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BLD2021-1395_Manufacturer_Specifications_and_Installation_Instructions_10.8.2021_12.10.09_PM_2452683IENNOX Service Literature R INSTALLATION AND SERVICE PROCEDURE Corp. 1502-1-7 M L 14XC 1 September, 2018 ML14XC1 (HFC-410A) SERIES UNITS WITH ALL -ALUMINUM COIL This literature is intended as a general guide and does not supersede local codes in any way. Consult authorities who have jurisdiction before installation. A IMPORTANT This unit must be matched with an indoor coil as specified in Lennox Engineering Handbook. Coils previously charged with HCFC-22 must be flushed. TABLE OF CONTENTS Model Number Identification ...................... 2 Typical Serial Number Identification .............. 2 Specifications ................................. 2 Electrical Data ................................ 3 Unit Dimensions ................................. 3 Typical Unit Parts Arrangement ................... 4 Component Specifications ........................ 5 Refrigerant Metering Devices - Indoor Coil .......... 5 Operating Manifold Gauge Set and Service Valves ... 5 Unit Placement .................................. 7 Removing and Installing Louvers .................. 8 New or Replacement Line Set ..................... 9 Brazing Connections ........................... 11 Flushing Line Set and Indoor Coil ................ 14 Installing Indoor Metering Device ................ 15 Leak Test Line Set and Indoor Coil ............... 16 Evacuating Line Set and Indoor Coil ............. 17 Electrical Connections .......................... 18 System Operation .............................. 22 Maintenance ................................... 22 Start -Up and Performance Checklist .............. 23 Typical Field Wiring ............................. 24 Servicing Unit Void of Charge .................... 26 Unit Start -Up .................................. 26 System Refrigerant ............................. 26 ML14XC1 Air Conditioners, which will be referred to in this instruction as the outdoor unit, uses HFC-410A refrigerant. This outdoor unit must be installed with a matching indoor unit and line set as outlined in the Lennox ML14XC1 Engineering Handbook. This outdoor unit is designed for use in systems that use one of the following refrigerant metering devices: • Thermal expansion valve (TXV) • Fixed orifice IMPORTANT : Special procedures are required for cleaning the aluminum coil in this unit. See page 22 in this manual for information. Page 1 Model Number Identification ML 14 X C 1 Product Tier ML = Merit® Series Nominal SEER Refrigerant X = R-410A Unit Type C = Air Conditioner Cooling Stages 1 = Single Stage Compressor Regional Standards — (dash) = All Regions or Southwest Region (dependent on size) S = North and South Regions Typical Serial Number Identification 036 230 A 01 Minor Revision Number Ratings Revision Level Voltage 230 = 208/230V-1 phase-60hz Nominal Cooling Capacity - Tons 018 = 1.5 024 = 2 030 = 2.5 036 = 3 041 = 3.5 042 = 3.5 047=4 048=4 059 = 5 060 = 5 19 09 C 05716 Location Code 19 = Saltillo, Mexico 58 = Marshalltown, IA 5 (or 6) Digit Unique Number Year Code Month Code 08 = 2008 A = January 09 = 2009 B = February 10 = 2010 C = March Specifications Unit Outdoor Fan Model Numbers Sound Ratin Number Factory Refri erant Number Blades Diameter (dB)� Charge of -inches. ML14XC1-018 73 4 lbs. 9 oz. 3 18 ML14XC1 S018 ML14XC1-024 76 4 lbs. 9 oz. 3 22 ML14XClS024 ML14XC1-030 76 5 lbs. 8 oz. 3 22 ML14XClS030 ML14XC1-036 76.5 71bs. 1 oz. 3 22 ML14XClS036 ML14XC1-041 74 9 lbs. 0 oz. 3 22 ML14XC1-042 76 8 lbs. 12 oz. 3 22 ML14XClSO42 ML14XC1-047 80 11 lbs. 0 oz. 4 26 ML14XC1-048 78 9 lbs. 12 oz. 4 22 ML14XC1-059 77 11 lbs. 13 oz. 4 26 ML14XC1-060 80 12 lbs. 0 oz. 4 26 1 Tested according to AHRI Standard 270-2008 test conditions. 2 Refrigerant charge sufficient for 15 feet length of refrigerant lines. Page 2 Electrical Data 208/230V - 60 Hz - 1 ph Unit Compressor Condenser Fan Maximum Model Numbers Over- Minimum Rated Load Locked Ro- Nominal Full Load Locked Ro- current Circuity Amps (RLA) for Amps Motor HP RPM Amps (FLA) for Amps Protection Ampacity2 (LRA) (LRA) (amps)1 ML14XC1-018 ML14XC1 S018 20 11.9 9.0 48.0 1/10 1075 0.7 1.3 ML14XC1-024 ML14XC1S024 25 14.6 10.9 59.3 1/6 825 1.0 1.9 ML14XC1-030 ML14XClS030 25 17.0 12.8 67.8 1/6 825 1.0 1.9 ML14XC1-036 ML14XC1S036 30 18.0 13.6 79.0 1/6 825 1.0 1.9 ML14XC1-041 30 19.3 14.7 75.0 1/6 825 1.0 1.9 ML14XC1-042 ML14XClSO42 40 23.4 17.9 112.0 1/6 825 1.0 1.9 ML14XC1-047 35 21.9 16.1 105.5 1/3 825 1.8 2.9 ML14XC1-048 40 24.2 18.0 117.0 1/4 825 1.7 3.2 ML14XC1-059 45 28.8 20.8 127.1 1/3 820 2.8 --- ML14XC1-060 50 29.6 22.2 127.9 1/3 825 1.8 2.9 1 HACR type circuit breaker or fuse. 2 Refer to National or Canadian Electrical Code manual to determine wire, fuse and disconnect size requirements. Unit Dimensions - Inches (mil i4oNIP OUTDOOR COIL FA COMPRESS1 SUCTION AND LIQUII LINE CONNECTIOI OPTIONAL UNIT STANDOFF KIT (4) (FIELD INSTALLED) SIDE VIEW A tDISCHARGE AIR SIDE VIEW Model A B -018 24-1/4 (616) 29-1/4 (743) -024 28-1/4 (724) 29-1/4 (743) -030 28-1/4 (724) 37-1/4 (946) -036 28-1/4 (724) 37-1/4 (946) -041 28-1/4 (724) 37-1/4 (946) -042 28-1/4 (724) 33-1/4 (845) -047 32-1/4 (819) 33-1/4 (845) -048 28-1/4 (724) 37-1/4 (946) -059 32-1/4 (819) 37-1/4 (946) -060 132-1/4 (819) 133-1/4 (845) Page 3 ML14XC1 SERIES Typical Unit Parts Arrangement GROUND LUG CONTACTOR 1-POLE (K1-1) HIGH PRESSU SWITCH (S4) LIQUID LINT SERVICE VALV LIQUID 1-I1' SERVICE VAU POF FIELD CONNECTION FOR LIQUID LINE SET FIELD CONNECTION FOR SUCTION LINE CONTROL BOX LINE ALVE PORT \ SUCTION LINE SERVICE VALVE TYPICAL PLUMBING (COPELAND COMPRESSOR) HIGH PRESSUI SWITCH (S4) LIQUID LIN SERVICE VALE LIQUID LIN SERVICE VALb POF FIELD CONN /FOR LIQUIDUID LINE SET FIELD CONNECTION FOR SUCTION LINE Figure 1. Typical Parts Arrangement CAPACITOR (C12) SUCTION LINE ERVICE VALVE PORT _INE SERVICE VALVE TYPICAL PLUMBING (LG COMPRESSOR) Page 4 Component Specifications Table 1. Service Valve Sizes and Refrigerant Line Set Recommendations Service Valve Sizes Recommended Line Set Model Liquid Line Suction Line Liquid Line Suction Line L15 Series Line Sets -018, -024, -030 3/8 in. (10 mm) 3/4 in. (19 mm) 3/8 in. (10 mm) 3/4 in. (19 mm) L15-41 — 15 feet to 50 feet (4.6 meters to 15 meters) -036, -041, -042, -047, -048 3/8 in. (10 mm) 7/8 in. (22 mm) 3/8 in. (10 mm) 7/8 in. (22 mm) L15-65 — 15 feet to 50 feet (4.6 meters to 15 meters) -059, -060 3/8 in. (10 mm) 1-1/8 in. (22 mm) 3/8 in. (10 mm) 1-1/8 in. (22 mm) NOTE — Some applications may require a field provided 7/8" to 1-1/8" adapter Refrigerant Metering Device - Indoor Coil FIXED ORIFICE (RFC) METERING The following table lists the indoor coil orifice sizes required for the specific outdoor unit listed. Refer to any of the publications listed in this section to obtain the required catalog number for a specific orifice size. Table 2. Fixed Orifice Sizes Model -018 Orifice Size .052 .060 -024 -030 .060 -036 .071 -042 .081 -048 .083 -060 .096 EXPANSION VALVE (TXV) METERING This unit is also compatible with systems that use an expansion valve. Refer to any of the publications listed below to obtain the required catalog number for a specific expansion valve. • Lennox ML14XC1 Product Specification (EHB) • Lennox Product Catalog Operating Manifold Gauge Set and Service Valves These instructions are intended as a general guide and do not supersede local codes in any way. Consult authorities who have jurisdiction before installation. TORQUE REQUIREMENTS When servicing or repairing heating, ventilating, and air conditioning components, ensure the fasteners are appropriately tightened. Table 3 lists torque values for fasteners. To prevent stripping of the various caps used, the appropriately sized wrench should be used and fitted snugly over the cap before tightening. When servicing or repairing HVAC components, ensure the fasteners are appropriately tightened. Table 3 provides torque values for fasteners. Table 3. Torque Requirements Parts Recommended Torque Service valve cap 8 ft.- lb. 11 NM Sheet metal screws 16 in.- lb. 2 NM Machine screws #10 28 in.- lb. 3 NM Compressor bolts 90 in.- lb. 10 NM Gauge port seal cap 8 ft.- lb. 11 NM USING MANIFOLD GAUGE SET When checking the system charge, only use a manifold gauge set that features low loss anti -blow back fittings. Manifold gauge set used with HFC-410A refrigerant systems must be capable of handling the higher system operating pressures. The gauges should be rated for use with pressures of 0 - 800 psig on the high side and a low side of 30" vacuum to 250 psig with dampened speed to 500 psi. Gauge hoses must be rated for use at up to 800 psig of pressure with a 4000 psig burst rating. OPERATING SERVICE VALVES The liquid and vapor line service valves are used for removing refrigerant, flushing, leak testing, evacuating, checking charge and charging. Each valve is equipped with a service port which has a factory -installed valve stem. Figure 2 provides information on how to access and operating both angle and ball service valves. Page 5 ML14XC1 SERIES SERVICE VALVES ANGLE AND BALL Operating Angle Type Service Valve: 1. Remove stem cap with an appropriately sized wrench. 2. Use a service wrench with a hex -head extension (3/16" for liquid line valve sizes and 5/16" for vapor line valve sizes) to back the stem out counterclockwise as far as it will go. / SERVICE PORT CAP SERVICE PORT CORE (VALVE STEM SHOWN TO INDOOR CLOSED) INSERT HEX UNIT (VALVE STEM SHOWN OPEN) WRENCH HERE INSERT HEX WRENCH HERE SERVICE PORT STEM CAP CORE TO OUTDOOR UNIT ANGLE -TYPE SERVICE VALVE ANGLE -TYPE SERVICE VALVE (FRONT -SEATED CLOSED) (BACK -SEATED OPENED) When service valve is OPEN, the service port is open to line When service valve is CLOSED, the service port is open to the line set, indoor and outdoor unit. set and indoor unit. Operating Ball Type Service Valve: To Access Service Port: A service port cap protects the service port core from contamination and 1. Remove stem cap with an appropriately sized wrench. serves as the primary leak seal. 2. Use an appropriately sized wrenched to open. To open valve, 1. Remove service port cap with an appropriately sized wrench. rotate stem counterclockwise 90°. To close rotate stem clockwise 90°. 2. Connect gauge set to service port. 3. When testing is completed, replace service port cap and tighten as follows: TO INDOOR UNIT To open rotate stem counterclockwise 90°. TURN torque cap per table 3. • With torque wrench: Finger tighten and610- Without torque wrench: Finger tighten and To1/6 close rotate stem / BALL (SHOWNCLOSED) use an appropriately sized wrench to turn clockwise 90°. o an additional 1/6 turn clockwise. VALVE STEM Reinstall Stem Cap: Stem cap protects the valve stem from damage and serves as the SERVICE PORT primary seal. Replace the stem cap and tighten as follows: 1/12 TURN SERVICE PORT • With Torque Wrench: Finger tighten and then _�/ CORE torque cap per table 3. 2 SERVICE PORT 1 2 • Without Torque Wrench: Finger tighten andCAP 1 O 1 use an appropriately sized wrench to turn an 9 3 TO OUTDOOR STEM CAP additional 1/12 turn clockwise. g 4 UNIT % 6 5 NOTE — A label with specific torque requirements may be affixed to the stem cap. If the label is present, use the specified torque. Figure 2. Angle and Ball Service Valves Page 6 F See NOTE See NOTES See OTES TROL See NOTES BOX / NOTES: Service clearance of 30 in. (762 mm) must be maintained on one of the sides adjacent to the control box. Clearance to one of the other three sides must be 36 in. (914 mm) Clearance to one of the remaining two sides may be 12 in. (305 mm) and the final side may be 6 in. (152 mm). A clearance of 24 in. must be maintained between two units. 48 in. (1219 mm) clearance required on top of unit. NOTICE: Specific applications may require adjustment of the listed installation clearances to provide protection for the unit from physical damage or to avoid conditions which limit operating efficiency. (Example: Clearances may have to be increased to prevent snow or ice from falling on the top of the unit. Additional clearances may also be required to prevent air recirculation when the unit is installed under a deck or in another tight space.) DETAIL A Figure 3. Installation Clearances INSTALL UNIT AWAY FROM WINDOWS \ I I WO 9U° ELt30WS INS IALLED IN LINE SET WILL REDUCE LINE SET VIBRATION A CAUTION DETAIL B Install unit level or, if on a slope, maintain slope tolerance of 2 degrees (or 2 inches per 5 feet [50 mm per 1.5 m]) away from building structure. Figure 4. Placement, and Slab Mounting Unit Placement See Unit Dimensions on page 3 for sizing mounting slab, platforms or supports. Refer to figure 3 for mandatory installation clearance requirements. A CAUTION objects.In order to avoid injury, take proper precaution when lifting heavy DISCHARGE AIR MOUNTING SLAB GROUND LEVEL POSITIONING CONSIDERATIONS Consider the following when positioning the unit: • Some localities are adopting sound ordinances based on the unit's sound level registered from the adjacent property, not from the installation property. Install the unit as far as possible from the property line. • When possible, do not install the unit directly outside a window. Glass has a very high level of sound transmission. For proper placement of unit in relation to a window see the provided illustration in figure 4, detail A. Page 7 ML14XC1 SERIES Roof Damage! This system contains both refrigerant and oil. Some rubber roofing material may absorb oil and cause the rubber to swell when it comes into contact with oil. The rubber will then bubble and could cause leaks. Protect the roof surface to avoid exposure to refrigerant and oil during service and installation. Failure to follow this notice could result in damage to roof surface. WARNING To prevent personal injury, or damage to panels, unit or structure, be sure to observe the following: While installing or servicing this unit, carefully stow all removed panels out of the way, so that the panels will not cause injury to personnel, nor cause damage to objects or structures nearby, nor will the panels be subjected to damage (e.g., being bent or scratched). While handling or stowing the panels, consider any weather conditions, especially windy conditions, that may cause panels to be blown around and battered. New or Replacement Line Set This section provides information on new installation or replacement of existing line set. If a new or replacement line set is not required, then proceed to Brazing Connections on page 11. Field refrigerant piping consists of liquid and suction lines from the outdoor unit (braze connections) to the indoor unit coil (flare or braze connections). Use Lennox L15 (braze, non -flare) series line set, or use field -fabricated refrigerant lines as listed in table 1. NOTE - When installing refrigerant lines longer than 50 feet, see the Lennox Refrigerant Piping Design and Fabrication Guidelines, CORP. 9351-L9, or contact Lennox Technical Support Product Applications for assistance. To obtain the correct information from Lennox, be sure to communicate the following points: • Model (ML14XC1) and size of unit (e.g. -060). • Line set diameters for the unit being installed as listed in table 1 and total length of installation. • Number of elbows and if there is a rise or drop of the piping. If refrigerant lines are routed through a wall, seal and isolate the opening so vibration is not transmitted to the building. Pay close attention to line set isolation during installation of any HVAC system. When properly isolated from building structures (walls, ceilings. floors), the refrigerant lines will not create unnecessary vibration and subsequent sounds. A IMPORTANT Mineral oils are not compatible with HFC-410A If oil must be added, it must be a Polyol ester oil. The compressor is charged with sufficient Polyol ester oil for line set lengths up to 50 feet. Recommend adding oil to system based on the amount of refrigerant charge in the system. No need to add oil in a system with 20 pounds of refrigerant or less. For systems over 20 pounds - add one ounce for every five pounds of refrigerant over 20 pounds. Recommended topping -off POE oils are Mobil EAL ARCTIC 22 CC or ICI EMKARATE rM RL32CF. MATCHING WITH NEW OR EXISTING INDOOR COIL AND LINE SET The RFC1-metering line consisted of a small bore copper line that ran from condenser to evaporator coil. Refrigerant was metered into the evaporator by utilizing temperature/pressure evaporation effects on refrigerant in the small RFC line. The length and bore of the RFC line corresponded to the size of cooling unit. If the ML14XCl is being used with either a new or existing indoor coil which is equipped with a liquid line which served as a metering device (RFCI), the liquid line must be replaced prior to the installation of the ML14XCl unit. Typically a liquid line used to meter flow is 1 /4" in diameter and copper. LIQUID LINE FILTER DRIER INSTALLATION The filter drier (one is shipped with each ML14XCl unit) must be field installed in the liquid line between the outdoor unit's liquid line service valve and the indoor coil's metering device (fixed orifice or expansion valve) as illustrated in figure 6. This filter drier must be installed to ensure a clean, moisture -free system. Failure to install the filter drier will void the warranty. A replacement filter drier is available from Lennox. See Brazing Connections on page for special procedures on brazing filter drier connections to the liquid line. BRAZE CONNECTION POINTS FLOW P LIQUID LINE LINE LIQUID SERVICE VALVE LINE LIQUID LINE FILTER DRIER OUTDOOR UNIT Figure 6. Typical Liquid Line Filter Drier Installation Page 9 ML14XCl SERIES Ll 'SET INSTALLATION Line Set Isolation — The following illustrations are examples of proper refrigerant line set isolation: REFRIGERANT LINE SET — TRANSITION FROM VERTICAL TO HORIZONTAL ANCHORED HEAVY NYLON WIRE TIE OR AUTOMOTIVE AUTOMOTIVE MUFFLER -TYPE HANGER MUFFLER -TYPE HANGER WALL STUD NON -CORROSIVE METAL SLEEVE iY STRAP LIQUID LINE TO VAPOR LINE LIQUID LINE VAPOR LINE - WRAPPED IN ARMAFLEX REFRIGERANT LINE SET — INSTALLING HORIZONTAL RUNS To hang line set from joist or rafter, use either metal strapping material or anchored heavy nylon wire ties. CTD MATERI/ VAPOR WIRE TIE (AROUND VAPOR LINE ONLY) 8 FEET (2.43 METERS)i O DDIAI (_` PE OR RE TIE rERS) TAPE OR STRAP THE VAPOR LINE TO THE JOIST WIRE TIE OR RAFTER AT 8 FEET (2.43 METERS) INTERVALS THEN STRAP THE LIQUID LINE TO THE VAPOR LINE. FLOOR JOIST OR ROOF RAFTER REFRIGERANT LINE SET — INSTALLING VERTICAL RUNS (NEW CONSTRUCTION SHOWN) NOTE— Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig. OUTSIDE WALL WOOD BLOCK BETWEEN STUDS VAPOR LINE LIQUID LINE WIRE TIE INSIDE WALL STRAP NON -CORROSIVE METAL SLEEVE WIRE TIE WOOD BLOCK WIRE TIE STRAP I SLEEVE VAPOR LINE WRAPPED \ WITH ARMAFLEX OUTSIDE WALL LIQUID I LINE PVC \ CAULK PIPE FIBERGLASS INSULATION i NOTE— Similar installation practices should be used if line set is to be installed on exterior of outside wall. Figure 7. Line Set Installation Page 10 Polyol ester (POE) oils used with HFC-410A refrigerant absorb moisture very quickly. It is very important that the refrigerant system be kept closed as much as possible. DO NOT remove line set caps or service valve stub caps until you are ready to make connections. If this unit is being matched with an approved line set or indoor unit coil which was previously charged with mineral oil, or if it is being matched with a coil which was manufactured before January of 1999, the coil and line set must be flushed prior to installation. Take care to empty all existing traps. Polyol ester (POE) oils are used in Lennox units charged with HFC-410A refrigerant. Residual mineral oil can act as an insulator, preventing proper heat transfer. It can also clog the expansion device, and reduce the system performance and capacity. Failure to properly flush the system per the instructions below will void the warranty. Danger of fire. Bleeding the refrigerant charge from only the high side may result in pressurization of the low side shell and suction tubing. Application of a brazing torch to a pressurized system may result in ignition of the refrigerant and oil mixture - Check the high and low pressures before applying heat. When using a high pressure gas such as dry nitrogen to pressurize a refrigeration or air conditioning system, use a regulator that can control the pressure down to 1 or 2 psig (6.9 to 13.8 kPa). Brazing alloys and flux contain materials which are hazardous to your health. Avoid breathing vapors or fumes from brazing operations. Perform operations only in well -ventilated areas. Wear gloves and protective goggles or face shield to protect against burns. Wash hands with soap and water after handling brazing alloys and flux. Connect gauge set low pressure side to vapor line service valve and repeat procedure starting at paragraph 4 for brazing the liquid line to service port valve. Allow braze joint to cool before removing the wet rag from the service valve. Temperatures above 250°F can damage valve seals. Use silver alloy brazing rods with 5% minimum silver alloy for copper -to -copper brazing. Use 45% minimum alloy for copper -to -brass and copper -to -steel brazing. Fire, Explosion and Personal Safety Hazard. Failure to follow this warning could result in damage, personal injury or death. Never use oxygen to pressurize or purge refrigeration lines. Oxygen, when exposed to a spark or open flame, can cause fire and/or an ex- plosion, that could result in property damage, personal injury or death. 1 CUT AND DEBUR CAP AND CORE REMOVAL Cut ends of the refrigerant lines square (free from nicks or dents) 2 Remove service cap and core from and debur the ends. The pipe must remain round. Do not crimp end both the suction / vapor and liquid line of the line. service ports. CUT AND DEBUR �i LINE SET SIZE MATCHES SERVICE VALVE CONNECTION SERVICE VALVE CONNECTION COPPERTUBE -� STUB \ REDUCER O O O LINE SET SIZE IS SMALLER THAN CONNECTION REFRIGERANT LINE SERVICE PORT CAP ci -�r SERVICE PORT CORE LIQUID LINE SERVICE '��N VALVE DO NOT CRIMP SERVICE VALVE CONNECTOR WHEN PIPE IS SMALLER THAN CONNECTION SUCTION / VAPOR LINE SERVICE VALVE 3 ATTACH THE MANIFOLD GAUGE SET FOR BRAZING LIQUID AND SUCTION / VAPOR LINE SERVICE VALVES Flow regulated nitrogen (at 1 to 2 psig) through the low -side refrigeration gauge set into the liquid line service port valve, and out of the suction / vapor line service port valve. A Connect gauge set low pressure side to liquid line service valve (service port). / B Connect gauge set center port to bottle of LOW 1 nitrogen with regulator. �\ C Remove core from valve in suction / vapor line service port to allow nitrogen to escape. ATTACH GAUGES SUCTION / VAPOR SERVICE PORT MUST BE OPEN TO ALLOW EXIT POINT FOR NITROGEN C SUCTION / VAPOR LINE SERVICE VAPOR LINE VALVE INDOOR UNIT �� 101 HIGH OUTDOOR UNIT USE REGULATOR TO FLOW NITROGEN AT 1 TO 2 PSIG. \ NITROGEN I I LIQUID LINE LIQUID LINE SERVICE O WHEN BRAZING LINE SET TO VALVE SERVICE VALVES, POINT FLAME AWAY FROM SERVICE VALVE. Figure 8. Brazing Procedures Page 12 4 WRAP SERVICE VALVES To help protect service valve seals during brazing, wrap water saturated cloths around service valve bodies and copper tube stubs. Use additional water saturated cloths underneath the valve body to protect the base paint. 5 FLOW NITROGEN Flow regulated nitrogen (at 1 to 2 psig) through the refrigeration gauge set into the valve stem port connection on the liquid service valve and out of the suction / vapor valve stem port. See steps 3A, 36 and 3C on manifold gauge set connections 6 BRAZE LINE SET Wrap both service valves with water saturated cloths as illustrated here and as mentioned in step 4, before brazing to line set. Water saturated cloths must remain water saturated throughout the brazing and cool -down process. LIQUID LINE SERVICE VALVE WHEN BRAZING LINE SET TO SERVICE VALVES, POINT FLAME AWAY FROM SERVICE VALVE. IMPORTANT — Allow braze joint to cool. Apply additional water saturated cloths to help cool brazed joint. Do not remove water saturated cloths until piping has cooled. Temperatures above 250°F will damage valve seals. WATER SATURATED CLOTH LIQUID LINE SUCTION / VAPOR LINE SERVICE VALVE brazing in the line set! The braze, when complete, must be quenched with water to absorb any residual heat. 2. Do not open service valves until refrigerant lines and HEN BRAZING LINE SET TO RVICE .� indoor coil have been leak -tested and evacuated. V OINTFROM SERVICE VALVE. Refer to procedures provided in this supplement. zcjr SUCTION / VAPOR LINE WATER SATURATED CLOTH 7 PREPARATION FOR NEXT STEP After all connections have been brazed, disconnect manifold gauge set from service ports. Apply additional water saturated cloths to both services valves to cool piping. Once piping is cool, remove all water saturated cloths. Refer to the unit installation instructions for the next step in preparing the unit. Figure 9. Brazing Procedures (continued) Page 13 ML14XC1 SERIES Flushing Line Set and Indoor Coil TYPICAL EXISTING FIXED ORIFICE TYPICAL EXISTING EXPANSION VALVE REMOVAL 1 A REMOVAL PROCEDURE (UNCASED OR PROCEDURE (UNCASED COIL SHOWN) COIL SHOWN) 1B DISTRIBUTOR TUBES LIQUID LINE ORIFICE HOUSING /TEFLONE'RING FIXED ORIFICE BRASS NUT DISTRIBUTOR ASSEMBLY REMOVE AND DISCARD WHITE TEFLON® SEAL (IF PRESENT) LIQUID LINE ASSEMBLY (INCLUDES STRAINER) STUB END TWO PIECE PATCH PLATE LIQUID LINE CHECK (UNCASED COIL ONLY) ORIFICE EXPANSION DISTRIBUTOR HOUSING VALVE TUBES TEFLOP \� I� RING 0 A On fully cased coils, remove the coil access and plumbing panels. B Remove any shipping clamps holding the liquid line and distributor as- sembly. C Using two wrenches, disconnect liquid line from liquid line orifice hous- ing. Take care not to twist or damage distributor tubes during this pro- cess. TEFLON& �SENSING RING LINE DISTRIBUTOR /I EQUALIZER ASSEMBLY/ LINE LIQUID LINE / ASSEMBLY WITH BRASS NUT / o MALE EQUALIZER / I LINE FITTING VAPOR LINE LIQUID SENSING BULB LINE D Remove and discard fixed orifice, valve stem assembly if present and A On fully cased coils, remove the coil access and plumbing panels. Teflon® washer as illustrated above. B Remove any shipping clamps holding the liquid line and distributor E Use a field -provided fitting to temporary reconnect the liquid line to the assembly. indoor unit's liquid line orifice housing. C 2 CONNECT GAUGES AND EQUIPMENT FOR FLUSHING PROCEDURE INVERTED HCFC-22 GAUGE CYLINDER CONTAINS MANIFOLD CLEAN HCFC-22* TO BE A USED FOR FLUSHING. 0 VAPOR LINE NEW r n SERVICE VALVE OUTDOOR /\ /\ UNIT EXISTING / ND o UNIT o LIQUID LINE SERVICE VALVE D E F G HIGH H OPENEDY H CLOSED Disconnect the equalizer line from the check expansion valve equalizer line fitting on the vapor line. Remove the vapor line sensing bulb. Disconnect the liquid line from the check expansion valve at the liquid line assembly. Disconnect the check expansion valve from the liquid line orifice housing. Take care not to twist or damage distributor tubes during this process. Remove and discard check expansion valve and the two Teflon® rings. Use a field -provided fitting to temporary reconnect the liquid line to the indoor unit's liquid line orifice housing. 3 FLUSHING LINE SET The line set and indoor unit coil must be flushed with at least the same amount of clean refrigerant* that previously charged the system. Check the charge in the flushing cylinder before proceeding. A Set the recovery machine for liquid recovery and start the recovery machine. Open the gauge set valves to allow the RECOVERY TANK recovery machine to pull a vacuum on the existing system line CYL11' E RETURN set and indoor unit coil. r D C B Invert the cylinder of clean HCFC-22* and open its valve to allow Do INLET liquid refrigerant to flow into the system through the vapor line So o DISCHARGE valve. Allow the refrigerant to pass from the cylinder and through the line set and the indoor unit coil before it enters the recovery RECOVERY MACHINE machine. A Inverted HCFC-22 cylinder with clean refrigerant* to the vapor service valve. B HCFC-22 gauge set (low side) to the liquid line valve. C HCFC-22 gauge set center port to inlet on the recovery machine with an empty recovery tank to the gauge set. D Connect recovery tank to recovery machines per machine instructions. C After all of the liquid refrigerant has been recovered, switch the recovery machine to vapor recovery so that all of the HCFC-22 vapor is recovered. Allow the recovery machine to pull down to 0 the system. D Close the valve on the inverted HCFC-22 drum and the gauge set valves. Pump the remaining refrigerant out of the recovery machine and turn the machine off. *IMPORTANT - Clean refrigerant is any refrigerant in a system that has not had compressor burn out. If the system has experienced burn out, it is recommended that the existing line set and indoor coil be replaced. Figure 10. Removing Metering Device and Flushing Page 14 Installing Indoor Metering Device This outdoor unit is designed for use in systems that use being installed in a field -provided plenum, install the either an fixed orifice (RFC), or expansion valve (TXV) expansion valve in a manner that will provide access for metering devices at the indoor coil. field servicing of the expansion valve. Refer to below The expansion valve can be installed internal or external to illustration for reference during installation of expansion the indoor coil. In applications where an uncased coil is valve unit. INDOOR EXPANSION VALVE INSTALLATION TWO PIECE PATCH PLATE (Uncased Coil Shown) (UNCASED COIL ONLY) LIQUID LINE STUB ORIFICE END HOUSING EXPANSION DISTRIBUTOR \ VALVE TUBES TEFLON@' RING 0 0 cD \ TEFLONE' \ ® RING SENSING • LINE DISTRIBUTOR - \ EQUALIZER ,Q ASSEMBLY�C�I LINE MALE EQUALIZER LINE FITTING (SEE EQUALIZER LINE INSTALLATION FOR FURTHER DETAILS) , LIQUID LINE / ASSEMBLY WITH / BRASS NUT A Remove the field -provided fitting that temporary 1/2 Turn reconnected the liquid line to the indoor unit's distributor assembly. 1 B Install one of the provided Teflon® rings around the 10 stubbed end of the expansion valve and lightly lubricate the connector threads and expose surface of the Teflon® 8 4 7 5 ring with refrigerant oil. C Attach the stubbed end of the expansion valve to the liquid line orifice housing. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above, or 20 ft-lb. D Place the remaining Teflon® washer around the other end of the expansion valve. Lightly lubricate connector threads and expose surface of the Teflon® ring with refrigerant oil. E Attach the liquid line assembly to the expansion valve. Finger tighten and use an appropriately sized wrench to turn an additional 1/2 turn clockwise as illustrated in the figure above or 20 ft-lb. SENSING BULB INSTALLATION A Attach the vapor line sensing bulb in the proper orientation as illustrated to the right using the clamp and VAPOR \ screws provided. LINE NOTE — Confirm proper thermal contact between vapor line LIQUID LINE and expansion bulb before insulating the sensing bulb once installed. Sensing bulb insulation is required if mounted external to the coil casing. See sensing bulb installation for bulb positioning. EQUALIZER LINE INSTALLATION A Remove and discard either the flare seal cap or flare nut with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure to the right. B Remove and discard either the flare seal cap or flare nut with copper flare seal bonnet from the equalizer line port on the vapor line as illustrated in the figure to the right. B Connect the equalizer line from the expansion valve to the equalizer vapor port on the vapor line. Finger tighten the flare nut plus 1/8 turn (7 ft-lbs) as illustrated below. 9 O'CLO�TO 3 O'CLOCK FLARE SEAL CAP I t—FLARE NUT X_ COPPER FLARE OR SEAL BONNET MALE BRASS EQUALIZER LINE FITTING VAPOR LINE 1/8 Turn I� 1� 10 9 8 4 7 6 5 D "7 l» • ON LINES SMALLER THAN 7/8", MOUNT SENSING Z — BULB BETWEEN THE 3 AND ( BULB BULB 9 O'CLOCK POSITIONS. VAPOR LINE / � ON 7/8" AND LARGER LINES, MOUNT SENSING BULB AT EITHER THE 4 OR 8 O'CLOCK ;BULB \ BULB POSITION. NEVER MOUNT ON BOTTOM OF LINE, NOTE— NEVER MOUNT ON BOTTOM OF LINE. Figure 11. Installing Indoor Expansion Valve Page 15 ML14XCl SERIES Leak Test Line Set and Indoor Coil AWARNING A IMPORTANT Leak detector must be capable of sensing HFC refrigerant. 1 CONNECT GAUGE SET A Connect an HFC-410A manifold gauge set high pressure LOW hose to the vapor valve service port. NOTE — Normally, the high pressure hose is connected to the liquid line port. However, connecting it to the vapor port better protects the manifold gauge set from high pressure 0 damage. B With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of the manifold gauge set. HIGH MANIFOLD GAUGE SET OUTDOOR UNIT NOTE — Later in the procedure, the HFC-410A container will be replaced by the nitrogen B A container. �W—Dmt TO VAPOR SERVICE VALVE NITROGEN HFC-410A 2 TEST FOR LEAKS After the line set has been connected to the indoor and outdoor units, check the line set connections and indoor unit for leaks. Use the following procedure to test for leaks: A With both manifold valves closed, connect the cylinder of HFC-410A refrigerant to the center port of the manifold gauge set. Open the valve on the HFC-410A cylinder (vapor only). B Open the high pressure side of the manifold to allow HFC-410A into the line set and indoor unit. Weigh in a trace amount of HFC-410A. (A trace amount is a maximum of two ounces (57 g) refrigerant or three pounds (31 kPa) pressure]. Close the valve on the HFC-410A cylinder and the valve on the high pressure side of the manifold gauge set. Disconnect the HFC-410A cylinder. C Connect a cylinder of dry nitrogen with a pressure regulating valve to the center port of the manifold gauge set. D Adjust dry nitrogen pressure to 150 psig (1034 kPa). Open the valve on the high side of the manifold gauge set in order to pressurize the line set and the indoor unit. E After a few minutes, open one of the service valve ports and verify that the refrigerant added to the system earlier is measurable with a leak detector. F After leak testing disconnect gauges from service ports. Figure 12. Leak Test Page 16 Evacuating Line Set and Indoor Coil 1 CONNECT GAUGE SET NOTE — Remove cores from service valves (if not already done). A Connect low side of manifold gauge set with 1/4 SAE in -line tee to vapor line service valve B Connect high side of manifold gauge set to liquid line service valve OUTDOOR C Connect micron gauge available UNIT connector on the 1/4 SAE in -line tee. A D Connect the vacuum pump (with vacuum gauge) to the center port of the 1*4000, manifold gauge set. The center port line will be used later for both the HFC-410Aand nitrogen containers. NITROGEN _r_ HFC-410A VACUUM PUMP at a B A34000 1/4 SAE TEE WITH SWIVEL COUPLER L c 791 LOW MANIFOLD GAUGE SET 500 MICRON GAUGE t TO VAPOR SERVICE VALVE TO LIQUID LINE SERVICE VALVE 1 HIGH 2 EVACUATE THE SYSTEM RECOMMEND A Open both manifold valves and start the vacuum pump. MINIMUM 3/8" HOSE B Evacuate the line set and indoor unit to an absolute pressure of 23,000 microns (29.01 inches of mercury). NOTE— During the early stages of evacuation, it is desirable to close the manifold gauge valve at least once. A rapid rise in pressure indicates a relatively large leak. If this occurs, repeat the leak testing procedure. NOTE — The term absolute pressure means the total actual pressure within a given volume or system, above the absolute zero of pressure. Absolute pressure in a vacuum is equal to atmospheric pressure minus vacuum pressure. C When the absolute pressure reaches 23,000 microns (29.01 inches of mercury), perform the following: • Close manifold gauge valves • Close valve on vacuum pump • Turn off vacuum pump • Disconnect manifold gauge center port hose from vacuum pump • Attach manifold center port hose to a dry nitrogen cylinder with pressure regulator set to 150 psig (1034 kPa) and purge the hose. • Open manifold gauge valves to break the vacuum in the line set and indoor unit. • Close manifold gauge valves. D Shut off the dry nitrogen cylinder and remove the manifold gauge hose from the cylinder. Open the manifold gauge valves to release the dry nitrogen from the line set and indoor unit. E Reconnect the manifold gauge to the vacuum pump, turn the pump on, and continue to evacuate the line set and indoor unit until the absolute pressure does not rise above 500 microns (29.9 inches of mercury) within a 20-minute period after shutting off the vacuum pump and closing the manifold gauge valves. F When the absolute pressure requirement above has been met, disconnect the manifold hose from the vacuum pump and connect it to an upright cylinder of HFC-410A refrigerant. Open the manifold gauge valve 1 to 2 psig in order to release the vacuum in the line set and indoor unit. G Perform the following: • Close manifold gauge valves. 1/6 TURN • Shut off HFC-410A cylinder. 1I • Reinstall service valve cores by removing manifold hose from service valve. Quickly install cores with core 11 10 � tool while maintaining a positive system pressure. 9 3 • Replace stem caps and secure finger tight, then tighten an additional one -sixth (1/6) of a turn as illustrated. g 4 7 5 Figure 13. Evacuating System Page 17 ML14XC1 SERIES Evacuating the system of non-condensables is critical for proper operation of the unit. Non-condensables are SIZE CIRCUIT AND INSTALL SERVICE DISCONNECT SWITCH Refer to the unit nameplate for minimum circuit ampacity, and maximum fuse or circuit breaker (HACR per NEC). Install power wiring and properly sized disconnect switch. MAIN FUSE BOX/ BREAKER PANEL SERVICE DISCONNECT SWITCH NOTE— Units are approved foruse only with copper conductors. Ground unit at disconnect switch or to an earth ground. AWARNING defined as any gas that will not condense under temperatures and pressures present during operation of an air conditioning system. Non-condensables and water suction combine with refrigerant to produce substances that corrode copper piping and compressor parts. A IMPORTANT Use a...-. gauge capable of accurately measuring down to 50 microns. Electrical In the U.S.A., wiring must conform with current local codes and the current National Electric Code (NEC). In Canada, wiring must conform with current local codes and the current Canadian Electrical Code (CEC). Refer to the furnace or air handler installation instructions for additional wiring application diagrams and refer to unit nameplate for minimum circuit ampacity and maximum overcurrent protection size. 24VAC TRANSFORMER Use the transformer provided with the furnace or air handler for low -voltage control power (24VAC - 40 VA minimum) INSTALL THERMOSTAT Install room thermostat (ordered separately) on an inside wall approximately in the center of the conditioned area and 5 feet (1.5m) from the floor. It should not be installed on an outside wall or where it can be affected by sunlight or drafts. THERM NOTE — 24VAC, Class // circuit connections are made in the control panel. Page 18 ROUTING HIGH VOLTAGE/ GROUND AND CONTROL WIRING HIGH VOLTAGE / GROUND WIRES HIGH VOLTAGE CONNECTIONS Any excess high voltage field wiring should be trimmed and (CONTACTOR) secured away from any low voltage field wiring. To facilitate a conduit, a cutout is located in the bottom of the control panel. Connect conduit to the control panel using a proper conduit fitting. CONTROL WIRING NOTE— Wire tie provides low voltage control wire strain relief and to GROUND maintain separation of field installed low and high voltage circuits. HIGH VOLTAGE NOTE — For proper voltages, select thermostat wire (control wires) FIELD WIRING gauge per table above. - LOW VOLTAGE FIELD WIRING NOTE— Do not bundle any excess 24VAC control wires inside _ FACTORY WIRING control panel. Install low voltage wiring from outdoor to indoor unit and from thermostat to indoor unit as illustrated. A Run 24VAC control wires through hole with grommet and secure with provided wire tie. B Make 24VAC thermostat wire connections. Locate the two wires from the contactor and make connection using field provided wire nuts: • Yellow to Y1 • Black to C (common) WIRE RUN LENGTH AWG# INSULATION TYPE LESS THAN 100' (30 METERS) 18 TEMPERATURE RATING MORE THAN 100' (30 METERS) 16 35°C MINIMUM. THERMOSTAT INDOOR UNIT POWER R R HEAT W1 W OUTDOOR UNIT COOLING y Y Y1 INDOOR G BLOWER G COMMON C C C SINGLE PHASE FLEXIBLE CONDUIT A GROMMET AND WIRE TIE Page 19 ML14XC1 SERIES GROUND W (GREEN CRANKCASE HEATER (HR1) 041. -047.-048.-059. -060 ONLY) Figure 14. Typical Factory Wiring Diagram Page 20 Figure 15. Typical Factory Wiring Diagram (-059 Only - Future Production) Page 21 ML14XC1 SERIES System Operation The outdoor unit and indoor blower will cycle on and off as dictated by demands from the room thermostat. When the thermostat's blower switch is in the ON position, the indoor blower will operate continuously. HIGH PRESSURE SWITCH (S4) ML14XC1 units are equipped with a high-pressure switch that is factory -wired and located in the liquid line. The switch is a Single Pole, Single Throw (SPST), auto -reset switch which is normally closed and removes power from the compressor when discharge pressure rises above factory setting at 590 ± 10 psig; resets at 418 ± 5 psig. CRANKCASE HEATER (HR1) AND THERMOSTAT (S40) Compressors in some models are equipped with a 40 watt or 70 watt, belly band type crankcase heater. HR1 prevents liquid from accumulating in the compressor. HR1 is controlled by a single pole, single through thermostat switch (S40) located on the liquid line (see figure 1 for location). When liquid line temperature drops below 50' F the thermostat closes energizing HR1. The thermostat will open, de -energizing HR1 once liquid line temperature reaches 70' F. THERMAL PROTECTION SWITCH (S173) - COMPRESSOR MOUNTED Some units are equipped with a compressor mounted normally closed temperature switch that prevents compressor damage due to overheating caused by internal friction. The switch is located on top of the compressor casing. This switch senses the compressor casing temperature and opens at 239-257°F (115°C-125°C) to shut off compressor operation. The auto -reset switch closes when the compressor casing temperature falls to 151-187°F (66°C-86°C), and the compressor is re -energized. This single -pole, single -throw (SPST) bi-metallic switch is wired in series with the 24V Y input signal to control compressor operation. Maintenance Your heating and air conditioning system should be inspected and maintained yearly (before the start of the cooling and heating seasons) by a licensed professional HVAC technician. You can expect the technician to check the following items. These checks may only be conducted by a licensed professional HVAC technician. Outdoor Unit 1. Inspect component wiring for loose, worn or damaged connections. Also check for any rubbing or pinching of wires. Confirm proper voltage plus amperage of outdoor unit. 2. Check the cleanliness of outdoor fan and blade assemblies. Check condition of fan blades (cracks). Clean or replace them, if necessary. 3. Inspect base pan drains for debris and clean as necessary. 4. Inspect the condition of refrigerant piping and confirm that pipes are not rubbing copper -to -copper. Also, check the condition of the insulation on the refrigerant lines. Repair, correct, or replace as necessary. 5. Test capacitor. Replace as necessary. 6. Inspect contactor contacts for pitting or burn marks. Replace as necessary. 7. Check outdoor fan motor for worn bearings/bushings. Replace as necessary. 8. Inspect and clean outdoor coils, if necessary and note any damage to coils or signs of leakage. NOTICE! Failure to follow instructions will cause damage to the unit. This unit is equipped with an aluminum coil. Alu- minum coils may be damaged by exposure to solu- tions with a pH below 5 or above 9. The aluminum coil should be cleaned using potable water at a moderate pressure (less than 50psi). If the coil can- not be cleaned using water alone, Lennox recom- mends use of a coil cleaner with a pH in the range of 5 to 9. The coil must be rinsed thoroughly after cleaning. In coastal areas, the coil should be cleaned with potable water several times per year to avoid corro- sive buildup (salt). Indoor Unit (Air Handler or Furnace) 1. Inspect component wiring for loose, worn or damaged connections. Confirm proper voltage plus amperage indoor unit. 2. Inspect and clean or replace air filters in indoor unit. 3. Check the cleanliness of indoor blower and clean blower, if necessary. 4. Inspect the evaporator coil (Indoor) drain pans and condensate drains for rust, debris, obstructions, leaks or cracks. Pour water in pans to confirm proper drainage from the pan through to the outlet of the pipe. Clean or replace as necessary. 5. Inspect and clean evaporator (indoor) coil, if necessary. 6. Inspect the condition of the refrigerant lines and confirm that pipes are not rubbing copper -to -copper. Page 22 Also, ensure that refrigerant pipes are not being affected by indoor air contamination. Check condition of insulation on the refrigerant lines. Repair, correct, or replace as necessary. 7. Inspect the duct system for leaks or other problems. Repair or replace as necessary. 8. Check for bearing/bushing wear on indoor blower motor. Replace as necessary. 9. Indoor unit inspections of gas- or oil -fired furnaces will also include inspection and cleaning of the burners, and a full inspection of the gas valve, heat exchanger and flue (exhaust) system. Start -Up and Performance Checklist Job Name Job Location Installer Unit Model No. Serial No. Nameplate Voltage Rated Load Ampacity Compressor Maximum Fuse or Circuit Breaker General System Test with System Operating 1. Your technician should perform a general system test. He will turn on the air conditioner to check operating functions such as the start-up and shut-off operation. He will also check for unusual noises or odors, and measure indoor/outdoor temperatures and system pressures as needed. 2. The technician will check the refrigerant charge per the charging sticker information on the outdoor unit. 3. Verify that system total static pressure and airflow settings are within specific operating parameters. 4. Verify correct temperature drop across indoor coil. Job no. City City Date State State Service Technician Outdoor Fan Electrical Connections Tight? ❑ Indoor Filter clean? ❑ Supply Voltage (Unit Off) Indoor Blower RPM S.P. Drop Over Indoor (Dry) Outdoor Coil Entering Air Temp. Discharge Pressure Suction Pressure Refrigerant Charge Checked? ❑ Refrigerant Lines: - Leak Checked? ❑ Properly Insulated? ❑ Outdoor Fan Checked? ❑ Service Valves: --- Fully Opened? ❑ Caps Tight? ❑ Thermostat Voltage With Compressor Operating Calibrated? ❑ Properly Set? ❑ Level? ❑ Page 23 ML14XC1 SERIES Typical Field Wiring OUTDOOR A� PURPLE BLACK ORANGE RED COMPRESSOR CRANKCASE HEATER 0 L1 -w- 208-230/60/1 L2 DESCRIPTION KEY COMPONENT A4 CONTROL -TIMED OFF B1 COMPRESSOR B4 MOTOR -OUTDOOR FAN C12 CAPACITOR -DUAL HR1 HEATER -COMPRESSOR K1,-1 CONTACTOR -COMPRESSOR S4 SWITCH -HIGH PRESSURE S24 SWTCH-LOSS OF CHARGE S40 TERMOSTAT-CRANKCASE 87 SWITCH -LOW PRESS, COMP 1 S173 SWITCH -THERMAL PROTECTION DUAL CAPACITOR A4 TO 24 VAC POWER F C H TIMED OFF SOURCE CONTROL 20 VA MINIMUM NEC CLASS 2 2 3 C Y1 BLACK I COMPRESSOR I I CONTACTOR I L2 GROUND IL1 LUG I 208-230/ 60/ 1 I I - GROUND F"HIGH BLACK K1-1 YELLOW S4RED S173 0 S87 OR ORANGE PRESSURE S24 SWITCH RED BLACK S173 - - - � 4 S40 C12 A4 Q H C F Ba sa I I z 3 S87 0 NOTE- K1 FOR USE WITH COPPER CONDUCTORS ONLY. REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND NOTE- © MAXIMUM OVERCURRENT PROTECTION SIZE TO 24 VAC IF ANY WIRE IN THIS APPLIANCE IS REPLACED,IT ,JUMPER IS USED WHEN TOC IS NOT USED POWER SOURCE MUST BE REPLACED WITH WIRE OF LIKE SIZE, © S173 SWITCH USED ONLY IN UNITS EQUIPPED 20 VA MINIMUM RATING, INSULATION THICKNESS, AND TERMINATION. WITH COMPRESSORS WHICH DO NOT INCLUDE NEC CLASS 2 INTERNAL SWITCH LINE VOLTAGE FIELD INSTALLED -------- CLASS II VOLTAGE FIELD WIRING ® S173 TO S87 WHEN A4 IS NOT USED DENOTES OPTIONAL COMPONENTS Figure 16. Typical Field Wiring (All Models Except -059) Page 24 OUTDOOR DUAL H O FAN BLUE C CAPACITOR A4 TIMED OFF CONTROL TO 24 VAC POWER SOURCE 20 VA MINIMUM YELLOW BLACK RED RED O 3 1 � 2 NEC CLASS 2 Y1 GREEN RED — — —I— J i&YELLOW BLACK R S C COMPRESSOR COMPRESSOR CONTACTOR L2 GROUND L1 ASE !H7EATER LUG 208-230/ 60/ 1 - GROUND S40 B1 K1-1 BLACKMBLUE 0 L1 1 RED 208-230/ 60/ 1 YELLOWH SSURE L2 REDTCH REDRED K1 GROUND S40 C1HC 1Q NOTE - FOR USE WITH COPPER CONDUCTORS ONLY. REFER TO UNIT RATING PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM OVERCURRENT PROTECTION SIZE DESCRIPTION KEY I COMPONENT A4 CONTROL -TIMED OFF B1 COMPRESSOR B4 MOTOR -OUTDOOR FAN C12 CAPACITOR -DUAL HR1 HEATER -COMPRESSOR K1,-1 CONTACTOR -COMPRESSOR S4 SWITCH -HIGH PRESSURE S24 SWITCH -LOSS OF CHARGE S40 TERMOSTAT-CRANKCASE S89 I SWITCH -THERMOSTAT, DISCHARGE TEMP S87 I SWITCH -LOW PRESS COMP 1 A4 S4 O — 3 K1 ---- 1 TO 24 VAC POWER SOURCE 20 VA MINIMUM NEC CLASS 2 NOTE - IF ANY WIRE IN THIS APPLIANCE IS REPLACED,IT MUST BE REPLACED WITH WIRE OF LIKE SIZE, RATING, INSULATION THICKNESS, AND TERMINATION. LINE VOLTAGE FIELD INSTALLED -------- CLASS II VOLTAGE FIELD WIRING DENOTES OPTIONAL COMPONENTS Supersedes 1211 :• • • New Form No. 537511-01 O 70� Litho U S A. Figure 17. Typical Field Wiring (-059 Only - Future Production) NOTE- The thermostat used may be electromechanical outdoor fan motor (134). or electronic. 4- Compressor (131) and outdoor fan motor (134) begin NOTE- Transformer in indoor unit supplies power (24 immediate operation.. VAC) to the thermostat and outdoor unit controls. COOLING: END OF COOLING DEMAND: 1- Cooling demand initiates at Y1 in the thermostat. 5- Cooling demand is satisfied. Terminal Y1 is 2- 24VAC from indoor unit (Y1) energizes the TOC timed de -energized . off control (if used) which energizes contactor K1 6- Compressor contactor K1 is de -energized. (provided S4 high pressure switch is closed). 7- K1-1 opens and compressor (131) and outdoor fan 3- K1-1 N.O. closes, energizing compressor (131) and motor (134) are de -energized and stop immediately. Page 25 ML14XC1 SERIES Servicing Units Void of Charge If the outdoor unit is void of refrigerant, clean the system using the procedure described below. 1. Leak check system using procedure outlined in figure 12. 2. Evacuate the system using procedure outlined in figure 13. 3. Use nitrogen to break the vacuum and install a new filter drier in the system. 4. Evacuate the system again using procedure outlined in figure 13.. 5. Weigh in refrigerant using procedure outlined under figure 21. Unit Start -Up A IMPORTANT If unit is ..-. with a crankcase heater, it should.- 1. Rotate fan to check for binding. 2. Inspect all factory- and field -installed wiring for loose connections. 3. After evacuation is complete, open the liquid line and suction line service valves to release the refrigerant charge (contained in outdoor unit) into the system. 4. Replace the stem caps and tighten as specified in Operating Service Valves on page 5. 5. Check voltage supply at the disconnect switch. The voltage must be within the range listed on the unit's nameplate. If not, do not start the equipment until you have consulted with the power company and the voltage condition has been corrected. 6. Set the thermostat for a cooling demand. Turn on power to the indoor indoor unit and close the outdoor unit disconnect switch to start the unit. 7. Recheck voltage while the unit is running. Power must be within range shown on the nameplate. 8. Check system for sufficient refrigerate using the procedures that follow. System Refrigerant This section outlines procedures for: 1. Connecting gauge set for testing and charging; 2. Checking and adjusting indoor airflow; 3. Adding or removing refrigerant. GAUGE SET MANIFOLD GAUGE SET CONNECTIONS FOR TESTING AND CHARGING LOW \ HIGH B SUCTION LINE / T SERVICE PORT CONNECTION O AClose manifold gauge set valves and connect the center hose to a cylinder of HFC-410A. Set for liquid phase charging. REFRIGERANT TANK BConnect the manifold gauge set's low pressure side to the suction line service port. CConnect the manifold gauge set's high pressure side to the liquid line service port. DPosition temperature sensor on liquid line near liquid line service port. CHARGELLLW7 LIQUID PHA DIGITAL SCALE t2S' C TO LIQUID LINE SERVICE VALVE D TEMPERATURE SENSOR OUTDOOR UNIT TEMPERATURE SENSOR (LIQUID LINE) Figure 18. Gauge Set Setup and Connections Page 26 ADDING OR REMOVING REFRIGERANT This system uses HFC-410A refrigerant which operates at much higher pressures than HCFC-22. The pre -installed liquid line filter drier is approved for use with HFC-410A only. Do not replace it with components designed for use with HCFC-22. This unit is NOT approved for use with coils which use capillary tubes or fixed orifices as a refrigerant metering device. Check airflow using the Delta-T (DT) process using the illustration in figure 19. AIRFLOW INDOOR COIL DT Temperature of air 2 80 24 24 24 23 23 22 22 22 20 19 1817 16 15 entering indoor -9 78 23 23 23 22 22 21 21 20 19 18 1716 15 14 coil IF �' 76 22 22 22 21 21 2019 19 18 17 1615 14 13 T 190 All temperatures are expressed in IF 0 7421 21 21 2019191817161615141312 72 20 20 19 18 17 17 161514131211 10 7019191818171716151514131211 10 Wet -bulb IF 57 58 59 60 6162 63 64 65 66 67 68 69 70 W01 INDOOR COIL Use the following procedure to adjust for optimal air flow across the indoor coil: 1. Determine the desired DT — Measure entering air temperature using dry bulb (A) and wet bulb (B). DT is the intersecting value of A and B in the table (see triangle). 2. Find temperature drop across coil — Measure the coil's dry bulb entering and leaving air temperatures (A and C). Temperature Drop Formula: (Tprop) = A minus C. 3. Determine if fan needs adjustment — If the difference between the measured Tprop and the desired DT (Tprop DT) is within +30, no adjustment is needed. See example below: Assume DT = 15 and A temp. = 720, these C temperatures would necessitate stated actions: C° Tprop — DT = °F ACTION 530 19 — 15 = 4 Increase the airflow Changing air flow affects all temperatures; recheck 580 14 — 15 = -1 within +31 range) change a temperatures to conform that the temperature drop 99 and DT are within +3 . 620 10 — 15 = -5 Decrease the airflow 4. Adjust the fan speed — See indoor unit instructions to increase/decrease fan speed. Figure 19. Checking Indoor Airflow over Evaporator Coil using Delta-T Chart Page 27 ML14XC1 SERIES WHEN TO CHARGE? • Warm weather best • Can charge in colder weather CHARGE METHOD? Determine by: • Metering device type • Outdoor ambient temperature REQUIREMENTS: • Sufficient heat load in structure • Indoor temperature between 70-80°F (21-26°C) • Manifold gauge set connected to unit • Thermometers: - to measure outdoor ambient temperature to measure liquid line temperature to measure suction line temperature I WATLA / 65°F 64°F (18.3°C) and (17.7°C) and � Above Below i APPROACH OR WEIGH-IN SUBCOOLING Which RFC metering device? Figure 20. Determining Charge Method � 40°F 39°F N (4.4°C) and (3.8°C) and Above Below SUPERHEAT WEIGH-IN WEIGH IN (RFC AND TXV) CALCULATING SYSTEM CHARGE FOR OUTDOOR UNIT VOID OF CHARGE If the system is void of refrigerant, first, locate and repair any leaks and then weigh in the refrigerant charge into the unit. To calculate the total refrigerant charge: Adjust amount. for variation Amount specified on in line set length listed on nameplate line set length table below. Total charge NOTE— The above nameplate is for illustration purposes only. Go to actual Refri er nt Charge per Line Set Len th nameplate on outdoor unit for charge information. ��■t� i Liquid Line Set Ounces per 5 feet (g per 1.5 m) adjust from 1 15 feet (4.6 m) line set" Diameter 3/8" 9.5 mm 3 ounce per 5' 85 q per 1.5 m NOTE — Insulate liquid line when it is routed through areas where the surrounding ambient temperature could become higher than the temperature of the liquid line or when pressure drop is equal to or greater than 20 psig. Figure 21. Using HFC-410A Weigh In Method Page 28 '�ITART. Measure outdoor ambient temperature 1 650F 1. Confirm proper airflow across coil using figure All 8.30C) and 19. Above 2• Compare unit pressures with normal operating pressures provided on applicable charging USE WEIGH-IN METHOD sticker as reference in table 1. Weigh-in or remove refriger- ABOVE or 3. Set thermostat to call for heat (must have a BELOW cooling load between 70-80 F (21-261 C). ant based upon line length 640E 4. Connect gauge set. (17.70C) and 5. When heat demand is satisfied, set thermostat APPROACH TXV Below to call for cooling. 6. Allow temperatures and pressures to stabilize. If refrigerant is added 7. Record outdoor ambient temperature: or removed, retest to AMB° = confirm that unit is properly charged. - --- =- — - 8. Record liquid line temperature: LIQ° _ 9. Subtract to determine approach (APP°): If value is greater than - _ LIQ° -AMB° =APP° shown (high approach), _ 10. Compare results with applicable charging add refrigerant; if less r; sticker located on unit access panel or copy than shown (liquid --- =_ —_ --- located at the end of this manual. See table 2 for temperaturetoo close to __' ___-_-_-_-_- to determine applicable charging information for ambient temperature, == _ = — - = specific model. low approach), remove 1 refrigerant. ... _ _ ::.-. nmm ��a Figure 22. HFC-410A Approach TXV Charge 650F 18.30C) and Above USE WEIGH-IN METHOD Weigh-in or remove refrigerant < ABOVE or based upon line length 640E BELOW SUBCOOLING TXV (17Beowand BLOCK OUTDOOR COIL: [sometimes necessary with lower temperatures] Use cardboard or plastic sheet to Lthe airflow through the outdoor coil to achieve s from 325-375 psig (2240-2585 kPa). Higher s are needed to check charge. Block equal of air intake panels and move coverings sideways liquid pressure is in the above noted ranges. CARDBOARD OR PLASTIC SHEET If refrigerant is If value is added or removed, MORE than verify charge using shown, rem the Approach refrigerant. Method. If value is LESS than shown, add MORE or refrigerant. r LESS 0 1. Confirm proper airflow across coil using figure 19. 2. Compare unit pressures with normal operating pressures provided on applicable charging sticker as reference in table 1. 3. Set thermostat to call for heat (must have a cooling load between 70-80°F (21-26°C) 4. Connect gauge set 5. Measure outdoor ambient temperature 6. When heat demand is satisfied, set thermostat to call for cooling 7. Allow temperatures and pressures to stabilize. NOTE - If necessary, block outdoor coil to maintain 325 - 375 psig. 8. Record liquid line temperature: LIQ° = 9. Measure liquid line pressure and use the value to determine saturation temperature (see table 4): SAT* = 10. Subtract to determine subcooling (SC°): SAT° - LIQ° = Sc* 11. Compare results with applicable charging sticker located on unit access panel or copy located at the end of this manual. See table 3 for to determine applicable charging information for specific model. Figure 23. HFC-410A Subcooling TXV Charge Page 29 ML14XC1 SERIES Table 4. HFC-410A Temperature - Pressure (Psig) T °C Psig T °C Psig -40 -40.0 11.6 60 15.6 170 -35 -37.2 14.9 65 18.3 185 -30 -34.4 18.5 70 21.1 201 -25 -31.7 22.5 75 23.9 217 -20 -28.9 26.9 80 26.7 235 -15 -26.1 31.7 85 29.4 254 -10 -23.3 36.8 90 32.2 274 -5 -20.6 42.5 95 35.0 295 0 -17.8 48.6 100 37.8 317 5 -15.0 55.2 105 40.6 340 10 -12.2 62.3 110 43.3 365 15 -9.4 70.0 115 46.1 391 20 -6.7 78.3 120 48.9 418 25 -3.9 87.3 125 51.7 446 30 -1.1 96.8 130 54.4 476 35 1.7 107 135 57.2 507 40 4.4 118 140 60.0 539 45 7.2 130 145 62.8 573 50 10.0 142 150 65.6 608 55 12.8 155 Page 30