ICP C4A318GKD100, C4A324GKD100, C4A330GKD100, C4A336GKD100, C4A342GKD100 Installation Guide

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These instructions must be read and understood completely before attempting installation.

Safety Labeling and Signal Words

DANGER, WARNING, CAUTION, and NOTE

The signal words DANGER, WARNING, CAUTION, and NOTE are used to identify levels of

hazard seriousness. The signal word DANGER is only used on product labels to signify an immediate

hazard. The signal words WARNING, CAUTION, and NOTE will be used on product labels and throughout this manual and other manuals that may

apply to the product. DANGER - Immediate hazards which will result in

severe personal injury or death. WARNING - Hazards or unsafe practices which

could result in severe personal injury or death. CAUTION - Hazards or unsafe practices which

may result in minor personal injury or product or property damage.

NOTE - Used to highlight suggestions which will result in enhanced installation, reliability, or

operation.

Signal Words in Manuals The signal word WARNING is used throughout this

manual in the following manner:

The signal word CAUTION is used throughout this manual in the following manner:

Signal Words on Product Labeling Signal words are used in combination with colors

and/or pictures on product labels.

TABLE OF CONTENTS

Inspect New Unit ............................... 2

Safety Considerations ........................... 2

Location ....................................... 2

Clearances ................................. 2 - 3

Unit Support ................................... 4

Refrigeration System ........................ 5 - 8

Electrical Wiring ............................ 9 - 10

Start-up Procedure ............................ 11

Refrigerant Charge ........................ 11 - 12

Sequence of Operation ......................... 12

Troubleshooting ............................... 13

Maintenance .................................. 13

Comfort Alert TM Diagnostics Codes .............. 14

R-410A Quick Reference Guide ................. 15

DEATH, PERSONAL INJURY, AND/OR PROPERTY DAMAGE HAZARD

Failure to carefully read and follow this warning

could result in equipment malfunction, property damage, personal injury and/or death.

Installation or repairs made by unqualified per-

sons could result in equipment malfunction, prop- erty damage, personal injury and/or death.

The information contained in this manual is in- tended for use by a qualified service technician fa-

miliar with safety procedures and equipped with

the proper tools and test instruments.

Installation must conform with local building

codes and with the National Electrical Code

NFPA70 current edition or Canadian Electrical

Code Part 1 CSA C.22.1.

421 01 5102 01 May 2009

INSPECT NEW UNIT

After uncrating unit, inspect thoroughly for hidden company immediately and file a concealed damage damage. If damage is found, notify the transportation claim.

SAFETY CONSIDERATIONS

Consult a qualified installer, service agency, or the dealer/distributor for information and assistance. The

qualified installer must use factory authorized kits and accessories when modifying this product. Refer to the

individual instructions packaged with the kit or accessory

when installing. The weight of the product requires careful and proper

handling procedures when lifting or moving to avoid personal injury. Use care to avoid contact with sharp or

pointed edges. Follow all safety codes. Wear safety glasses, protective

clothing, and work gloves. Use a heat sinking material - such as a wet rag - during brazing operations. Keep a fire

extinguisher available. Consult local codes and the

National Electric Code (NEC) for special requirements. Improper installation, adjustment, alteration, service or

maintenance can void the warranty.

ELECTRICAL SHOCK HAZARD Failure to turn off the main (remote) electrical dis-

connect 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. Lock out and tag switch with a suitable warning label.

PROPERTY DAMAGE HAZARD Failure to follow this caution may result in proper-

ty damage

R-410A systems operate at higher pressures than R-22 systems. When working with R-410A sys-

tems, use only service equipment and replace-

ment components specifically rated or approved

for R-410A service.

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.

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).

CLEARANCES

Nominal minimum clearances are 48 inches (1.2m) above unit for discharge air and 18 inches (457mm) on each side of the coil for intake air. Clearance on any one side of the coil (normally between unit and structure) may

be reduced to 6 inches (152mm). Nominal minimum clearances are based on a solid parallel object such as a wall or roof overhang.

The clearance may be reduced for a single object with small surface area, such as the end of a wall, outside corner of a wall, fence section, post, etc. As a general

rule, the minimum clearance from the unit should equal the width of the object. For example, a 6 inch (152mm) fence post should be a minimum of 6 inches (152mm)

from the unit.

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.

Do not install unit under roof overhangs unless gutters are present. A minimum vertical clearance of 48 inches (1.2m) is required to the overhang.

Inside corner locations on single story structures require

evaluation. Large overhanging soffits may cause air recirculation in a corner area even though recommended

minimum clearances are maintained. As a guide, locate the unit far enough out so that half of the discharge grille is

out from under the soffit. When placing two or more units side-by-side, provide a

minimum of 18 inches (457mm) between units. Provide minimum service clearance of 24 inches

(610mm) from control box corner and side service panel. Refer to Figure 1.

2 421 01 5102 01

Figure1 _ Clearances (various examples)

liiii !!i,!i

(152mm)

24"

(610mm)

Service

18"

(457mm)

18"

(457mm)

18"

(457mm)

24" i

(610mm) Service _;

152ram)

18"

(457mm)

24"

(610mm) I

Service L_"

(6lOre.m) i

(152mm)

(102mm)

24" i

18"

(152mm)

(102mm)

wide fence

(610mm)

Service

24" Jr

(152mm)

24"

(610mm)

18"

(457mm)

Service

(152mm)

Post

(610mm)

Service

24" __

18"

(457mm)

18"

(457mm)

18"

(457mm)

I 18"

421 01 5102 01 3

UNIT SUPPORT

NOTE: Unit must be level + 2 degrees {% inch rise or fall

per foot of run (10mm rise or fall per 305 mm of run) }or compressor may not function properly.

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 or

pad does not shift or settle and leave the unit partially supported. Minimum pad dimensions are shown in Figure

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 fiat roof, locate unit minimum 6 inches

(152mm) 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 2).

Contact local distributor for hurricane hold-down details and the P.E. (Professional Engineer) certification, when

required.

Figure 2 J Tie Down Knockouts

%" (10rnrn) dia. Tie Down Knockouts [ View From Top In Base Pan (2 places)

Base

Pan

Depth

o o

Base Pan Width

Inches (mm)

Base Pan

Width x Depth

23 x 23

(584 x 584)

25%6 x 25%6

(652 x 652)

31YBx 31Y8

(791 x 791)

3415_6x 3415_6

(887 x 887)

Tie Down

Knockouts

A B C

73_ 47_6 18

(197) (113) (457)

9_6 47_6 21¼

(230) (113) (540)

9_e 6Y2 24%

(230) (165) (625)

9_e 6Y2 287_6

(230) (165) (722)

Minimum

MountingPad

Dimensions

23 x 23

(584 x 584)

26 x 26

(660 x 660) 31Y2x 31Y2

(800 x 800)

35 x 35

(889 x 889)

PROPERTY DAMAGE HAZARD Failure to follow this caution may result in proper-

ty damage.

Inadequate unit support may cause excessive

vibration, noise, and/or stress on the refrigerant

lines, leading to refrigerant line failure.

4 421 01 5102 01

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. If any other type of metering device is installed on the indoor coil,

consult the indoor coil manufacturer to determine ifa TXV conversion kit is available.

PRODUCT DAMAGE HAZARD Failure to follow this caution may result in product

damage. Indoor coil and outdoor unit must be listed as a

certified combination (match) in the ARI Unitary Directory of Certified Products.

Indoor coil must have R-410A specific, hard shut- off TXV refrigerant metering device.

When installing a TXV on an indoor coil, follow the

instructions provided with the new TXV. A typical TXV installation is shown in Figure 3.

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 (61m).

A crankcase heater must be used when the refrigerant line length exceeds 80 feet (24.4m).

If outdoor unit is more than 10 feet (3m) 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 (30m).

When the outdoor unit is lower than the indoor coil, the vertical separation must not exceed 50 feet (15.2m).

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.

Be extra careful when bending refrigeration tubing. Tubing can "kink" easily, and if this occurs, the entire length of tubing must be replaced.

Figure 3 _ Typical TXV Installation

EQUALIZER

TUBE

SENSING SUCTION BULB TUBE

LIQUID

TUBE

TXV

SENSING BULB

(EITHER SIDE) STRAP

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.

8 O'CLOCK 4 O'CLOCK

421 01 5102 01 5

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" (25mm) 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 improp-

er product operation.

Do not leave system open to atmosphere any lon-

ger than absolutely required for installation. Inter-

nal system components - especially refrigerant oils - are extremely susceptible to moisture con- tamination. Keep ends of tubing sealed during

installation until the last possible moment.

Figure 4

Routing and Suspending Refrigerant Lines

oo ooo w ,,-X , ooo w ,y

I_CAU LK_[-F[_ V_[-[-,_"

_ LIQUID TUBE

-- LIN SULATION __/_]- SUCTION TUBE

THROUGH THE WALL

UNIT OPERATION HAZARD Failure to follow this caution may result in improp-

er product operation.

Do not bury more than 36" (lm) of line set under- ground. Refrigerant may migrate to cooler buried

section during extended periods of unit shut-

down, causing refrigerant slugging and possible compressor damage at start-up.

If ANY section of the line set is buried under- ground, provide a minimum 6" (152mm) vertical

rise at the service valve.

HANGER STRAP

(AROUND SUCTION _,_ --

TUBE ONLY) _,'

1"(25mrr_f-_l I_

MIN LIQUID TUBE

SUSPENSION

Figure 5

Liquid Line Filter-Drier

lf JOiST

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.

6 421 01 5102 01

38-11-84

F, SERVICEVALVES

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.

Figure 6 _ Service Valve

VALVE CORE X

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.

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 of the system be- fore 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 SiI-Fos or Phos-copper alloy.

PRODUCT DAMAGE HAZARD

Failuretofollow thiscautionmayresultinproductdamage.

Braze with SiI-Fos or Phos-copper alloy on cop-

per-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.

PRODUCT DAMAGE HAZARD Failureto follow thiscautionmay resultinproductdamage. Never use the outdoor unit compressor as a vacu-

um 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 system (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 1500

1000

500

-4

Deep Vacuum Gauge Response

and System Conditions

TIGHT

DRY SYSTEM

I I I I I I I I

0 1 2 3 4 5 6 7

MINUTES

421 01 5102 01 7

TripleEvacuationMethod

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 (711mm Hg). Refer to Fig. 8 and proceed as

follows:

Pull system down to 28 inches of mercury (711 mm 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.

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

[BREAKVACUUM WITH DRY NITROGEN ]

Triple Evacuation Sequence

IEVACUATE I

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 Y6of a turn (1 wrench fiat) to properly seat the sealing surfaces.

J. GAUGE PORTS Check for leaks at the schrader ports and tighten valve

cores if necessary. Install plastic caps finger tight.

IEVACUATE I

[BREAKVACUUM WITH DRY NITROGEN l

1EVACUATE 1

CHECK FOR TIGHT, DRYSYSTEM 1

(IF IT HOLDS DEEP VACUUM)

I CHARGESYSTEM 1

8 421 01 5102 01

ELECTRICAL WIRING

ELECTRICAL SHOCK HAZARD Failure to turn off the main (remote) electrical dis-

connect 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

Alert TM Diagnostics device. If Comfort Alert is used as a field installed option, then a hot bundle must be run for proper connection.

Figure 9

Electrical Supply (Line Voltage) Connections

DISCONNECT

PER NEC AND/OR

LOCAL CODES

CONTACTOR

FIELD POWER

WIRING L2

FIELD GROUND

WIRING j

GROUND

3or 13

-®

LUG

421 01 5102 01 9

Figure10

Typical Thermostat Connections

THERMOSTAT FURNACE AIR CONDITIONER

24 VAC HOT D

24 VAC COM D

HEAT STAGE 1

COOL STAGE 1 F_

INDOOR FAN D

THERMOSTAT

24 VAC HOT D

24 VAC COM D

HEAT STAGE 1

COOL STAGE 1 F_

INDOOR FAN D

THERMOSTAT

--I-q

- -D -

-4B

-D

FAN COIL

--E]

- -D -

-4B

--_-

-D

FAN COIL

...... i

{c}

..... J

...... i

..... .1

AIR CONDITIONER

AC with Comfort Alert

24 VAC HOT D

24 VAC COM D

HEAT STAGE 1

COOL STAGE 1 F_

INDOOR FAN D

.... D

.... D _

_ . _ _ -

.... D

10 421 01 5102 01

START-UP PROCEBIJRE

1. Set indoor thermostat selector switch to OFF.

2. Turn ON all electrical disconnect devices.

3. If unit has a crankcase heater, energize the heater and wait 24 hours before proceeding.

REFRIGERANT CHARGE

4. Set indoor thermostat at desired temperature. Be sure setpoint is below indoor ambient temperature

or thermostat will not call for cooling.

5. Set indoor thermostat selector switch to COOL. Operate unit for minimum 15 minutes, then check

the system refrigerant charge.

Outdoor units are shipped with a refrigerant charge to

match a specific indoor coil and 15 feet (4.6m) of refrigerant line. If shorter or longer refrigerant lines or a

different indoor coil are used, the charge will have to be adjusted.

For different line lengths, add or remove charge based on

0.6 ounces (17g) charge per foot (305mm) of difference. For example, a 25 foot (7.6m) line set is 10 feet (3m)

longer than the specified 15 feet (4.6m). Add 0.6 ounces (17g) charge for each of the extra 10 feet (3m):

10 x 0.6 = 6.0 ounces additional charge (3m x 17g = 51g additional charge)

This outdoor unit is designed for use only with indoor coils that utilize a TXV refrigerant metering device. With an

indoor TXV, use the subcooling method to make final

charge adjustments:

NOTE: Only use subcooling charging method when

• outdoor ambient temperature is between 70°F and 100°F (21°C and 38°C)

• indoor temperature is between 70° and 80°F (21 °C and

27°C)

• line set is less that 80 feet (24.4m).

1. Operate unit a minimum of 15 minutes before checking charge.

NOTE: If outdoor unit has a 2-speed fan motor, motor will operate in low speed when outdoor

ambient temperature is below 82°F (28°C). Pull one of the yellow low voltage wires off the fan

control and the unit will default to high speed fan for servicing. Reconnect wire after servicing.

2. Measure liquid service valve pressure by attaching an accurate gauge to service port.

3. Measure liquid line temperature by attaching an accurate thermistor type sensor or electronic thermometer to liquid line near outdoor coil.

4. Refer to unit rating plate for required subcooling temperature.

5. Refer to Figure 11. Find the required liquid line temperature where the rating plate subcooling temperature intersects measured liquid service

valve pressure.

6. If the measured liquid line temperature is higher than the chart number, add refrigerant to lower the

measured temperature.

NOTE: When adding refrigerant, charge in liquid form, using a flow restricting device, into the suction port.

If the measured liquid line temperature is lower than the

chart number, reclaim refrigerant to raise the measured temperature. Tolerance is + 3°F (+1.7°C).

421 01 5102 01 11

Figure11

Measured Liquid

Pressure (psig)

251 78 76 74 72 70 68 259 80 78 76 74 72 70

266 82 80 78 76 74 72 274 84 82 80 78 76 74

283 86 84 82 80 78 76 291 88 86 84 82 80 78 299 90 88 86 84 82 80

308 92 90 88 86 84 82 317 94 92 90 88 86 84 326 96 94 92 90 88 86

335 98 96 94 92 90 88 345 100 98 96 94 92 90 364 104 102 100 98 96 94

374 106 104 102 100 98 96 384 108 106 104 102 100 98 395 110 108 106 104 102 100

406 112 110 108 106 104 102 416 114 112 110 108 106 104

427 116 114 112 110 108 106 439 118 116 114 112 110 108

450 120 118 116 114 112 110 462 122 120 118 116 114 112 474 124 122 120 118 116 114

Rating Plate (required) Subcooling Temperature °F (°C)

°F F °F (i ............................................

8 10 ...........................................12 .....................................................................................

R-410A Required Liquid Line Temperature °F (°C)

SEQUENCE OF OPERATION

With power supplied to indoor and outdoor units, transformer is energized.

On a call for cooling, the thermostat makes circuits R-Y and R-G. Circuit R-Y energizes contactor, starting

outdoor fan motor and compressor. Circuit R-G energizes indoor unit blower relay, starting indoor blower

motor.

When thermostat is satisfied, its contacts open, de-energizing contactor and blower relay. Compressor

and motors stop.

NOTE: If indoor unit is equipped with a time-delay relay

circuit, the blower runs an additional length of time to

increase system efficiency.

12 421 01 5102 01

TROUBLESHOOTING

Some models are factory equipped with the Comfort Alert TM Diagnostics device in the control box (refer to

Figure 12). Comfort Alert provides around-the-clock

monitoring for common electrical problems, compressor defects, and broad system faults. Iftrouble is detected, an alert code is displayed with a flashing LED indicator. Alert codes are listed in Figure 13.

The device is factory wired and requires no

modification. Low voltage lead wires are provided in the control box for connection to thermostat wires (use wire

nuts). The Comfort Alert device operates by monitoring the

compressor power leads and the thermostat demand signal (Y terminal).

MAINTENANCE

Condensate Drain

During the cooling season, check monthly for free flow of drainage and clean if necessary.

Cleanliness These tips will help keep the air conditioner looking better

and working more efficiently:

Free flow of air is essential. Keep fences, shrubs,

trash cans, and other obstructions at least 18 inches (457mm) from all coil inlets.

Keep the coil free of grass clippings, leaves, weeds, and other debris.

NOTE: Coil may occasionally require cleaning with a liquid solution. The coil must be cold when

cleaning. Use an alkaline based cleaner only. Cleaning a hot coil or using an acid based cleaner

will remove the paint from the fins and may clog the coil.

Never use a weather cover over the outdoor unit unless it is a ventilated type or made of breathable

fabric that will allow moisture to evaporate rapidly. A cover that holds moisture in the unit will cause

more rust build-up and damage than normal exposure to weather.

Figure 12

Comfort Alert TM Diagnostics

(some models)

421 01 5102 01 13

Figure13

StatusLED

Green"POWER"

Red "TRIP"

Yellow "ALERT"

Flash Code 1

Yellow "ALERT"

Flash Code 2

Yellow "ALERT"

Flash Code 3

Yellow "ALERT"

Flash Code 4

Yellow "ALERT"

Flash Code 5

Yellow "ALERT"

Flash Code 6

Yellow "ALERT"

Flash Code 7

Yellow "ALERT"

Flash Code 9

• Flash Code number corresponds to a number of LED flashes, followed by a pause and then repeated•

• TRIP and ALERT LEDs flashing at same time means control circuit voltage is too low for operation•

Status LED Description

Module has power Thermostat demand signal Y1 is present, but the compressor is not running 3.

Long Run Time 1 Compressor is running 2. extremely long run cycles 3.

System Pressure Trip 1 Discharge or suction 2. pressure out of limits or 3. compressor overloaded 4.

Short Cycling 1 Compressor is running 2. only briefly 3.

Locked Rotor 1

Open Circuit 1

Open Start Circuit 1 Current only in run circuit 2.

Open Run Circuit 1 Current only in start circuit 2.

Low Voltage 1. Control circuit transformer is overloaded Control circuit < 17VAC 2. Low line voltage (contact utility if voltage at disconnect is low)

Comfort Alert TM

Supply voltage is present at module terminals

1. Compressor protector is open

2. Outdoor unit power disconnect is open Compressor circuit breaker or fuse(s) is open

Broken wire or connector is not making contact

Low pressure switch open if present in system

Compressor contactor has failed open

•Low refrigerant charge Evaporator blower is not running

Evaporator coil is frozen

Faulty metering device

Condenser coil is dirty

Liquid line restriction (filter drier blocked if present in system)

Thermostat is malfunctioning

•High head pressure

Condenser coil poor air circulation (dirty, blocked, damaged) Condenser fan is not running

Return air duct has substantial leakage

• If high pressure switch open, go to Flash Code 2 information If low pressure switch open, go to Flash Code 1 information

Thermostat demand signal is intermittent

Loose wiring at contactor coil

•Run capacitor has failed

Low line voltage (contact utility if voltage at disconnect is low)

Excessive liquid refrigerant in compressor

Compressor bearings are seized

•Outdoor unit power disconnect is open

Compressor circuit breaker or fuse(s) is open

Compressor contactor has failed open

High pressure switch is open and requires manual reset

Open circuit in compressor supply wiring or connections

Unusually long compressor protector reset time due to

extreme ambient temperature

Compressor windings are damaged

•Run capacitor has failed

Open circuit in compressor start wiring or connections

Compressor start winding is damaged

•Open circuit in compressor run wiring or connections

Compressor run winding is damaged

Diagnostics (some models)

Status LED Troubleshooting Information

14 421 01 5102 01

R-410A QUICK REFERENCE GUIDE

• R-410A refrigerant operates at 50% - 70% higher pressures than R-22. Be sure that servicing equipment and replacement components are designed to operate with R-410A.

• R-410A refrigerant cylinders are rose colored.

• Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.

• R-410A systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose.

• Manifold sets should be 750 psig high-side and 200 psig low-side with 520 psig low-side retard.

• Use hoses with 750 psig service pressure rating.

• Leak detectors should be designed to detect HFC refrigerant.

• R-410A, as with other HFC refrigerants, is only compatible with POE oils.

• Vacuum pumps will not remove moisture from oil.

• Do not use liquid line filter-driers with rated working pressures less than 600 psig.

• Do not install a suction line filter-drier in liquid line.

• POE oils absorb moisture rapidly. Do not expose oil to atmosphere.

• POE oils may cause damage to certain plastics and roofing materials.

• Wrap all filter-driers and service valves with wet cloth when brazing.

• A liquid line filter-drier is required on every unit.

• Do not use with an R-22 TXV.

• If indoor unit is equipped with an R-22 TXV, it must be changed to an R-410A TXV.

• Never open system to atmosphere while it is under a vacuum.

• When system must be opened for service, break vacuum with dry nitrogen and replace all filter-driers.

• Do not vent R-410A into the atmosphere.

• Do not use capillary tube indoor coils.

• Observe all WARNINGS, CAUTIONS, NOTES, and bold text.

International Comfort Products, LLC

421 01 5102 01 Lewisburg, TN 37091 USA 15

ICP C4A318GKD100, C4A324GKD100, C4A330GKD100, C4A336GKD100, C4A342GKD100 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual