ICP C4H418GKD100, C4H424GKD100, C4H430GKD100, C4H436GKD100, C4H442GKD100 Installation Guide
...
INSTALLATION INSTRUCTIONS
R−410A Split System Heat Pump
N4H3, C4H3, H4H3, T4H3,
N4H4, NXH5, CXH5, HXH5, TXH5
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:
WARNING
!
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.
WARNING
CAUTION
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 Alertt Diagnostics Codes 17..............
R−410A Quick Reference Guide 18.................
Specifications subject to change without notice.
!
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 persons could result in equipment malfunction, property damage, personal injury and/or death.
The information contained in this manual is intended for use by a qualified service technician familiar 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.
WARNING
428 01 5106 02 5/14/14
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
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.
!
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. Lock out and tag switch with a suitable
warning label.
!
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result 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.
WARNING
CAUTION
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.
UNIT SUPPORT
NOTE: Unit must be level " 2 degrees [3/8 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.
!
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.
2 428 01 5106 02
Specifications subject to change without notice.
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property damage.
Top surface of platform must be above estimated snowfall level to prevent snow blocking coil and to allow water
melt to drain from unit.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
Figure 1 Tie Down Knockouts
a” (10mm) dia. Tie Down Knockouts
In Base Pan (2 places)
A
Base Pan Width
View From Top
Base
Pan
Depth
C
B
Inches (mm)
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)
Tie Down
Knockouts
A B C
7−3/4
4−7/16
(197)
9−1/16
(230)
9−1/16
(230)
9−1/16
(230)
(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)
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)
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 P.E. (Professional Engineer) certification, when
required.
!
CAUTION
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.
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
INDOOR
EQUALIZER
TUBE
SENSING
BULB
TXV
10 O’Clock
7/8
2 O’Clock
SUCTION TUBE
IN. OD & SMALLER
COIL
SUCTION
TUBE
LIQUID
TUBE
SENSING BULB
STRAP
428 01 5106 02 3
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
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
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
match, replace indoor piston with cooling
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
HEX NUT
!
PRODUCT OPERATION HAZARD
Failure to follow this caution may result in improper product
operation.
If using a TXV in conjunction with a single−phase reciprocating compressor, a compressor start capacitor and relay are
required. Consult outdoor unit pre−sale literature for start assist kit part number.
B. REFRIGERANT LINE SETS
The refrigerant line set must be properly sized to assure
maximum efficiency and proper oil circulation.
4 428 01 5106 02
TEFLON SEAL
TEFLON RING
PISTON
FLOW IN
COOLING
PISTON
RETAINER
STRAINER
CAUTION
DISTRIBUTOR
BRASS
HEX BODY
!
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 improper product operation.
Do not leave system open to atmosphere any lon-
L10S017
Specifications subject to change without notice.
ger 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.
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
WARNING
CAUTION
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
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
Figure 4
OUTDOOR WALL INDOOR WALL
CAULK
INSULATION
THROUGH THE WALL SUSPENSION
Routing and Suspending Refrigerant Lines
LIQUID TUBE
SUCTION TUBE
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.
JOIST
HANGER STRAP
(AROUND SUCTION
TUBE ONLY)
1” (25mm) MIN
INSULATION
SUCTION TUBE
LIQUID TUBE
D. OUTDOOR UNIT HIGHER THAN INDOOR UNIT
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in improp-
er product operation.
Do not bury more than 36” (1m) 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 underground, provide a minimum 6” (152mm) vertical
rise at the service valve.
Figure 5
CAUTION
Liquid Line Filter−Drier
Installed at Indoor Coil
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. 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 in the 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,
then wrench additional ½ turn only [15−ft lbs (20.3
Filter−Drier
428 01 5106 02 5
38−11 −84
Specifications subject to change without notice.
N−m)]. Over tightening may damage the plastic
washer.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
Service valve bodies are brass and suction tube stub is
copper.
Figure 6
LIQUID SERVICE VALVE
VALVE CORE
Liquid Service Valve with Heating
Piston and Adapter Tube
BRASS NUT
ADAPTER TUBE
PLASTIC WASHER
PISTON
PISTON BODY
Vapor Service Valve
SERVICE VALVE
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.
!
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.
CAUTION
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.
!
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 before brazing any component or lines.
WARNING
!
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 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.
CAUTION
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.
6 428 01 5106 02
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
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 (711mm Hg). Refer to Figure 8 and proceed is
as follows:
Figure 7
5000
4500
4000
3500
3000
2500
2000
MICRONS
1500
1000
500
Deep Vacuum Gauge Response
and System Conditions
01
246
375
MINUTES
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
Figure 8 Triple Evacuation Sequence
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
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.
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.
J. GAUGE PORTS
Check for leaks at the schrader ports and tighten valve
cores if necessary. Install plastic caps finger tight.
ELECTRICAL WIRING
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
CHARGE SYSTEM
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.
4. Close nitrogen valve and allow system to stand for
1 hour. During this time, dry nitrogen will diffuse
throughout the system absorbing moisture.
!
WARNING
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.
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.
428 01 5106 02 7
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
Wiring Connections
Make all outdoor electrical supply (Line Voltage)
16 AWG color−coded wires to avoid excessive voltage
drop.
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
Figure 9
DISCONNECT
PER NEC AND/OR
LOCAL CODES
Electrical Supply (Line Voltage)
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
FIELD POWER
WIRING
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
FIELD GROUND
WIRING
thermostat is located more than 100 feet (30.5 m) from
unit as measured along the control voltage wires, use No.
Figure 10 Typical Thermostat (Control Circuit) Connections
THERMOSTAT
SUBBASE
NOTE: WHEN USING OUTDOOR THERMOSTATS, W
SYSTEMS WITH ONE OUTDOOR THERMOSTAT
INDOOR
SPLICE
CONNECTION
W
3
OUTDOOR
SPLICE
CONNECTION
MUST BE ENERGIZED WHEN REQUESTING SUPPLEMENTAL HEAT.
2
SYSTEMS WITH TWO OUTDOOR THERMOSTATS
DEFROST
BOARD
THERMOSTAT
SUBBASE
INDOOR
SPLICE
CONNECTION
W
3
Connections
L1
L2
GROUND
OUTDOOR
SPLICE
CONNECTION
LUG
CONTACTOR
11
23 or 13
DEFROST
BOARD
ODT
SHR
SHR
C
W
2
Y
ODT
O
R
C
W
2
L
G
Y
E
O
R
C
W2E
G
R
C
W
2
ODT
Y
O
R
C
W
2
L
G
Y
EHR
E
O
R
C
W
2
G
E
R
REMOVE WIRES FROM CRIMP NUT IN INDOOR FAN COIL WHEN INSTALLING OUTDOOR THERMOSTATS.
SYSTEMS WITHOUT OUTDOOR THERMOSTATS
THERMOSTAT
SUBBASE
C
W
2
L
G
Y
E
O
R
INDOOR
SPLICE
CONNECTION
C
W
2
G
R
OUTDOOR
SPLICE
CONNECTION
C
W
2
Y
O
R
DEFROST
BOARD
LEGEND
24−V FACTORY WIRING
24−V FIELD WIRING
FIELD SPLICE CONNECTION
OUTDOOR THERMOSTAT
EMERGENCY HEAT RELAY
EHR
SHR
SUPPLEMENTAL HEAT RELAY
8 428 01 5106 02
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
DEFROST SYSTEM
A. DEFROST THERMOSTAT
The defrost thermostat is factory installed on a short tube
stub extending from the coil end plate. Refer to Figure 11
and confirm that the thermostat is securely fastened in
place on the tube stub.
Figure 11 Defrost Thermostat
FEEDER TUBE
TUBE STUB
COIL
DEFROST
THERMOSTAT
B. DEFROST CONTROL BOARD
The defrost board is a time/temperature control which
includes a field−selectable time period between defrost
cycles of 30, 60, or 90 minutes (quick−connects located
at board edge, factory set at 60 or 90 minutes).
Defrost mode is identical to cooling mode except that
outdoor−fan motor stops and second−stage heat is
turned on to continue warming conditioned space.
Initially, the defrost cycle timer starts when the contactor
is energized and a 24 VAC signal is present on the T1
terminal. Then the defrost cycle begins when the defrost
thermostat is closed and the cycle timer times out (30, 60,
90 or minutes).
There are two timers involved in the defrost sequence:
Interval Timer – 30, 60, or 90 minutes, selected by
setting the jumper on the defrost board. Timer is only
active during calls for heating. Timer starts when the
defrost thermostat closes 32° F (0°C ). Timer stops when
a defrost is initiated by the defrost board or when the
defrost thermostat opens 65° F (18° C).
Defrost Timer – 10 minutes, not adjustable. Timer is only
active while the coil is defrosting. Timer starts when the
defrost board initiates a defrost. Timer stops when the
defrost thermostat opens 65° F (18° C) or after timing out
at 10 minutes (whichever comes first).
SPEEDUP pins are provided on the defrost board to help
in troubleshooting without waiting for timers to expire.
Jumpering the SPEEDUP pins causes any active timer to
run very fast (256 times normal speed). Jumpering the
SPEEDUP pins does not by itself initiate any timers, it
only affects timers that are already running or are already
part of the sequence.
To initiate a forced defrost cycle (test cycle), the defrost
thermostat (Figure 11) must be closed.
There are two ways to verify that the defrost thermostat
is closed:
1. Jumper across the DFT terminals on the defrost
board (Figure 12). With this method, the defrost
thermostat is removed from the circuit, and operation
of the defrost thermostat itself will not be observed.
Skip to #3.
2. Use a volt-meter to confirm there is no voltage across
the DFT leads. 24 volts across the SFT terminals
indicates an OPEN defrost thermostat. Zero volts
across the DFT terminals indicates a CLOSED defrost
thermostat.
With this method, the operation of the defrost
thermostat can be observed during the test. If the
defrost thermostat is confirmed closed, skip to #3.
If the defrost thermostat is open (24 volts across DFT
leads) it may be possible to close the defrost thermostat
by forcing a frost buildup on the outdoor coil. Follow
these steps:
S Turn off power to unit.
S Disconnect outdoor fan-motor lead from OF2 on
control board (Figure 12). Tape lead to prevent
grounding.
S Restart unit in heating mode; wait for
accumulation of frost on outdoor coil. Use
volt-meter to confirm there are zero volts across
the DFT leads (thermostat closed).
S Turn off power to unit. Replace outdoor fan-motor
lead to OF2 on control board (Figure 12). Restart
the unit in heating mode.
3. With unit running in heating mode and the defrost
thermostat closed, the entire defrost sequence can
be sped up for testing by shorting together the
SPEEDUP pins on the defrost board. Use a
flat-headed screwdriver to short the pins together.
4. Hold the SPEEDUP pins shorted together until the
reversing valve shifts.
SPEEDUP reduces whatever time was left on the
interval timer (30/60/90 minutes). In normal operation
the reversing valve will always shift with the SPEEDUP
pins shorted for between 1 and 21 seconds.
5. After shorting the SPEEDUP pins together as
described in #4, the reversing valve will energize
(shift to AC mode), the outdoor fan will stop, the strip
heat will energize, and the coil will begin to defrost.
There are two options for the defrost test:
a. Remove the short from between the SPEEDUP
pins immediately after the reversing valve shifts,
and the unit will defrost for a shortened period of
time (something less than 10 minutes). The
defrost will stop when the defrost thermostat
opens (reaches 65° F)(18° C) or when the defrost
timer times out (something less than 10 minutes).
b. Leave the SPEEDUP pins shorted together for
more than 2 seconds after the reversing valve
shifts, and the unit will immediately return to
heating operation (#6 below). Continue to leave
the pins shorted together and the sequence
starts over at #4 above.
6. Unit returns to heating mode after defrost sequence.
Reversing valve shifts back, outdoor fan starts up,
and strip heat de-energizes.
428 01 5106 02 9
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
Figure 12 Defrost Control Board
H9C1
OF1
C US
K1
O1
R21
C2
R6
R14
R13
D13
C19
D10
CEBD430524−01A 5501A
T1 C C O
D1
OF2
C9
D2
R26
C1
A29
R9
D4
D3
D6
JW1
C16
R28
C10
JW2
1
C7
1
R20
U1
C17
R1R2R3
C4
JW3
R8
C13
R7
R4
U3
R11
R5
HK32EA001
1
Y
P2
DFT
P3
1
P1
1
SPEEDUP
J2
W1
30 60 90
J1
1
O
R
W
2
Y
C
10 428 01 5106 02
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
START−UP PROCEDURE
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.
4. Set indoor thermostat at desired temperature. Be
sure setpoint is below indoor ambient temperature
to call for cooling, or above indoor ambient to call
for heating.
5. Set indoor thermostat selector switch to COOL or
HEAT. Operate unit for minimum 15 minutes, then
check the system refrigerant charge.
REFRIGERANT CHARGE
Factory charge amount and desired subcooling are
shown on unit rating plate. Charging method is shown on
information plate inside unit. Additional subcooling may
be required to achieve optimal heating performance
based on installed indoor unit. (see figure 17)
For TXV, use subcooling method.
For Piston, use superheat method.
To properly check or adjust charge, conditions must be
favorable for subcooling or superheat charging.
Favorable conditions exist when the outdoor temperature
is between 70_F and 100_F (21_C and 38_C), and the
indoor temperature is between 70_F and 80_F (21_C and
27_C). Follow the procedure below.
Unit is factory charged for 15 feet (4.6m) of lineset. Adjust
charge by adding or removing 0.6 oz/ft (17 g/mm) of 3/8
liquid line above or below 15 feet (4.6 m) respectively.
For standard refrigerant line lengths 80 feet (24.4m) or
less, allow system to operate in cooling mode at least 15
minutes. If conditions are favorable, check system
charge by super heat method for fixed metering device
and subcooling method for TXV. If any adjustment is
necessary, adjust charge slowly and allow system to
operate for 15 minutes to stabilize before declaring a
properly charged system.
If the indoor temperature is above 80_F (27_C), and the
outdoor temperature is in the favorable range, adjust
system charge by weight based on line length and allow
the indoor temperature to drop to 80_F (27_C) before
attempting to check system charge by subcooling method
as described above.
If the indoor temperature is below 70_F (21_C), or the
outdoor temperature is not in the favorable range, adjust
charge for line set length above or below 15 feet (4.6m)
only. Charge level should then be appropriate for the
system to achieve rated capacity. The charge level could
then be checked at another time when the both indoor and
outdoor temperatures are in a more favorable range.
NOTE: If line length is beyond 80 feet (24.4m) or greater
than 20 feet (6.1m) vertical separation, See Long Line
Guideline for special charging requirements.
A. UNITS WITH COOLING MODE TXV
Units installed with cooling mode TXV require charging by
the subcooling method.
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
the BRN/YEL low voltage wire 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 gage to service port.
3. Measure liquid line temperature by attaching an
accurate thermistor type or electronic
thermometer to liquid line near outdoor coil.
4. Refer to unit rating plate for required subcooling
temperature.
5. Refer to Figure 15. Find the point where required
subcooling temperature intersects measured
liquid service valve pressure.
6. To obtain required subcooling temperature at a
specific liquid line pressure, add refrigerant if liquid
line temperature is higher than indicated or reclaim
refrigerant if temperature is lower. Allow a
tolerance of "3_F (|1.7_C).
B. UNITS WITH INDOOR PISTON
Units installed with indoor pistons require charging by the
superheat method.
The following procedure is valid when indoor airflow is
within "21 percent of its rated CFM.
1. Operate unit a minimum of 15 minutes before
checking charge.
2. Measure suction pressure by attaching an
accurate gage to suction valve service port.
3. Measure suction temperature by attaching an
accurate thermistor type or electronic
thermometer to suction line at service valve.
4. Measure outdoor air dry−bulb temperature with
thermometer.
5. Measure indoor air (entering indoor coil) wet−bulb
temperature with a sling psychrometer.
6. Find outdoor temperature and evaporator entering
air wet−bulb temperature. At this intersection, note
superheat. Where a dash (−−) appears on the
table, do not attempt to charge system under these
conditions or refrigerant slugging may occur.
Charge must be weighted in, adding or removing
0.6 oz/ft of 3/8 liquid line above or below 15 feet
(4.6m) respectively.
7. Find superheat temperature (from #6 above) and
suction pressure. At this intersection, note suction
line temperature.
8. If unit has a higher suction line temperature than
charted temperature, add refrigerant until charted
temperature is reached.
9. If unit has a lower suction line temperature than
charted temperature, reclaim refrigerant until
charted temperature is reached.
10. When adding refrigerant, charge in liquid form into
suction service port using a flow−restricting
device.
428 01 5106 02 11
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
11. If outdoor air temperature or pressure at suction
valve changes, charge to new suction line
temperature indicated on chart.
12. Optimum performance will be achieved when
the operating charge produces 5_ to 6_F
suction superheat at suction service valve
with 82_F (28_C) outdoor ambient and 80_F
(27_C) dry bulb (67_F / 19_C) wet bulb) indoor
temperature (DOE “B” test conditions) at rated
airflow.
C. HEATING MODE
To check system operation during heating cycle, refer to
the Tech Label on outdoor unit. This chart indicates
whether a correct relationship exists between system
operating pressure and air temperature entering indoor
and outdoor units. If pressure and temperature do not
match on chart, system refrigerant charge may not be
correct. Do not use chart to adjust refrigerant charge.
NOTE: When charging is necessary during heating
season, charge must be weighed in accordance with unit
rating plate 0.6 ounces per foot of a inch liquid line above
or below 15 feet respectively (17g per 305mm of 10mm
liquid line above or below 4.6m respectively).
SEQUENCE OF OPERATION
A. COOLING MODE
On a call for cooling, the thermostat makes circuits R−O,
R−Y, and R−G. Circuit R−O energizes reversing valve,
switching it to cooling position. 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. (Applies to both cooling and
heating modes.)
B. HEATING MODE
On a call for heating, the thermostat makes circuits R−Y
and R−G (circuit R−O is NOT made, and the reversing
valve stays in the de−energized, heating position). Circuit
R−Y energizes contactor, starting outdoor fan motor and
compressor. Circuit R−G energizes indoor blower relay,
starting blower motor. If the room temperature continues
to fall, circuit R−W2 is made through the second−stage
room thermostat bulb. Circuit R−W2 energizes a
sequencer, bringing on the first bank supplemental
electric heat and providing electrical potential to the
second heater sequencer (if used). If outdoor
temperature falls below the setting of the outdoor
thermostat (field−installed option), contacts close to
complete the circuit and bring on the second bank of
supplemental electric heat.
When the thermostat is satisfied, its contacts open,
de−energizing contactor, blower relay, and sequencer.
Compressor, motors, and heaters stop.
12 428 01 5106 02
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
SUPERHEAT CHARGING TABLE ˚F SUPERHEAT CHARGING TABLE ˚C
Figure 13
EVAPORATOR ENTEREING AIR ˚F AT WB EVAPORATOR ENTEREING AIR ˚C AT WB
˚F 50 52 54 56 58 60 62 64 66 68 70 72 74 76 ˚C 10 11 12 13 14 16 17 18 19 20 21 22 23 24
Outdoor
Temp
SUPERHEAT ˚F AT LOWSIDE SERVICE PORT
55 9 12 14 17 20 23 26 29 32 35 37 40 42 45 13 5 7 8 9 11 13 14 16 18 19 21 22 23 25
60 7 10 12 15 18 21 24 27 30 33 35 38 40 43 16 4 6 7 8 10 12 13 15 17 18 19 21 22 24
65 6 10 13 16 19 21 24 27 30 33 36 38 41 18 3 6 7 9 11 12 13 15 17 18 20 21 23
70 7 10 13 16 19 21 24 27 30 33 36 39 21 4 6 7 9 11 12 13 15 17 18 20 22
75 6 9 12 15 18 21 24 28 31 34 37 24 3 5 7 8 10 12 13 16 17 19 21
80 5 8 12 15 18 21 25 28 31 35 27 3 4 7 8 10 12 14 16 17 19
85 8 11 15 19 22 26 30 33 29 4 6 8 11 12 14 17 18
90 5 9 13 16 20 24 27 31 32 3 5 7 9 11 13 15 17
95 6 10 14 18 22 25 29 35 3 6 8 10 12 14 16
100 8 12 15 20 23 27 38 4 7 8 11 13 15
105 5 9 13 17 22 26 41 3 5 7 9 12 14
110 6 11 15 20 25 43 3 6 8 11 14
115 8 14 18 23 46 4 8 10 13
*Optimum performance point, 95°F (35°C) outdoor ambient and (80°F / 27°C dry bulb), (67°F / 19°C wet bulb) indoor conditions. (DOE A Test Conditions)
Where a dash (-) appears do not attempt to charge system under these conditions or refrigerant slugging may occur. Charge must be weighed in.
Note: Superheat °F is at low-side service port, Allow a tolerance of ± 3°F (± 1.7°C)
Note: Indoor dry bulb between 70°F and 80°F (21°C and 27°C)
Figure 14 SUCTION PRESSURE AT SERVICE PORT PSIG SUCTION PRESSURE AT SERVICE PORT kPa
SUPER-
HEAT
TEMP ˚F
108 112 117 121 126 131 139 141 146
REQUIRED SUCTION TUBE TEMPERATURE ˚F
(MEASURED AT LOW-SIDE SERVICE PORT)
0 35 37 39 41 43 45 47 49 51 0 2 3 4 5 6 7 8 9 11
2 37 39 41 43 45 47 49 51 53 1 3 4 5 6 7 8 9 11 12
4 39 41 43 45 47 49 51 53 55 2 4 5 6 7 8 9 11 12 13
6 41 43 45 47 49 51 53 55 57 3 5 6 7 8 9 11 12 13 14
8 43 45 47 49 51 53 55 57 59 4 6 7 8 9 11 12 13 14 15
10 45 47 49 51 53 55 57 59 61 6 7 8 9 11 12 13 14 15 16
12 47 49 51 53 55 57 59 61 63 7 8 9 11 12 13 14 15 16 17
14 49 51 53 55 57 59 61 63 65 8 9 11 12 13 14 15 16 17 18
16 51 53 55 57 59 61 63 65 67 9 11 12 13 14 15 16 17 18 19
18 53 55 57 59 61 63 65 67 69 10 12 13 14 15 16 17 18 19 21
20 55 57 59 61 63 65 67 69 71 11 13 14 15 16 17 18 19 21 22
22 57 59 61 63 65 67 69 71 73 12 14 15 16 17 18 19 21 22 23
24 59 61 63 65 67 69 71 73 75 13 15 16 17 18 19 21 22 23 24
26 61 63 65 67 69 71 73 75 77 14 16 17 18 19 21 22 23 24 25
28 63 65 67 69 71 73 75 77 79 16 17 18 19 21 22 23 24 25 26
30 65 67 69 71 73 75 77 79 81 17 18 19 21 22 23 24 25 26 27
Outdoor
Temp
SUPER-
HEAT
TEMP ˚C
SUPERHEAT ˚C AT LOWSIDE SERVICE PORT
743 774 805 836 869 902 957 971 1005
REQUIRED SUCTION TUBE TEMPERATURE ˚C
(MEASURED AT LOW-SIDE SERVICE PORT)
428 01 5106 02 13
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
Figure 15 Rating Plate (required) Subcooling Temperature ° F (° C)
° F (° C) ° F (° C) ° F (° C) ° F (° C) F (° C) F (° C)
Measured Liquid
6 3 8 4 10 6 12 7 14 8 16 9
Pressure (psig)
R−410A Required Liquid Line Temperature ° F (° C)
251 78 26 76 24 74 23 72 22 70 21 68 20
259 80 27 78 26 76 24 74 23 72 22 70 21
266 82 28 80 27 78 26 76 24 74 23 72 22
274 84 29 82 28 80 27 78 26 76 24 74 23
283 86 30 84 29 82 28 80 27 78 26 76 24
291 88 31 86 30 84 29 82 28 80 27 78 26
299 90 32 88 31 86 30 84 29 82 28 80 27
308 92 33 90 32 88 31 86 30 84 29 82 28
317 94 34 92 33 90 32 88 31 86 30 84 29
326 96 36 94 34 92 33 90 32 88 31 86 30
335 98 37 96 36 94 34 92 33 90 32 88 31
345 100 38 98 37 96 36 94 34 92 33 90 32
364 104 40 102 39 100 38 98 37 96 36 94 34
374 106 41 104 40 102 39 100 38 98 37 96 36
384 108 42 106 41 104 40 102 39 100 38 98 37
395 110 43 108 42 106 41 104 40 102 39 100 38
406 112 44 110 43 108 42 106 41 104 40 102 39
416 114 46 112 44 11 0 43 108 42 106 41 104 40
427 116 47 114 46 11 2 44 110 43 108 42 106 41
439 118 48 116 47 11 4 46 112 44 110 43 108 42
450 120 49 118 48 11 6 47 114 46 112 44 110 43
462 122 50 120 49 118 48 116 47 114 46 112 44
474 124 51 122 50 120 49 118 48 11 6 47 114 46
14 428 01 5106 02
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
Figure 16 - Additional Subcooling
15 SEER 13 & 14 SEER
Subcooling Delta from Rating Plate
Value
OUTDOOR UNIT TONNAGE OUTDOOR UNIT TONNAGE
Indoor Models 18 24 30 36 42 48 60 18 24 30 36 42 48 60
ED*4X18B**/EA*4X18*14A*
EN(A,D)4X18*14**
FEM4(P,X)18**A*+TXV
F(E,S)A4X18**A*
FXM4X18**A* +3
FS(M,U)4P18**A*+TXV
ED*4X24***/EA*4X24*(14,17)A* +3 +3
EN*4X24***** +3 +3
EHD4X24A** +5 +5
FEM4P24**A*+TXV
F(E,S)A4X24**A* +5 +3
(FVM/FCM)4X24**** +3 +5 +3 +3
FXM4X24**A* +5 +3
FEM4X24**A* +3 +3
FS(M,U)4P24**A*+TXV +5 +3
ED*4X30***/EA*4X30*(14,17)A* +3
EN*4X30***** +3 +3
EHD4X30A** +3 +3
FEM4(P,X)30**A*+TXV +3
FSA4X30**A* +3
FEA4X30**A* +3
FXM4X30**A* +3 +5 +5
FS(M,U)4P30**A*+TXV +3 +5 +5
(FVM/FCM)4X36**** +5 +3
ED*4X36***/EA*4X36*(14,17,21)A* +5 +3
EN*4X36***** +3
EHD4X36A** +5 +3
FEM4P36**A*+TXV
FSA4X36**A* +5 +3
FEA4X36**A* +5 +3
F(E,X)M4X36**A* +5 +5 +5
FS(M,U)4P36**A*+TXV +5 +3
ED*4X42***/EA*4X42*(21,24)A* +3
EN*4X42*21** +3
END4X42*17** +3
EHD4X42A** +5
FEM4(P,X)42**A*+TXV +5
FXM4X42**A* +5
FS(M,U)4P42**A*+TXV +5
ED*4X48F**/EA*4X48*17A* +5 +5 +3
ED*4X48(J,L)**/EA*4X48*(21,24)A* +3 +3
EN*4X48*****
EHD4X48A** +3
FEM4P48**A*+TXV
(FVM/FCM)4X48**** +3 +3 +3 +5 +5 +3
F(E,X)M4X48**A* +3 +3
FS(M,U)4P48**A*+TXV +3 +3
ED*4X60***/EA*4X60*(21,24)A* +5 +5 +3
Subcooling Delta from Rating Plate
Value
428 01 5106 02 15
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
Figure 17 - Additional Subcooling Tables
15 SEER 13 & 14 SEER
Subcooling Delta from Rating Plate
Value
OUTDOOR UNIT TONNAGE OUTDOOR UNIT TONNAGE
Indoor Models 18 24 30 36 42 48 60 18 24 30 36 42 48 60
EN*4X60*24** +3
EHD4X60A** +3 +5 +3
FEM4X60**B* +5
(FVM/FCM)4X60**** +5 +5 +3 +5 +5 +5 +3
FXM4X60**A* +3 +5 +3
FS(M,U)4X60**A* +3 +5 +3
Subcooling Delta from Rating Plate
Value
TROUBLESHOOTING
Some models are factory equipped with the Comfort
Alertt Diagnostics device in the control box (refer to
Figure 17). Comfort Alert provides around−the−clock
monitoring for common electrical problems, compressor
defects, and broad system faults. If trouble is detected, an
alert code is displayed with a flashing LED indicator. Alert
codes are listed in Figure 18.
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). It draws constant 24 VAC power at the
R and C terminals.
Figure 17
R
Comfort Alertt Diagnostics
(some models)
Compressor Wires
Pass Through Holes (3)
“Power” LED
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 heat pump looking better and
working more efficiently:
1. Free flow of air is essential. Keep fences, shrubs,
trash cans, and other obstructions at least 18
inches (457mm) from all coil inlets.
2. 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.
3. 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.
C
Y
C
S
R
Thermostat Demand
24 VAC Common
“Alert” LED
“Trip” LED
24 VAC Hot
16 428 01 5106 02
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
Figure 18 Comfort Alertt Diagnostics (some models)
Status LED Status LED Description Status LED Troubleshooting Information
Green “POWER” Module has power Supply voltage is present at module terminals
Red “TRIP” Thermostat demand signal
Y1 is present, but the compressor is not running
1. Compressor protector is open
2. Outdoor unit power disconnect is open
3. Compressor circuit breaker or fuse(s) is open
4. Broken wire or connector is not making contact
5. Low pressure switch open if present in system
6. Compressor contactor has failed open
Yellow “ALERT”
Flash Code 1
Long Run Time
Compressor is running extremely long run cycles
1. Low refrigerant charge
2. Evaporator blower is not running
3. Evaporator coil is frozen
4. Faulty metering device
5. Condenser coil is dirty
6. Liquid line restriction (filter drier blocked if present in system)
7. Thermostat is malfunctioning
Yellow “ALERT”
Flash Code 2
System Pressure Trip
Discharge or suction pressure out of limits or compressor overloaded
1. High head pressure
2. Condenser coil poor air circulation (dirty, blocked, damaged)
3. Condenser fan is not running
4. Return air duct has substantial leakage
5. If low pressure switch present in system, check Flash Code 1
information
Yellow “ALERT”
Flash Code 3
Short Cycling
Compressor is running only
briefly
1. Thermostat demand signal is intermittent
2. Time delay relay or control board defective
3. If high pressure switch present go to Flash Code 2 information
4. If low pressure switch present go to Flash Code 1 information
Yellow “ALERT”
Flash Code 4
Locked Rotor
1. Run capacitor has failed
2. Low line voltage (contact utility if voltage at disconnect is low)
3. Excessive liquid refrigerant in compressor
4. Compressor bearings are seized
Yellow “ALERT”
Flash Code 5
Open Circuit
1. Outdoor unit power disconnect is open
2. Compressor circuit breaker or fuse(s) is open
3. Compressor contactor has failed open
4. High pressure switch is open and requires manual reset
5. Open circuit in compressor supply wiring or connections
6. Unusually long compressor protector reset time due to extreme ambient temperature
7. Compressor windings are damaged
Yellow “ALERT”
Flash Code 6
Open Start Circuit
Current only in run circuit
1. Run capacitor has failed
2. Open circuit in compressor start wiring or connections
3. Compressor start winding is damaged
Yellow “ALERT”
Flash Code 7
Yellow “ALERT”
Flash Code 8
Yellow “ALERT”
Flash Code 9
Open Run Circuit
Current only in start circuit
Welded Contactor
Compressor always runs
Low Voltage
Control circuit < 17VAC
1. Open circuit in compressor run wiring or connections
2. Compressor run winding is damaged
1. Compressor contactor has failed closed
2. Thermostat demand signal not connected to module
1. Control circuit transformer is overloaded
2. Low line voltage (contact utility if voltage at disconnect is low)
S Flash Code number corresponds to a number of LED flashes, followed by a pause and then repeated.
S TRIP and ALERT LEDs flashing at same time means control circuit voltage is too low for operation.
S Reset ALERT Flash code by removing 24VAC power from module.
S Last ALERT Flash code is displayed for 1 minute after module is powered on.
428 01 5106 02 17
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
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.
18 428 01 5106 02
Specifications subject to change without notice.
Copyright 2014 International Comfort Products
Lewisburg, TN 37091 USA
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