Assessments - 5, GPA: 4
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5. Refrigerant tubing and indoor coil are now read for leak testing. This check should include all field and factory joints. MECHANICAL CONNECTION (38CKQ MODELS) 1. Cut tubing to correct length, deburr, and size as necessary, making sure tube ends are square. If a large burr is evident, ID and OD must be deburred to allow tube to bottom in valve. 2. Remove lock nuts and ferrules from plastic bags taped to service panel. (See Fig. 5.) A92120VALVE FITTING FERRULE LOCK NUT Fig. 5—Mechanical Fitting Assembly (38CKQ) If undersized, damaged, or elliptically shaped tubing is used when making connection, leaks could result. 3. Slide lock nut and ferrule onto each tube. (See Fig. 6.) TUBING FERRULE LOCK NUT A92121 Fig. 6—Lock Nut/Ferrule Positioning (38CKQ) 4. Apply a few drops of refrigerant oil to ferrule and valve threads to reduce assembly torque and assist sealing. 5. Insert tube end into service valve until it bottoms. 6. Push ferrule into place and hand tighten nut until an increase in torque is felt. 7. Mark nut and tube and tighten 1-1/2 turns from mark. (See Fig. 7.) Keep tube bottomed in valve while tightening nut. NOTE: A backup wrench on the hex part of the suction valve is required while tightening. The tube end must stay bottomed in the service valve during final assembly to ensure proper seating, sealing, and rigidity. MECHANICAL FITTING REPAIR To replace damaged ferrule or tubing proceed as follows. 1. Attach gages to service valves. 2. Close liquid service valve and operate unit to pump refrigerant charge into condenser coil. 3. When suction pressure reaches 5 psig, shut unit off. Do not operate unit in a vacuum. 4. Close suction service valve and recover refrigerant in tubing. 5. Back-off locknut and ferrule onto tube. 6. Remove damaged part of tubing using tubing cutter. Repeat installation procedure previously outlined using new ferrule. 7. Evacuate tubing set and indoor coil. Check for leaks. 8. Open service valves or recharge unit. Check refrigerant charge. Step 7—Install Solenoid Valve In Liquid Tube (If Required) Not all applications require use of a liquid tube solenoid valve. If your unit has been shipped with a liquid tube solenoid valve in the unit, it must be installed for performance enhancement. The liquid tube solenoid valve must be energized during evacuation for complete removal of refrigerant. Before making liquid tube connections, install factory-supplied solenoid valve on indoor liquid fitting. (See Fig. 8.) Be sure to use flare adapter supplied with the indoor coil when making connections. 3 Fig.7—ProperMarkingofValveAssembly(38CKQ) A92122LOCK NUT MARK ON LOCK NUT AND TUBE TUBING LOCK NUT MARK ON LOCK NUT AND TUBE TUBING ELECTRICAL JUNCTION ELECTRICAL COIL VALVE FLOW ARROW STRAIGHT 3/8 IN. STUD NOTE:System flow direction must match arrow on bottom of body. A87044 Fig. 8—Solenoid Valve Installation Wiring must comply with local codes and NEC requirements, if a field-supplied control power source is needed when adding solenoid. 1. Remove coil liquid connection cap and discard. 2. Mount solenoid valve on liquid tube, making sure valve flow arrow points toward indoor coil. Mount valve in any position except valve body at top and electric coil at bottom. (See Fig. 8.) Solenoid valve is to be installed a maximum of 2 ft from indoor coil. Avoid valve damage while brazing by wrapping valve with a heat-sinking material such as a wet cloth. 3. Braze valve onto end of liquid tube using silver bearing or non-silver bearing brazing material. Consult local code requirements. 4. Braze flare adapter onto outlet end of solenoid valve. 5. Wire solenoid coil into system control circuit. Step 8—Make Electrical Connections To avoid personal injury or death, do not supply power to unit with compressor terminal box cover removed. Be sure field wiring complies with local and national fire, safety, and electrical codes, and voltage to system is within limits shown on unit rating plate. Contact local power company for correction of improper voltage. See unit rating plate for recommended circuit protection device. NOTE: Operation of unit on improper line voltage constitutes abuse and could affect unit reliability. See unit rating plate. Do not install unit in system where voltage or phase imbalance (3 phase) may fluctuate above or below permissible limits. NOTE: Use copper wire only between disconnect switch and unit. NOTE: Install branch circuit disconnect of adequate size per NEC to handle unit starting current. Locate disconnect within sight from and readily accessible from unit, per Section 440-14 of NEC. ROUTE GROUND AND POWER WIRES — Remove access panel to gain access to unit wiring. Extend wires from disconnect through power wiring hole provided and into unit control box. The unit cabinet must have an uninterrupted or unbroken ground to minimize personal injury if an electrical fault should occur. The ground may consist of electrical wire or metal conduit when installed in accordance with existing...