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ESI Outdoor Unit Installation Instruction

05.2018

Manufacturer reserves the right to change at any time for specifications or designs without notice and incurring obligations.

Notes:

Summary of Contents for 2436

Page 1: ...uting 6 Refrigerant Pipe Brazing 7 Refrigerant System Leak Check 8 Evacuation 9 Service Valves 10 Electrical Low Voltage 11 Electrical High Voltage 12 Start Up 13 System Charge Adjustment 14 System Operation 15 Troubleshooting 2 4 6 7 9 10 11 11 12 13 14 15 16 20 29 All phases of this installation must comply with National State and Local Codes IMPORTANT This document is customer s property and is...

Page 2: ...tmosphere to limit this hygroscopic action The system should remain sealed whenever possible If a system has been open to the atmosphere for more than 4 hours the compressor oil must be replaced Never break a vacuum with air and always change the driers when opening the system for component replacement SERVICE VALVES Failure to follow this warning will result in abrupt release of system charge and...

Page 3: ...e minor to severe burning Failure to follow this caution could result in property damage or personal injury Do not touch top of compressor GROUNDING REQUIRED Failure to inspect or use proper service tools may result in equipment damage or personal injury Reconnect all grounding devices All parts of this product that are capable of conducting electrical current are grounded if grounding wires screw...

Page 4: ...handling It is the receiving party s responsibility to inspect the equipment upon arrival Any obvious damage to the carton box should be reported on the bill of lading and a claim should be filed with the transportation company and the factory should be noticed All units should be stored in the factory shipping carton with internal packaging in a dry place until installation Carefully remove the p...

Page 5: ...etween units Position unit so water snow or ice from roof or overhang cannot fall directly on unit Cold Climate Considerations Precautions must be taken for units being installed in areas where snow accumulation and prolonged below freezing temperatures occur Units should be elevated 3 12 inches above the pad or rooftop depending on local weather This additional height will allow drainage of snow ...

Page 6: ...ust be separated from any structure The pad must be level The pad must be high enough above grade to allow for drainage The pad location must comply with National State and Local codes IMPORTANT NOTE These instructions are intended to provide a method to tie down unit to cement slab as a securing procedure for high wind areas Check local codes for tie down methods and protocols Figure 3 1 Position...

Page 7: ...s indicated in Table 4 1 and determine required pipe length 4 1 Refrigerant Pipe and Service Valve Connection Sizes 4 2 Refrigerant Pipe Limits Model Suction pipe Liquid pipe Suction pipe connection Liquid pipe connection 2436 3 4 3 8 3 4 3 8 4860 7 8 7 8 Figure 4 1 Pipe length limit Figure 4 2 Elevation difference limit Maximum pipe length 100 feet Max 100ft Maximum elevation difference 50 feet M...

Page 8: ...sting refrigerant pipes make sure that all joints are brazed not soldered IMPORTANT The manufacturer recommends installing only approved matched indoor and outdoor systems All of the manufacturer s split systems are AHRI rated only with TXV indoor systems Some of the benefits of installing approved matched indoor and outdoor split systems are maximum efficiency optimum performance and the best ove...

Page 9: ...isolating pipe sets from joists rafters walls or other structural elements Take precautions to prevent noise within the building structure due to vibration transmission from the refrigerant pipes For Example Use isolation type hangers when the refrigerant pipes have to be fastened to floor joists or other framing Isolation hangers should also be used when refrigerant pipes traverse stud spaces or ...

Page 10: ...rfaces of the tubing using an emery cloth 2 Remove the pressure tap cap from both service valves 3 Purge the refrigerant pipes and indoor coil with dry nitrogen from gas service valve 4 Wrap a wet rag around the valve body to avoid heat damage and continue the dry nitrogen purge Braze the refrigerant pipes to the service valves Install a bidirectional filter drier in liquid side to protect the hea...

Page 11: ...t least 150 PSIG using dry nitrogen 2 Check for leaks by using a soapy solution or bubbles at each brazed location 150PSIG 8 Evacuation Figure 7 1 Charge dry nitrogen to the system Figure 7 2 Leak check Do not open the service valves until the leak check and evacuation are complete 1 Evacuate until the micron gauge reads no higher than 350 microns then close the valve to the vacuum pump 2 Evacuati...

Page 12: ...alve stem just touches the rolled edge approximately five turns 3 Replace and tighten the valve stem cap to prevent leaks Additional 1 6 turn may be required Repeat 1 to 3 for Liquid Service Valve Figure 9 1 Open the service valves Service Port Rolled edge to captivate stem Cap 3 16 Hex Wrench for Liquid Service Valve 5 16 Hex Wrench for Suction Service Valve WARNING Extreme caution should be exer...

Page 13: ...1 Low voltage wire requirement CONTROL WIRING Wire Size Max Wire Length 18 AWG 150Ft 10 2 Low voltage hook up diagrams G R C W1 C Y O W W2 O C R G Y G2 G2 INDOOR UNIT OUTDOOR UNIT THERMOSTAT ONLY AVAILABLE TO ECOER THERMOSTAT WITH EAHATN SERIES INDOOR UNIT GREEN RED BLACK BROWN WHITE BLACK YELLOW WHITE ORANGE Thermostat wiring connector Figure 10 1 Low voltage control wiring connection Notes 1 Be ...

Page 14: ...switch Figure 11 1 Read the Warning Label Figure 11 2 Install an independent switch WARNING During installation testing servicing and trouble shooting of this product it may be necessary to work with live electrical components Failure to follow all electrical safety precautions when exposed to live electrical components could result in death or serious injury Figure 11 3 Unit grounding 11 3 High v...

Page 15: ...e been completed 1 Set the thermostat to OFF 2 Turn on disconnect switch to apply power to the indoor and outdoor units 3 Wait one hour before starting the unit if the outdoor ambient temperature is below 59 º F 60 MIN 4 Set the thermostat to ON Note It may take up to 45 minutes in the first time for heating operation to exit start up control This is normal function to preheat lubricants in the bo...

Page 16: ...42 1 2 2 Only take pipe length over 15ft into consideration A B C D Model Factory charge Indoor Model Charge amount for indoor unit oz Charge multiplier for interconnecting refrigerant tube length 2 2436 The data on nameplate 36K 0 0 6 oz ft 36K 14 1 4860 60K 0 60K 14 1 For new installation Calculate additional charge for liquid pipe which is greater than 15 ft 1 Total pipe length ft A 2 Standard ...

Page 17: ...lays for more than 20 minutes stop charging and check the TXV adjustment to ensure proper superheat at the suction pipe Maintain a minimum of 5 minutes operation after every refrigerant charge or TXV opening adjustment Refrigerant coefficient 0 0 4 0 6 1 0 Insufficient Excess Just The refrigerant coefficient is used to evaluate the amount of refrigerant Use either way below to end AUTO charge mode...

Page 18: ...05 101 97 93 89 50 123 118 114 110 105 101 97 93 52 128 123 118 114 110 105 101 97 54 133 128 123 118 114 110 105 101 56 138 133 128 123 118 114 110 105 58 143 138 133 128 123 118 114 110 60 148 143 138 133 128 123 118 114 62 153 148 143 138 133 128 123 118 64 159 153 148 143 138 133 128 123 66 164 159 153 148 143 138 133 128 68 170 164 159 153 148 143 138 133 70 176 170 164 159 153 148 143 138 72...

Page 19: ...lize the system 1 Wait five 5 minutes for the unit to stabilize between adjustments When the sub cooling matches the chart the system is properly charged 2 Remove gages 3 Replace and tighten service port caps to prevent leaks Plus an additional 1 6 turn may be STEP3 Adjust refrigerant level to attain proper gage pressure Add refrigerant if the sub cooling is lower than the chart value 1 Connect ga...

Page 20: ...ackup state 4 IPM module temperature sensor TF fault backup state 5 Ambient temperature sensor TA fault backup state 6 Condenser coil sensor TH fault backup state 7 Suction temperature sensor TS fault backup state 8 Liquid temperature sensor TL fault backup state 9 Demand response state Protection State Codes Description 0 Running under high pressure limit 1 Running under low pressure limit 2 Runn...

Page 21: ...Capacity selection ON 2 or 4 Ton OFF factory 3 or 5 Ton 3 AC only heat pump selection ON AC only OFF factory Heat pump 4 Response for IoT ON Do not respond to IoT command OFF factory Respond to IoT command Mode types Default mode press BS3 Used to spot check system operating states e g high pressure temperature compressor frequency and error code etc Setting mode hold BS1 for 5 seconds Used to set...

Page 22: ...r back button BS2 UP button BS3 Spot check and confirm button BS2 BS3 Press buttons Off Blinking On SEG1 SEG2 SEG3 Setting mode Default mode Use BS3 button to query operating states Press and hold BS1for 5 seconds Press BS3 Symbol selection by pressing BS2 button Setting item selection by pressing BS2 button Contents display Press BS3 Press BS3 Query setting mode Press BS3 Symbol selection by pres...

Page 23: ...utdoor unit capacity C3 C AC only H heat pump 3 3Ton 2 3 4 5Ton 02 Sub cooling 10 10F 03 Superheat 18 18F 04 Frequency of compressor 56 56rps 05 Electric expanse valve opening 360 360pls 06 Step of fan 8 8th Step 07 Low pressure LP sensor 145 145psig 08 High pressure HP sensor 350 350psig 09 TA temperature 95 95F 10 TS temperature 70 70F 11 TD temperature 170 170F 12 TH temperature 80 80F 13 TL te...

Page 24: ... 1 OFF No 24VAC output n03 Outdoor unit D W terminal outputs 24V when ambient temperature is lower than specify value for auxiliary heating resource to start 0 factory TA 15F 24VAC output 1 TA 10F 24VAC output 2 TA 5F 24VAC output 3 TA 3F 24VAC output 4 OFF No 24VAC output n04 Defrost mode setting 0 Easy to defrost for high humidity area 1 factory Standard mode 2 Hard to defrost for low humidity a...

Page 25: ...nic expansion valve EEV 1 Fully open during cooling mode and defrost operation 2 Control discharge superheat in heating mode 4 way valve ST1 Switches the operation mode between heating and cooling including defrost control Thermistor TH Uses to control defrosting during heating operation TA Uses to detect outdoor air temperature and control fan speed TS Uses to detect suction temperature and calcu...

Page 26: ... startup O OFF Outdoor unit rotation Cooling or heating operation Oil return IN conditions are met Defrost IN conditions are met NO NO Oil return operation 1 YES Defrost operation 1 YES Outdoor unit rotation Normal operation Compressor PI control EEV PI control Fan motor control Protection control Restart standby compressor stops Malfunction Thermostat OFF O be changed Malfunction Thermostat OFF O...

Page 27: ...minutes Fixed speed in most cases Depending on the load of the room Standby MAX 6 minutes for pressure equalization 2ton 3ton 4ton 5ton STEP frequency STEP RPS STEP RPS STEP RPS STEP RPS STEP RPS 1 12 10 30 19 48 28 66 37 84 2 14 11 32 20 50 29 68 38 86 3 16 12 34 21 52 30 70 39 88 4 18 13 36 22 54 31 72 40 90 5 20 14 38 23 56 32 74 6 22 15 40 24 58 33 76 7 24 16 42 25 60 34 78 8 26 17 44 26 62 35...

Page 28: ...st cases Standby after getting start signal MAX STEP Cooling fan control by high pressure Heating fan control by low pressure 14 4 4 Electronic expansion valve EEV control Startup control PI control Directive control Cooling 480pls Heating Differential control Fixed speed in most cases Standby after getting start signal Cooling 360pls 480pls Heating 360pls 0pls Cooling 480pls Heating Depending on ...

Page 29: ...irty air filter Blocked outlet of indoor unit The system is in startup control Outside temperature is too high Too little refrigerant in the system Clean or replace the air filter Eliminate any obstacles Wait the system to enter PI control Protection control for the system Check for leaks and refrigerant charge System cannot heat well Lack of refrigerant No third party heat source in cold winter C...

Page 30: ... load protection F1 Ambient temperature sensor fault TA Backup running 2 F2 Suction temperature sensor fault TS Backup running 2 F3 Liquid temperature sensor fault TL Backup running 2 F4 Condenser coil temperature sensor fault TH Backup running 2 F5 Discharge temperature sensor fault TD Backup running 2 F6 Module temperature sensor fault TF Backup running 2 F7 High pressure sensor fault HP Backup ...

Page 31: ...sten screws for it Turn off the unit for five minutes to fasten the screw Replace the fan motor YES Replace the main control board Replace the low pressure sensor Is the voltage between CN18 and CN19 i e L1 L2 208 230VAC Turn off the power supply for five minutes to confirm if cables connected to P2 and P3 terminals are securely fastened by screws Use multi meter to check whether the inductance is...

Page 32: ...one because of damaged TXV in cooling mode or damaged EEV in heating mode G signal is lost resulting in indoor unit FAN OFF in heating mode Damaged high pressure sensor Damaged main control board YES Note Connect a pressure gauge to liquid stop valve in cooling mode gas stop valve in heating mode Compare the value difference between gauged pressure and the transduced one by sensor NO Replace the h...

Page 33: ...or Damaged main control board Note Connect a pressure gauge to gas stop valve compare the difference between the gauged pressure and the transduced one by low pressure sensor NO YES NO Replace the low pressure sensor Can the pressure transduce measure properly according to Low Pressure Sensor Voltage Characteristics C YES Correct specific point Check visible parts for the system 1 Closed service v...

Page 34: ...unit Damaged discharge temperature sensor Damaged main control board NO NO Reset the sensor or reconnect the wire YES Replace the faulty sensor YES Check the refrigerant amounts NO Replace the compressor Display Are the stop valves of outdoor unit open NO Open the stop valve Check whether the discharge temperature sensor is properly seated on the discharge pipe and securely connected to CN7 termin...

Page 35: ...s disconnected or damaged Damaged main control board Loose connection at port on main control board There are other heat sources around the sensor Display YES NO Check whether TD sensor is seated to the compressor discharge pipe and securely connected to CN7 terminal on the main control board Reset and reconnect the TD sensor Check whether the Resistance of Temperature sensor B is correct YES NO R...

Page 36: ...used by resistance drift of TF sensor Dirty and blocked heat exchanger for the ODU Damaged TF sensor Damaged main control board Display YES NO Does the heat discharge channel for outside exchanger and the fan work properly Exclude heat discharge factor Is the heat exchanger in the back of main control board dirty or corroded resulting in poor performance NO YES Remove the dirty or blocked material...

Page 37: ...in control board Indoor unit is suddenly powered off Damaged compressor Display NO YES The power supply voltage is less than175VAC Contact agency supplying power to verify that they are sending the correct voltage Are the compressor wirings U V W connected correctly YES NO Reconnect the compressor wiring Check whether the compressor is open circuited Note NO YES Replace the compressor Can the syst...

Page 38: ...EV of outdoor unit in heating mode Damaged main control board Cooling mode Connect a pressure gauge at the gas stop valve to calculate suction superheat SH Display YES NO Has the proper R410A TXV been used for indoor unit R410A TXV is required for this inverter system Is the superheat at gas stop valve larger than 6F YES NO Check indoor unit e g TXV has no adjusting fan does not work filter is dir...

Page 39: ... the gauged one YES NO Replace the high pressure sensor Set high capacity mode and restart the unit does the error code remain NO Keep running Replace the main control board YES NO Reset the sensor or reconnect the wire YES Check whether the discharge temperature sensor is properly seated on the discharge pipe and securely connected to CN7 terminal on the main control board Lock the liquid stop va...

Page 40: ...otor cable connected to CN8 on main control board Connect the cable Turn off power supply check whether the motor shaft is stuck Try using tools to rotate the motor manually NO YES Replace the motor Replace the main control board Low compressor voltage protection 1 Error definition P8 The detected compressor voltage by main chip is less than 310VDC E8 System locks up when P8 has occurred three tim...

Page 41: ...board Loose connection at port on main control board Damaged temperature sensor There are other heat sources around the sensor YES NO Check whether TA sensor is seated to the specified location and connected to CN2 on the main control board Reconnect the sensor Check whether the resistance of sensor is in the range of Temperature sensor A YES NO Replace the faulty sensor Are there any other heat s...

Page 42: ...sensor Check whether the resistance of sensor is in the range of Temperature sensor A YES NO Replace the faulty sensor Are there any other heat sources around the sensor NO YES Remove other heat source Can the system go into backup running YES Replace the sensor Replace the main control board NO 1 Error definition The suction temperature sensor TS is short circuit or open circuit 2 Possible causes...

Page 43: ...oard Loose connection at port on main control board Damaged temperature sensor There are other heat sources around the sensor YES NO Check whether TL sensor is seated to the specified location and connected to CN4 on the main control board Reconnect the sensor Check whether the resistance of sensor is in the range of Temperature sensor A YES NO Replace the faulty sensor Are there any other heat so...

Page 44: ...ontrol board Loose connection at port on main control board Damaged temperature sensor There are other heat sources around the sensor YES NO Check whether TH sensor is seated to the specified location and connected to CN4 on the main control board Reconnect the sensor Check whether the resistance of sensor is in the range of Temperature sensor A YES NO Replace the faulty sensor Are there any other...

Page 45: ... Loose connection at port on main control board Temperature sensor failure There are other heat sources around the sensor YES NO Check whether TD sensor is seated to the specified location and connected to CN7 on the main control board Reconnect the sensor Check whether the resistance of sensor is in the range of Temperature sensor B YES NO Replace the faulty sensor Check whether there are other h...

Page 46: ... range of Temperature sensor B YES NO Replace the faulty sensor Note Check whether there are other heat sources around sensor NO YES Remove all the other heat source Replace the main control board 1 Error definition The module temperature sensor TF is short circuit or open circuit 2 Possible causes Damaged main control board Loose connection at port on main control board Temperature sensor failure...

Page 47: ...ittle refrigerant remains in the system 3 2 1 High pressure sensor red White black CN10 5V Measure voltage within this space High Pressure Sensor Voltage Characteristics D IC A D input GND YES NO Is the high pressure sensor connected to CN10 Reconnect the sensor Are the service valves opened YES NO Open stop valves Low pressure at gas stop valve to malfunction is 24 5 psig NO YES Check any refrige...

Page 48: ...little refrigerant remains in the system 3 2 1 Low pressure sensor red White black CN9 5V Measure voltage within this space Low Pressure Sensor Voltage Characteristics C IC A D input GND YES NO Is the low pressure sensor connected to CN9 Reconnect the sensor Are the service valves opened YES NO Open stop valves Low pressure at gas stop valve to malfunction is 24 5 psig NO YES Check any refrigerant...

Page 49: ...ive chip YES Replace the main control board NO External factor other than malfunction e g noise interference 1 Error definition and method to check Communication fault between the main control chip and inverter chip 2 Possible causes Loose connection at CN21 terminal Damaged main control board Turn off the power supply until the LED display lights off Unplug the cable from terminal CN21 Restart po...

Page 50: ...ambient temperature sensor TA Damaged main control board YES NO Check whether the ambient temperature sensor TA is seated to the specified location and connected to CN2 of PCB Reconnect the sensor Check whether the resistance of sensor is in the range of Temperature sensor A YES NO Replace the fault sensor Check whether there are other heat sources around sensor NO YES Remove all the other heat so...

Page 51: ...y too low voltage Temperature sensor TH failure 4 way valve is set up power on when cooling mode Display YES NO Is the output on connector CN14 4 way valve 220VAC in heating mode Replace the main control board Is the gas pipe close to service valve hot NO YES Check whether TH temperature sensor is failed Change the coil of 4 way valve and restart the system does the problem remain YES NO Normal co...

Page 52: ...econnect the cable Check whether the resistance of sensor is in the range of Temperature sensor A YES NO Replace the faulty sensor Are there any other heat sources around the sensor NO YES Remove all the other heat source Can the system go into back up running YES Replace the sensor Replace the main control board NO 1 Error definition The coil temperature sensor TH is short circuit or open circuit...

Page 53: ... power supply is turned off 2 Possible causes Damaged main control board Display Low voltage alarm 1 Error definition Power supply voltage is less than175VAC 2 Possible causes Abnormal power supply voltage Damaged main control board YES Cycle power for the unit can the system back to normal External interference e g electromagnetic Replace the main control board NO YES The power supply voltage is ...

Page 54: ...tion E0 System locks up when C0 C8 has occurred six times in 60 minutes 2 Possible causes Abnormal power supply voltage Vdc increases due to storm or hurricane Dirty compressor terminal Damaged main control board Damaged compressor Display YES NO The power supply voltage is not in the range of 175 280VAC Contact agency supplying power to verify that they are sending the correct voltage Is the fan ...

Page 55: ...9 32 89 6 7 31 2 42 33 91 4 6 99 2 44 34 93 2 6 70 2 47 35 95 6 41 2 50 36 96 8 6 14 2 52 37 98 6 5 89 2 55 38 100 4 5 64 2 57 39 102 2 5 41 2 60 40 104 5 19 2 62 41 105 8 4 97 2 64 42 107 6 4 77 2 66 43 109 4 4 58 2 69 44 111 2 4 39 2 71 45 113 4 22 2 73 46 114 8 4 05 2 74 47 116 6 3 89 2 76 48 118 4 3 74 2 78 49 120 2 3 59 2 80 50 122 3 45 2 81 51 123 8 3 32 2 83 52 125 6 3 19 2 85 53 127 4 3 07...

Page 56: ... 2 15 45 113 24 32 2 17 46 114 8 23 38 2 20 47 116 6 22 49 2 23 48 118 4 21 63 2 26 49 120 2 20 81 2 29 50 122 20 02 2 31 51 123 8 19 27 2 34 52 125 6 18 55 2 37 53 127 4 17 86 2 39 54 129 2 17 20 2 42 55 131 16 57 2 44 56 132 8 15 96 2 46 57 134 6 15 38 2 49 58 136 4 14 82 2 51 59 138 2 14 29 2 53 60 140 13 77 2 55 61 141 8 13 28 2 57 62 143 6 12 81 2 59 63 145 4 12 36 2 61 64 147 2 11 92 2 63 65...

Page 57: ... 9 22 01 1 34 0 44 63 8 21 14 1 38 0 46 66 7 20 32 1 42 0 48 69 6 19 54 1 46 0 50 72 5 18 81 1 50 0 52 75 4 18 11 1 54 0 54 78 3 17 45 1 58 0 56 81 2 16 82 1 62 0 58 84 1 16 22 1 66 0 61 88 5 15 37 1 72 0 63 91 4 14 84 1 76 0 65 94 3 14 33 1 80 Low pressure MPa Low pressure psig Resistance KΩ Output voltage V 0 68 98 6 13 61 1 86 0 70 102 13 15 1 90 0 73 106 12 50 1 96 0 76 110 11 89 2 02 0 78 113...

Page 58: ...4 203 15 41 1 72 1 5 217 5 14 27 1 80 1 6 232 13 25 1 89 1 7 246 5 12 31 1 98 1 8 261 11 45 2 07 1 9 275 5 10 66 2 15 2 0 290 9 94 2 24 2 1 304 5 9 26 2 33 2 2 319 8 64 2 41 2 3 333 5 8 06 2 50 2 4 348 7 52 2 59 2 5 362 5 7 01 2 67 2 6 377 6 54 2 76 2 7 391 5 6 09 2 85 2 8 406 5 67 2 93 2 9 420 5 5 28 3 02 3 0 435 4 90 3 11 High pressure MPa High pressure psig Resistance KΩ Output voltage V 3 1 44...

Page 59: ...ESI Outdoor Unit Installation Instruction 05 2018 Manufacturer reserves the right to change at any time for specifications or designs without notice and incurring obligations EODA18H 2436 15 3 Wiring Diagram ...

Page 60: ...60 61 ESI Outdoor Unit Installation Instruction 05 2018 Manufacturer reserves the right to change at any time for specifications or designs without notice and incurring obligations EODA18H 4860 ...

Page 61: ...61 61 ESI Outdoor Unit Installation Instruction 05 2018 Manufacturer reserves the right to change at any time for specifications or designs without notice and incurring obligations Notes ...

Page 62: ...62 61 ESI Outdoor Unit Installation Instruction 05 2018 Manufacturer reserves the right to change at any time for specifications or designs without notice and incurring obligations ...

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