ICP C4A318GKA100, C4A318GKD100, C4A324GKD100, C4A330GKA100, C4A330GKD100 Installation Guide
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INSTALLATION INSTRUCTIONS
R- 410A Split System Air Conditioner
C4A3, H4A3, T4A3,
CXA6, HXA6, TXA6
These instructions must be read and understood completely before attempting installation.
IMPORTANT: Effective January 1, 2015, all split system and packaged air conditioners must be installed pursuant to
applicable regional efficiency standards issued by the Department of Energy.
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical
shock, or other conditions which may cause death,
personal injury, or property damage. Consult a qualified
installer, service agency, or your distributor or branch for
information or assistance. The qualified installer or
agency must use factory- authorized kits or accessories
when modifying this product. Refer to the individual
instructions packaged with the kits or accessories when
installing.
Follow all safety codes. Wear safety glasses, protective
clothing, and work gloves. Use quenching cloth for
brazing operations. Have fire extinguisher available.
Read these instructions thoroughly and follow all
warnings or cautions included in literature and attached
to the unit. Consult local building codes and current
editions of the National Electrical Code (NEC) NFPA 70.
In Canada, refer to current editions of the Canadian
electrical code CSA 22.1.
Recognize safety information. This is the safety- alert
!
!
symbol
instructions or manuals, be alert to the potential for
personal injury. Understand these signal words;
DANGER, WARNING, and CAUTION. These words are
used with the safety- alert symbol. DANGER identifies
the most serious hazards which will result in severe
personal injury or death. W ARNING signifies hazards
which could result in personal injury or death. CAUTION
is used to identify unsafe practices which would result in
minor personal injury or product and property damage.
NOTE is used to highlight suggestions which will result
in enhanced installation, reliability, or operation.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF
position. There may be more than 1 disconnect
switch. Lock out and tag switch with a suitable
warning label.
When you see this symbol on the unit and in
!
WARNING
!
WARNING
EXPLOSION HAZARD
Failure to follow this warning could
result in death, serious personal
injury, and/or property damage.
Never use air or gases containing
oxygen for leak testing or
operating refrigerant compressors.
Pressurized mixtures of air or
gases containing oxygen can lead
to an explosion.
INSPECT NEW UNIT
After uncrating the unit, inspect it thoroughly for any
obvious or hidden damage. If damage is found, notify the
transportation company immediately and file a
concealed damage claim.
!
PROPERTY DAMAGE HAZARD
Failure to follow this caution mayresult in property damage
R- 410A systems operate at higher pressures than
R- 22 systems. When working with R- 410A systems, use only service equipment and replacement components specifically rated or approved
for R- 410A service.
CUT HAZARD
Failure to follow this c aution may result in personal
injury.
Sheet metal parts may have sharp edges or burrs. Use
care and wear appropriate protective clothing and
gloves when handling parts.
CAUTION
!
CAUTION
LOCATION
Check local codes for regulations concerning zoning,
noise, platforms, and other issues.
Locate unit away from fresh air intakes, vents, or
bedroom windows. Noise may carry into the openings
and disturb people inside.
421 01 5103 05 9/22/17
INSTALLA TION INSTRUCTIONS R- 410A Split System Air Conditioner
Locate unit in a well drained area, or support unit high
enough so that water runoff will not enter the unit.
Locate unit away from areas where heat, lint, or exhaust
fumes will be discharged onto unit (as from dryer vents).
Locate unit away from recessed or confined areas where
recirculation of discharge air may occur (refer to
CLEARANCES section of this document).
Roof- top installation is acceptable providing the roof will
support the unit and provisions are made for water
drainage and noise/vibration dampening.
NOTE: Roof mounted units exposed to wind may require
wind baffles. Consult the manufacturer for additional
information.
CLEARANCES
When installing, allow sufficient space for airflow
clearance, wiring, refrigerant piping, and service. Allow
24 in. (610 mm) clearance to service end of unit and 48 in.
(1219.2 mm) above unit. For proper airflow , a 6 in. (152.4
mm) clearance on one side of unit and 12 in. (304.8 mm)
on all remaining sides must be maintained. Maintain a
distance of 24 in. (609.6 mm) between units or 18 in.
(457.2 mm) if no overhang within 12 ft. (3.66 m). Position
so water, snow, or ice from roof or eaves cannot fall
directly on unit.
Operating Ambient
The minimum outdoor operating ambient in cooling mode
without accessory is 55_F (12.78_C). The maximum outdoor
operating ambient in cooling mode is 125_F (51.7_C) for
non- 13 SEER models and 115_F (46.11_C) for 13 SEER
models.
UNIT SUPPORT
NOTE: Unit must be level + 2 degrees [a ⅜inch rise or fall
per foot of run (10 mm rise or fall per 305 mm of run)] or
compressor may not function properly.
or pad does not shift or settle and leave the unit partially
supported. Minimum pad dimensions are shown in
Figure 1.
If beams or an open platform are used for support, it is
recommended that the soil be treated or area be
graveled to reduce the growth of grasses and weeds.
To minimize vibration or noise transmission, it is
recommended that supports not be in contact with the
building structure. However, slabs on grade
constructions with an extended pad are normally
acceptable.
B. ROOF TOP INSTALLATION
This type of installation is not recommended on wood
frame structures where low noise levels are required.
Supporting structure or platform for the unit must be
level. If installation is on a flat roof, locate unit minimum 6
inches (152 mm) above roof level.
Place the unit over one or more load bearing walls. If
there are several units, mount them on platforms that are
self- supporting and span several load bearing walls.
These suggestions are to minimize noise and vibration
transmission through the structure. If the structure is a
home or apartment, avoid locating the unit over
bedrooms or study.
NOTE: When unit is to be installed on a bonded
guaranteed roof, a release must be obtained from the
building owner to free the installer from all liabilities.
C. FASTENING UNIT DOWN
If conditions or local codes require the unit be attached in
place, remove the knockouts in the base pan and install
tie down bolts through the holes (refer to Figure 1).
Contact local distributor for hurricane hold- down details
and the P .E. (Professional Engineer) certification, when
required.
!
CAUTION
A. GROUND LEVEL INSTALLATION
The unit must be level and supported above grade by
beams, platform, or a pad. Platform or pad can be of
open or solid construction but should be of permanent
materials such as concrete, bricks, blocks, steel, or
pressure- treated timbers approved for ground contact.
Soil conditions must be considered so that the platform
2 421 01 5103 05
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in
property damage.
Inadequate unit support may cause excessive vibration, noise, and/or stress on the refrigerant
lines, leading to refrigerant line failure.
INSTALLA TION INSTRUCTIONS R- 410A Split System Air Conditioner
Figure 1 Tie Down Knockouts
a” (10mm) dia. Tie Down Knockouts
In Base Pan (2 places)
A
Base Pan
Width x
Depth
23 x 23
(584 x 584)
25- 11/16 x
25- 11/16
(652 x 652)
31- 1/8 x
31- 1/8
(791 x 791)
34- 15/16 x
34- 15/16
(887 x 887)
Base Pan Width
Inches (mm)
Tie Down
Knockouts
A B C
7- 3/4
(197)
9- 1/16
(230)
9- 1/16
(230)
9- 1/16
(230)
4- 7/16
(113)18(457)
4- 7/16
(113)
6- 1/2
(165)
6- 1/2
(165)
21- 1/4
(540)
24- 5/8
(625)
28- 7/16
(722)
View From Top
Base
Pan
Depth
C
B
Minimum
Mounting Pad
Dimensions
23 x 23
(584 x 584)
26 x 26
(660 x 660)
31- 1/2 x
31- 1/2
(800 x 800)
35 x 35
(889 x 889)
REFRIGERATION SYSTEM
A. COMPONENT MATCHES
Check to see that the proper system components are in
place, especially the indoor coil.
R- 410A outdoor units can only be used with R- 410A
specific indoor coils. If there is a refrigerant mis- match,
consult the indoor coil manufacturer to determine if a
refrigerant conversion kit is available for the indoor coil.
This outdoor unit is designed for use only with indoor
coils that utilize a TXV refrigerant metering device or
Piston with Teflon ring metering device. If any other type
of metering device is installed on the indoor coil, consult
the indoor coil manufacturer to determine if a TXV
conversion kit is available.
Installing with TXV
When installing a TXV on an indoor coil, follow the
instructions provided with the new TXV.
A typical TXV installation is shown in Figure 2.
Figure 2
Typical TXV Installation
INDOOR
COIL
EQUALIZER
TUBE
SENSING
BULB
SUCTION
TUBE
LIQUID
TUBE
TXV
10 O’clock
3/4
2 O’clock
SENSING BULB
STRAP
SUCTION TUBE
IN. OD & SMALLER
Installing with Indoor Piston - cooling operation.
Check piston size shipped with indoor unit to see if it
matches required indoor piston size. If it does not
match, replace indoor piston with the correct piston size.
NOTE: Correct pistons are shipped with select outdoor
units in the accessory bag and are only for use in certain
qualified and approved fancoils, i.e. FEM4P. (See
Product Specifications for list of approved fancoils that
use accessory piston.)
The piston included with the FMA4P* and FM(C,U)4P*
fancoils are unique to those products and cannot be
replaced with the piston shipped with the outdoor unit.
Refer to the AHRI Directory to check if your combination
can use a piston or requires an accessory TXV.
SeeFigure3.
When changing indoor piston, use a back- up wrench.
Hand tighten hex nut, then tighten with wrench 1/2 turn.
Do not exceed 30 ft- lbs.The indoor piston contains a
Teflon ring (or seal) which is used to seat against the
inside of distributor body, and must be installed properly
to ensure proper seating in the direction for cooling
operation.
421 01 5103 05 3
Specifications subject to change without notice.
INSTALLA TION INSTRUCTIONS R- 410A Split System Air Conditioner
Figure 3 Indoor (cooling) Piston
BRASS
HEX NUT
B. REFRIGERANT LINE SETS
The refrigerant line set must be properly sized to assure
maximum efficiency and proper oil circulation.
Refer to Product Specifications and Long Line
Applications Guideline for line set sizing.
NOTE: Total line set length must not exceed 200 feet (61
m).
A crankcase heater must be used when the refrigerant
line length exceeds 80 feet (24.4 m).
If outdoor unit is more than 10 feet (3 m) higher than the
indoor coil, refer to the Long Line Applications Guideline
for instructions.
When the outdoor unit is higher than the indoor coil, the
vertical separation must not exceed 100 feet (30 m).
When the outdoor unit is lower than the indoor coil, the
vertical separation must not exceed 50 feet (15.2 m).
If it is necessary to add refrigerant line in the field, use
dehydrated or dry, sealed, deoxidized, copper
refrigeration tubing. Do not use copper water pipe.
Do not remove rubber plugs or caps from copper tubing
until connections are ready to be made.
TEFLON SEAL
PISTON
RETAINER
STRAINER
TEFLON RING
PISTON
FLOW IN
COOLING
DISTRIBUTOR
BRASS
HEX BODY
L10S017
Be extra careful when bending refrigeration tubing.
Tubing can “kink” easily, and if this occurs, the entire
length of tubing must be replaced.
!
PERSONAL INJURY HAZARD
Failure to relieve system pressure could result in
personal injury and/or death.
Relieve pressure and recover all refrigerant before servicing existing equipment, and before final unit disposal. Use all service ports and open
all flow- control devices, including solenoid
valves.
C. ROUTING AND SUSPENDING REFRIGERANT
LINES
Run refrigerant lines as straight and direct as possible,
avoiding unnecessary bends and turns. Always insulate
the entire suction line. Both lines should be insulated
when routed through an attic or when routed through an
underground raceway.
When routing refrigerant lines through a foundation or wall,
do not allow refrigerant lines to come in direct contact with
the building structure. Make openings large enough so that
lines can be wrapped with extra insulation. Fill all gaps with
RTV caulk. This will prevent noise transmission between
the tubing and the foundation or wall.
Along floor or ceiling joists, suspend refrigerant lines so
that they do not contact the building structure, water
pipes, or ductwork. Use insulated or suspension type
hangers. Metal straps must be at least 1” (25 mm) wide to
avoid cutting into the tube insulation. Keep the liquid and
suction lines separate. Refer to Figure 4.
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper product operation.
Do not leave system open to atmosphere any longer than absolutely required for installation. Internal system components - especially refrigerant
oils - are extremely susceptible to moisture contamination. Keep ends of tubing sealed during installation until the last possible moment.
WARNING
CAUTION
4 421 01 5103 05
INSTALLA TION INSTRUCTIONS R- 410A Split System Air Conditioner
Figure 4 Routing and Suspending Refrigerant Lines
OUTDOOR WALL INDOOR WALL
!
CAULK
INSULATION
THROUGH THE WALL SUSPENSION
CAUTION
LIQUID TUBE
SUCTION TUBE
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper product operation.
Do not bury more than 36” (1m) of line set underground. Refrigerant may migrate to cooler buried
section during extended periods of unit shutdown, causing refrigerant slugging and possible
compressor damage at start- up.
If ANY section of the line set is buried underground, provide a minimum 6” (152mm) vertical
rise at the service valve.
HANGER STRAP
(AROUND SUCTION
TUBE ONLY)
1” (25mm)
MIN
Figure 5
JOIST
INSULATION
SUCTION TUBE
LIQUID TUBE
Liquid Line Filter- Drier
Installed at Indoor Coil
D. OUTDOOR UNIT HIGHER THAN INDOOR UNIT
Proper oil return to the compressor should be maintained
with suction gas velocity. If velocities drop below 1500
fpm (feet per minute), oil return will be decreased. To
maintain suction gas velocity, do not upsize vertical
suction risers.
E. LIQUID LINE FILTER- DRIER
Outdoor units are shipped with an appropriate filter- drier
for installation in the liquid line. Leave the plugs in the
tube ends until the filter- drier is installed. The optimal
location for the filter- drier is close to the indoor coil.
Install the filter- drier with the arrow pointing towards the
indoor coil. Refer to Figure 5.
Filter- Drier
(arrow points towards indoor coil)
38- 11- 84
F. SERVICE VALVES
Service valves are closed and tube stubs are plugged
from the factory. Outdoor units are shipped with a
refrigerant charge sealed in the unit. Leave the service
valves closed until all other refrigerant system work is
complete or the charge will be lost. Leave the plugs in
place until line set tubing is ready to be inserted.
Service valve bodies are brass and tube stubs are
copper.
421 01 5103 05 5
Specifications subject to change without notice.
INSTALLA TION INSTRUCTIONS R- 410A Split System Air Conditioner
Figure 6 Service Valve
VALVE CORE
SERVICE VALVE
G. BRAZING CONNECTIONS
NOTE: Remove valve core from schrader port on both
Service Valves BEFORE brazing. This helps prevent
overheating and damage to valve seals (refer to Figure 6).
Replace valve core when brazing is completed.
!
WARNING
FIRE HAZARD
Failure to remove refrigerant and oil charge before brazing could result in personal injury, death,
and/or property damage.
Refrigerant and oil mixture could ignite and burn
as it escapes and contacts brazing torch. Make
sure the refrigerant charge is properly removed
from both the high and low sides ofthe system before brazing any component or lines.
Clean line set tube ends with emery cloth or steel brush.
Remove any grit or debris.
Insert line set tube ends into service valve tube stubs.
Apply heat absorbing paste or heat sink product between
service valve and joint. Wrap service valves with a heat
sinking material such as a wet cloth.
Braze joints using a Sil- Fos or Phos- copper alloy.
!
CAUTION
!
CAUTION
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product damage.
Never use the outdoor unit compressor as a vacuum pump. Doing so may damage the compressor .
Line set and indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns. If
deep vacuum equipment is not available, the alternate
triple evacuation method may be used by following the
specified procedure.
If vacuum must be interrupted during the evacuation
procedure, always break vacuum with dry nitrogen.
Deep Vacuum Method
The deep vacuum method requires a vacuum pump
capable of pulling a vacuum to 500 microns and a
vacuum gauge capable of accurately measuring this
vacuum level. The deep vacuum method is the most
positive way of assuring a system is free of air and water.
Watch the vacuum gauge as the system is pulling down.
The response of the gauge is an indicator of the condition
of the syst em (refer to Figure 7).
With no leaks in the system, allow the vacuum pump to
run for 30 minutes minimum at the deep vacuum level.
Figure 7
5000
4500
4000
3500
3000
2500
2000
MICRONS
1500
1000
500
Deep Vacuum Gauge Response
and System Conditions
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product damage.
Braze with Sil- Fos or Phos - copper alloy on copper- to- copper joints and wrap a wet cloth around
rear of fitting to prevent damage to TXV.
H. EVACUATING LINE SET AND INDOOR COIL
The unit is shipped with a factory refrigerant charge. The
liquid line and suction line service valves have been closed
after final testing at the factory. Do not disturb these valves
until the line set and indoor coil have been evacuated and
leak checked, or the charge in the unit may be lost.
NOTE: Do not use any portion of the factory charge for
purging or leak testing. The factory charge is for filling the
system only after a complete evacuation and leak check
has been performed.
01
Triple Evacuation Method
The triple evacuation method should only be used when
system does not contain any water in liquid form and
vacuum pump is only capable of pulling down to 28 inches
of mercury (71 1mm Hg). Refer to Figure 8 and proceed as
follows:
1. Pull system down to 28 inches of mercury
(711mm Hg) and allow pump to continue
operating for an additional 15 minutes.
2. Close manifold valves or valve at vacuum pump
and shut off vacuum pump.
3. Connect a nitrogen cylinder and regulator to
system and fill with nitrogen until system pressure
is 2 psig.
375
246
MINUTES
6 421 01 5103 05
INSTALLA TION INSTRUCTIONS R- 410A Split System Air Conditioner
4. Close nitrogen valve and allow system to stand for
1 hour. During this time, dry nitrogen will diffuse
throughout the system absorbing moisture.
5. Repeat this procedure as indicated in Figure 8.
6. After the final evacuate sequence, confirm there
are no leaks in the system. If a leak is found,
repeat the entire process after repair is made.
Figure 8
BREAK VACUUM WITH DRY NITROGEN
BREAK VACUUM WITH DRY NITROGEN
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
I. OPENING SERVICE VALVES
Outdoor units are shipped with a refrigerant charge
sealed in the unit. Opening the service valves releases
this charge into the system.
NOTE: Open the Suction service valve first. If the Liquid
service valve is opened first, oil from the compressor
may be drawn into the indoor coil TXV, restricting
refrigerant flow and affecting operation of the system.
Remove Suction service valve cap and insert a hex
wrench into the valve stem. Hold the valve body steady
with an end- wrench and back out the stem by turning the
hex wrench counterclockwise. Turn the stem until it just
contacts the rolled lip of the valve body.
After the refrigerant charge has bled into the system,
open the Liquid service valve.
NOTE: These are not back- seating valves. It is not
necessary to force the stem tightly against the rolled lip.
The service valve cap is a primary seal for the valve and
must be properly tightened to prevent leaks. Make sure
cap is clean and apply refrigerant oil to threads and
sealing surface on inside of cap.
Tighten cap finger tight and then tighten additional 6 of a
turn (1 wrench flat) to properly seat the sealing surfaces.
421 01 5103 05 7
Triple Evacuation Sequence
EVACUATE
WAIT
EVACUATE
WAIT
EVACUATE
CHARGE SYSTEM
Specifications subject to change without notice.
J. GAUGE PORTS
Check for leaks at the schrader ports and tighten valve
cores if necessary. Install plastic caps finger tight.
ELECTRICAL WIRING
(*XA6 all sizes; *4A3 sizes 18, 36- 60
only)
NOTE: *4A3 sizes 24 and 30 on page 14.
!
ELECTRICAL SHOCK HAZARD
Failure to turn off the main (remote) electrical disconnect device could result in personal injury or
death.
Before installing, modifying or servicing system,
turn OFF the main (remote) electrical disconnect
device. There may be more than one disconnect
device.
The supply voltage must be 208/230 volts (197 volt
minimum to 253 volts maximum) 60 Hz single phase.
Outdoor units are approved for use with copper
conductors only. Do not use aluminum wire.
Refer to unit rating plate for minimum circuit ampacity
and circuit protection requirements.
Grounding
Permanently ground unit in accordance with the National
Electrical Code and local codes or ordinances. Use a
copper conductor of the correct size from the grounding
lug in control box to a grounded connection in the service
panel or a properly driven and electrically grounded
ground rod.
Wiring Connections
Make all outdoor electrical supply (Line Voltage)
connections with raintight conduit and fittings. Most
codes require a disconnect switch outdoors within sight
of the unit. Consult local codes for special requirements.
Route electrical supply (Line Voltage) wiring through
knockout hole in bottom of Control Box. Connect wires to
Contactor and Ground Lug according to Wiring Diagram
on unit. Refer to Figure 9.
Route thermostat wiring through rubber grommet in
bottom of Control Box. Low voltage lead wires are
provided in the control box for connection to thermostat
wires (use wire nuts). Refer to Wiring Diagram on unit
and Figure 10 for low voltage wiring examples.
NOTE: Use No. 18 AWG (American Wire Gage)
color- coded, insulated (35 ° C minimum) wire. If
thermostat is located more than 100 feet (31 m) from unit
as measured along the control voltage wires, use No. 16
AWG color- coded wires to avoid excessive voltage
drop.
NOTE: Some models are factory equipped with Comfort
Alertt Diagnostics device. If Comfort Alert is used as a
field installed option, then a hot bundle must be run for
proper connection.
WARNING
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