ICP C4H318GKA100, C4H324GKA100, C4H330GKA100, C4H330GKE100, C4H336GKA100 Installation Guide
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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 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
Unit Support ................................... 2
Refrigeration System ........................... 3
Electrical Wiring ................................ 7
Defrost System ................................ 9
Start-up Procedure ............................ 11
Refrigerant Charge ............................ 11
Sequence of Operation ......................... 12
Troubleshooting ............................... 16
Maintenance .................................. 16
Comfort Alert TM Diagnostics Codes .............. 17
R-410A Quick Reference Guide ................. 18
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.
428 01 5106 03 03/04/15
INSPECT NEW UNIT
After uncrating unit, inspect thoroughly for hidden
damage. If damage is found, notify the transportation
company immediately and file a concealed damage
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.
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.
(3.66m). Position so water, snow, or ice from roof or
eaves cannot fall directly on unit.
On rooftop applications, locate unit at least 6 in.
(152.4mm) above roof surface.
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.
UNIT SUPPORT
NOTE: Unit must be level I 2 degrees {a 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 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.
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property damage.
Top surface of platform must be above estimated snow-
fall level to prevent snow blocking coil and to allow water
melt to drain from unit.
2 specificationssubjectto change without notice. 428 01 5106 03
I
Figure 1 J Tie Down Knockouts
a" (10mm) dia. Tie Down Knockouts [ View From Top
In Base Pan (2 places)
Base
Pan
Depth
o o
A
Base Pan Width
Inches (mm)
Base Pan
Width x Depth
23 x 23
(584 x 584)
25-11/16 x
25-11/t6
(652 x 652)
31-1/8 x 31-1/8
(791 x 791)
34-15/16 x
34-15/16
(887 x 887)
Tie Down
Knockouts
A
7-3/4
(197)
9-1/16
(230)
9-1/16
(230)
9-1/16 6-1/2 28-7/16
(230) (165) (722)
B C
4-7/16 18
(113) (457)
4-7/16 21-1/4
(113) (540)
6-1/2 24-5/8
(165) (625)
Minimum
MountingPad
Dimensions
23 x 23
(584 x 584)
26 x 26
(660 x 660)
31-1/2 x 31-t/2
(800x800)
35 x 35
(889 x 889)
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
(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 1).
Contact local distributor for hurricane hold-down details and
the RE. (Professional Engineer) certification, when
required.
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 re-
frigerant line failure.
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 to achieve maximum
efficiency when used 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 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
EQUALIZER
TUBE
SENSING
BULB
TXV
_.--10 O'Clock
'_ 2 O'Clock 7
__T/U__BE STRAP
SUCTION
TUBE
LIQUID
TUBE
SENSING BULB
7/8 IN. OD & SMALLER
428 01 5106 03 Specifications subject to change without notice. 3
Installing with Indoor Piston - cooling operation.
(Heat pumps also use an outdoor piston for heating
operation, refer to section F.)
Check piston size shipped with indoor unit to see if it
matches required indoor piston size shown on outdoor
unit rating plate.
If it does not match, replace indoor piston with cooling
piston, according to size marked on outdoor unit rating
plate. (Some outdoor models include a cooling piston in
the accessory bag.)
Heating piston is shipped in the service valve - refer to
section F.
Example fan coils with piston: FEM4P, FSM4P, FSU4P,
FMA4P, FMC4P, FMU4P.
See Figure 3.
When changing indoor piston, use a back-up wrench.
Finger tighten hex nut, then tighten with wrench 1/2 turn.
Do not exceed 30 ft-lbs (40.7 N-m).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.
Figure 3 _ Indoor (cooling) Piston
Refer to Product Specifications and Long Line
Applications Guideline for line set sizing.
NOTE: Total line set length must not exceed 200 feet
(61m).
NOTE: 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.
NOTE: When the outdoor unit is higher than the indoor
coil, the vertical separation must not exceed 100 feet
(30m).
NOTE: 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.
BRASS "='=_ T"- DISTRIBUTOR
HEXNUT\ TEFLONSEAL \
TEFLON RING \
PISTON HEX BODY
RETAINER
STRAINER
L10S017
PRODUCT OPERATION HAZARD
Failure to follow this caution may result in improper product
operation.
If using a TXV in conjunction with a single-phase reciprocat-
ing compressor, a compressor start capacitor and relay are
required. Consult outdoor unit pre-sate literature for start as-
sist kit part number.
B. REFRIGERANT LINE SETS
The refrigerant line set must be properly sized to assure
maximum efficiency and proper oil circulation.
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.
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.
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
4 Specificationssubjectto change without notice. 428 01 5106 03
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.
Figure 4
OUTDOOR WALL's. INDOOR WAL_7
--'?___NSU LATI ON y-_ SUCTION TUBE
1
I_CAU LK_,,_f-i-i_ V_i-F_ ¥
_ LIQUID TUBE
THROUGH THE WALL
Routing and Suspending Refrigerant Lines
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.
Liquid Line Filter-Drier
Figure 5 1
Installed at Indoor Coil
HANGER STRAP "_
(AROUND SUCTION _,= --
TUBE ONLY) _
1" (25mm) MIN ._D,.--I I_
SUSPENSION
t_:U cTLA:IoONNTUBE
lf JOiST
'4
LIQUID
TUBE
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 inthe tube
ends until the filter-drier is installed. The optimal location
for the filter-drier is close to the indoor coil. Heat pump
filter-driers are "bi-flow" type. Either end can be pointed
towards indoor coil. Refer to Figure 5.
F. SERVICE VALVES
Service valves are closed and 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.
Heat pumps require a piston metering device inthe liquid
service valve for proper heating operation. Piston is
shipped in the piston body of the liquid service valve,
temporarily held in place with a plastic cap. Do not remove
the plastic cap until line set tubing is ready to be installed.
Refer to Figure 6 and follow these steps for piston
installation:
1. Remove plastic cap holding piston in piston body of
liquid service valve.
2. Check that piston size (stamped on side of piston)
matches with number listed on unit rating plate.
Return piston to piston body of liquid service valve
(either direction).
3. Find plastic bag taped to unit containing copper
adapter tube, brass nut, and plastic washer.
4. Install plastic washer in the seat inside piston body.
5. Fit brass nut onto adapter tube and install tube
onto liquid service valve. Tighten nut finger tight,
\
Filter-Drier
428 01 5106 03 Specifications subject to change without notice. 5
38-11-84
then wrench additional 1/2turn only [15-ft Ibs (20.3
N-m)]. Over tightening may damage the plastic
washer.
Service valve bodies are brass and suction tube stub is
copper.
Figure 6 Liquid Service Valve with Heating
BRASS NUT
'_-_'_ ADAPTER TUBE
Piston and Adapter Tube
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
_ PLASTIC WASHER
LIQUID SERVICEVALVE--'_ .. j
Vapor Service Valve
G. BRAZING CONNECTIONS
NOTE:
For Liquid Service Valve - Braze lineset to adapter tube
BEFORE bolting adapter to valve. This helps prevent
overheating and damage to plastic washer or o-ring.
For Vapor Service Valve - remove valve core from
schrader port on Service Valve BEFORE brazing. This
helps prevent overheating and damage to valve seals
(refer to Figure 6). Replace valve core when brazing is
completed.
Failure to follow this caution may result in product
damage.
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
Failure to follow this caution may result in product
damage.
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
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.
6 Specificationssubjectto change without notice. 428 01 5106 03
The deep vacuum method requires a vacuum pump
capable of pulling avacuum 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.
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