continuously to provide constant air circulation. Operating Sequence COOLING UNITS -- When the thermostat call for cooling, terminals R and Y1 are energized. The indoor (evaporator) fan contactor (IFC), and compressor contactor no.1 (CCI) are energized and the evaporator-fan motor, compressor and condenser fan start. The condenser-fan motor runs continuously while unit is cooling. If the thermostat calls for a second stage of cooling by energizing Y2, compressor contactor no.2 (CC2) is energized and compressor becomes fully loaded.

Proceed as follows to inspect and prepare the unit for initial startup: 1. 2. 3. Remove all access panels. Read and follow instructions on all WARNING, CAUTION, and INFORMATION labels attached to or shipped with unit. Make the following inspections: a. Inspect for shipping and handling damages such as broken lines, loose parts, or disconnected wires. 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 connections rising electronic leak detector, halide torch, or liquid-soap solution. 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 handling, carefully straighten fins with a fin comb. Verify the following conditions: a Make sure that outdoor-fan blades are correctly positioned in fin orifice. b Make sure that air filter(s) is in place. c Make sure that condensate drain trip is filled with water to ensure proper drainage.

4.

SERVICE CAUTION ! When servicing unit, shut off all electrical power to unit avoid shock hazard or injury from rotating parts. Cleaning-- Inspect unit interior at the beginning of cooling season or as operating conditions require. EVAPORATOR COIL 1. Turn unit power off. Remove evaporator coil access panel. 2. Remove filters, if present. 3. Clean coil using a commercial coil cleaner or dishwasher detergent in a pressurized spray canister. Wash both sides of coil and flush with clean water. For best results, backflush toward return-air section to remove foreign material. 4. Flush condensate pan after completion. 5. Reinstall filters. 6. Reconnect wiring. 7. Replace access panels. CONDENSER COILS-- Inspect coils monthly. Clean condenser coils annually, and as required by location and outdoor air conditions. Clean coils as follows: 1. Turn off unit power. 2. Remove top panel screws on condenser end of unit. 3. Remove condenser coil corner post and plastic mesh. To hold top panel open, place coil corner post between top panel and center post. (See Fig. 6) 4. Use a water hose or other suitable equipment to flush down between the coil sections to remove dirt and debris. Clean the outer surfaces with a stiff brush in the normal manner. 5. Reposition the outer coil section, and remove the coil corner post from between the top panel and centre post. Secure the sections together. Install the coil corner post, coil side panels and replace all screws. CONDENSATE DRAIN-- Check and clean each year at start of cooling season. In winter, keep drain dry or protect against freezeup. FILTERS-- Clean or replace at start of each cooling season, or more often if operating conditions require it. Replacement filters must be same dimensions as original filters. Lubrication COMPRESSORS-- Each compressor is charged with correct amount of oil at the factory. FAN MOTOR BEARINGS-- Lubricate condenser fan motors every six months with SAE 20 oil. Condenser Fan Adjustment 1. Shut off unit power supply. 2. Remove grille, and loosen fan hub setscrew. 10

3. Adjust fan height 4. Tighten setscrew and replace condenser-fan grille. Refrigerant Charge-- Amount of refrigerant charge is listed on unit nameplate (also refer to Table 1). Unit panels must be in place when unit is operating during charging procedure. NO CHARGE -- Use standard evacuating techniques. After evacuating eystem, weigh in the specified amount of refrigerant (refer to Table 1).

Fig. 6 -- Cleaning Condenser Coil

TROUBLESHOOTING
P ROBLEM CAUSE Power failure Fuse blown or circuit breaker tripped Defective thermostat, contactor, transformer or control relay Insufficient line voltage Incorrect or faulty wiring Thermostats setting to high High pressure switch tripped Low pressure switch tripped REMEDY Call power company Replace fuse or circuit breaker Replace component Determine cause and correct Check wiring diagram and rewire correctly Lower thermostat setting below room temperature See problem 'Excessive head pressure' Check wiring diagram and rewire correctly Check wiring and repair or replace Determine cause, replace compressor Determine cause and replace Replace fuse or reset circuit breaker. Determine cause Reclaim refrigerant, evacuate system, and recharge to nameplate Replace and determine cause Determine cause and correct Determine cause and correct Determine cause and replace Replace thermostat Replace Locate restriction and remove Replace filter Decrease load or increase unit size Reset thermostat Locate leak, repair and recharge Replace compressor Reclaim refrigerant, evacuate system, and recharge to nameplate Clean coil or remove restriction Replace filter Clean coil Remove excess refrigerant Reclaim refrigerant, evacuate system, and recharge to nameplate Determine cause and correct Check for leaks, repair and recharge Replace compressor Reclaim excess refrigerant Check for leaks, repair and recharge Replace compressor Reclaim excess refrigerant Replace filter Check for leaks, repair and recharge Remove source of restriction Increase air quantity. Check filter and replace if necessary Reset thermostat Replace

Compressor and condenser fan will not start

Faulty wiring or loose connections in compressor circuit Compressor will not start Compressor motor burned out, seized, or internal overload open but condenser fan run Defective run/start capacitor, overload, or start relay One leg of three phase power dead Refrigerant overcharge or undercharge Defective compressor Insufficient line voltage Blocked condenser Defective run/start capacitor, overload, or start relay Defective thermostat Faulty condenser fan motor or capacitor Restriction in refrigerant system Dirty air filter Unit undersized for load Thermostat set to high Low refrigerant charge Leaking valves in compressor Air in system Condenser coil dirty or restricted Dirty air filter Dirty condenser coil Refrigerant overcharged Air in system Condenser air restricted or air short-cycling Low refrigerant charge Compressor valves leaking Refrigerant overcharged High heat load Compressor valves leaking Refrigerant overcharged Dirty air filter Low refrigerant charge Metering device or low side restricted Insufficient evaporator airflow Temperature too low in conditioned area Field installed filter drier restricted

Compressor cycles (other than normally satisfying thermostat)

Compressor operates continuously

Excessive head pressure

Head pressure too low Excessive suction pressure

Static pressure too low

11

(Remove and Store in Job File) TECHNICIAN: JOB NAME: JOB LOCATION: DATE: JOB NO.: MAKE:

START-UP CHECKLIST

MODEL NO: PRE-START-UP (Check box as each item is completed)

SERIAL NO:

Verify that condensate connection is installed per installation instructions Check all electrical connections and teminals for tightness Check that indoor filters are clean and in place Verify that unit installation is level Check fan wheel and propeller for location in housing/orifice and set screw tightness Check pulley alignment and belt tension per installation instruction START-UP COMPRESSOR SUCTION PRESSURE MOTOR AMPS COIL PRESSURE DISCHARGE LINE TEMP CONDENSER/AIR COOLED TEMPERATURE IN FAN MOTOR AMPS SIGHT GLASS EVAPORATOR/AIR COOLED TEMPERATURE IN FAN MOTOR AMPS TEMPERATURE OUT VOLTS TEMPERATURE OUT VOLTS LIQUID LINE TEMP DISCHARGE PRESSURE VOLTS UNLOADER SET POINT

TIME OF DAY WEATHER

________________________________ SUNNY CLOUDY RAINY

12

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