ICP CCA724GKA100, CCA736GKA100, CCA748GKA100, CCA760GKA100, HCA724GKA100 Installation Guide

INSTALLATION INSTRUCTIONS

R- 410A TwoStage Split System Air Conditioner

CCA7, HCA7, TCA7

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

IMPORTANT: Effective January 1, 2015, all split system and packaged air conditioners must be installed pursuant to applicable regional efficiency standards issued by the Department of Energy.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factoryauthorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes and current editions of the National Electrical Code ( NEC ) NFPA 70. In Canada, refer to current editions of the Canadian electrical code CSA 22.1.

Recognize safety information. This is the safetyalert symbol !! When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand these signal words; DANGER, WARNING, and CAUTION. These words are used with the safetyalert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

!WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury and/or death.

Before installing, modifying, or servicing system, main electrical disconnect switch must be in the OFF position. There may be more than 1 disconnect switch. Lock out and tag switch with a suitable warning label.

!CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing and gloves when handling parts.

INSTALLATION RECOMMENDATIONS

NOTE: In some cases noise in the living area has been traced to gas pulsations from improper installation of equipment.

1.Locate unit away from windows, patios, decks, etc. where unit operation sound may disturb customer.

2.Ensure that vapor and liquid tube diameters are appropriate for unit capacity.

3.Run refrigerant tubes as directly as possible by avoiding unnecessary turns and bends.

4.Leave some slack between structure and unit to absorb vibration.

5.When passing refrigerant tubes through the wall, seal opening with RTV or other pliable siliconbased caulk. (See Fig. 1.)

6.Avoid direct tubing contact with water pipes, duct work, floor joists, wall studs, floors, and walls.

7.Do not suspend refrigerant tubing from joists and studs with a rigid wire or strap which comes in direct contact with tubing.(See Fig. 1.)

8.Ensure that tubing insulation is pliable and completely surrounds vapor tube.

9.When necessary, use hanger straps which are 1 in. (25.4 mm) wide and conform to shape of tubing insulation. (See Fig. 1.)

10.Isolate hanger straps from insulation by using metal sleeves bent to conform to shape of insulation.

421 01 1702 05 10/18/16

INSTALLATION INSTRUCTIONS

	Figure 1	Connecting Tube Installation
	NOTE: Avoid contact between tubing and structure
	OUTDOOR WALL	INDOOR WALL
	CAULK	LIQUID TUBE
		VAPOR TUBE
	INSULATION
	THROUGH THE WALL
		JOIST
	HANGER STRAP
	(AROUND VAPOR	INSULATION
	TUBE ONLY)
		VAPOR TUBE
	1″ (25.4 mm)MIN.
		LIQUID TUBE
	SUSPENSION

Outdoor unit contains system refrigerant charge for operation with AHRI rated indoor unit when connected by 15 ft. (4.57 m) of fieldsupplied or factory accessory tubing. For proper unit operation, check refrigerant charge using charging information located on control box cover and/or in the Check Charge section of this instruction.

IMPORTANT: Maximum liquidline size is 3/8- in. OD for all residential applications including long line.

IMPORTANT: Always install the factorysupplied liquidline filter drier. Obtain replacement filter driers from your distributor or branch.

INSTALLATION

!WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could result in personal injury or equipment damage.

R- 410A refrigerant systems operate at higher pressures than standard R- 22 systems. Do not use R- 22 service equipment or components on R- 410A refrigerant equipment.

Specifications for this unit in residential new construction market require the outdoor unit, indoor unit, refrigerant tubing sets, metering device, and filter drier listed in presale literature. There can be no deviation.

Check Equipment and Job Site Unpack Unit

Move to final location. Remove carton. Do not to damage unit.

Inspect Equipment

File claim with shipping company prior to installation if shipment is damaged or incomplete. Locate unit rating plate on unit corner panel. It contains information needed to properly install unit. Check rating plate to be sure unit matches job specifications.

Install on a Solid, Level Mounting Pad

If conditions or local codes require the unit be attached to pad, tie down bolts should be used and fastened through knockouts provided in unit base pan. Refer to unit mounting pattern in Fig. 2 to determine base pan size and knockout hole location.

R- 410A Split System Air Conditioner

For hurricane tie downs - contact your local distributor for details and PE (Professional Certification), if required by local authorities.

On rooftop applications, mount on level platform or frame. Place unit above a loadbearing wall and isolate unit and tubing set from structure. Arrange supporting members to adequately support unit and minimize transmission of vibration to building. Consult local codes governing rooftop applications.

Roof mounted units exposed to winds may require wind baffles. Consult the LowAmbient pressure switch installation instructions for wind baffle construction.

NOTE: Unit must be level to within 2_ ( 3/8 in./ft..) per compressor manufacturer specifications.

Clearance Requirements

When installing, allow sufficient space for airflow clearance, wiring, refrigerant piping, and service. Allow 24 in. (609.6 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. Position so water, snow, or ice from roof or eaves cannot fall directly on unit.

Figure 2	Tie Down Knockouts

3/8- in. (9.53 mm) Dia. Tiedown Knockouts in Basepan(2) Places

View From Top

	UNIT BASE PAN	TIEDOWN KNOCKOUT LOCATIONS in. (mm)
	Dimension	A	B	C
	31–1/2 X 31–1/2	9–1/8 (231.8)	6–9/16 (166.7)	24–11/16 (627.1)
	(800 X 800)
	35 X 35	9–1/8 (231.8)	6–9/16 (166.7)	28–7/16 (722.3)
	(889 X 889)

On rooftop applications, locate unit at least 6 in. (152.4 mm) above roof surface.

Operating Ambient

The minimum outdoor operating ambient in cooling mode is 55°F (12.78 _C), and the maximum outdoor operating ambient in cooling mode is 125°F (51.67_C).

*CA7 product is approved for low ambient cooling operation down to an ambient as low as 0 _F (- 17.78 _C) with low ambient accessory kits.

Make Piping Connections

!WARNING

PERSONAL INJURY AND ENVIRONMENTAL HAZARD

Failure to follow this warning could result in personal injury or death.

Relieve pressure and recover all refrigerant before system repair or final unit disposal.

Use all service ports and open all flowcontrol devices, including solenoid valves.

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INSTALLATION INSTRUCTIONS

!CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

Do not leave system open to atmosphere any longer than minimum required for installation. POE oil in compressor is extremely susceptible to moisture absorption. Always keep ends of tubing sealed during installation.

If ANY refrigerant tubing is buried, provide a 6 in. (152.4 mm) vertical rise at service valve. Refrigerant tubing lengths up to 36 in. (914.4 mm) may be buried without further special consideration. Do not bury lines more than 36 in. (914.4 mm).

Outdoor units may be connected to indoor section using accessory tubing package or fieldsupplied refrigerant grade tubing of correct size and condition. For tubing requirements

R- 410A Split System Air Conditioner

beyond 80 ft/24.38 m, substantial capacity and performance losses can occur. Following the recommendations in the Long Line Applications Guideline for SplitSystem Air Conditioners and Heat Pumps will reduce these losses. Refer to Table 1 for accessory requirements. Refer to Table 2 for field tubing diameters.

There are no buriedline applications greater than 36 in. (914.4 mm).

If refrigerant tubes or indoor coil are exposed to atmosphere, they must be evacuated to 500 microns to eliminate contamination and moisture in the system.

Outdoor Unit Connected to Factory Approved Indoor Unit

Outdoor unit contains correct system refrigerant charge for operation with factory approved AHRI rated indoor unit when c o n n e c t e d b y 1 5 f t . ( 4 . 5 7 m ) o f f i e l d - s u p p l i e d o r factoryaccessory tubing, and factory supplied filter drier. Check refrigerant charge for maximum efficiency.

Table 1 - Accessory Usage

		REQUIRED FOR LOW AMBIENT
		COOLING APPLICATIONS	REQUIRED FOR LONG LINE	Required for Sea Coast Applica-
	Accessory	(Below 55 F / 12.8 C)	APPLICATIONS* (Over 80 ft. / 24.38 m)	tion (within 2 miles/3.22 km)
	Crankcase Heater	Yes Standard on some units	Yes, standard on some units	No
	Compressor Start Assist Ca-	No	No	No
	pacitor and Relay
	Liquid Line Solenoid Valve	No	See Long Line Applications Guideline	No
	Support Feet	Recommended	No	Recommended
	Hard Shutoff TXV	Yes (Standard with factory approved	Yes (Standard with factory approved in-	Yes (Standard with factory ap-
		indoor unit)	door unit)	proved indoor unit)
	Evaporator Freeze Thermostat	Yes	No	No
	Low-Ambient Pressure Switch	Yes	No	No
	Winter Start Control	Yes	No	No

* For tubing line sets between 80 and 200 ft. (24.38 and 60.96 m) and/or 20 ft. (6.09 m) vertical differential, refer to Long Line Applications Guideline.

Table 2 - Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters (In.)

			RATED VAPOR
	LIQUID		up to 80 ft. (24.38 m)*
	Connection and Tube	Connection		Rated Tube
UNIT SIZE	Diameter	Diameter		Diameter
*CA724	3/8	3/4		3/4
*CA736	3/8	7/8		7/8
*CA748	3/8	7/8		1- 1/8
*CA760	3/8	7/8		1- 1/8

* Units are rated with 25 ft. (7.6 m) of lineset. See Specification sheet for performance data when using different size and length linesets.

Notes:

1.Do not apply capillary tube or fixed orifice indoor coils to these units.

2.For Tubing Set lengths between 80 and 200 ft. (24.38 and 60.96 m) horizontal or 35 ft. (10.7 m) vertical differential 250 ft. (76.2 m) Total Equivalent Length), refer to the Long Line Applications Guideline.

Install Liquid Line Filter Drier Indoor

!CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

Installation of filter drier in liquid line is required. Filter drier must be wrapped in a heatsinking material such as a wet cloth while brazing.

Refer to Fig. 3 and install filter drier as follows:

1.Braze 5 in. (127 mm) liquid tube to the indoor coil.

2.Wrap filter drier with damp cloth.

3.Braze filter drier to above 5 in. (127 mm) liquid tube. Flow arrow must point towards indoor coil.

4. Connect and braze liquid refrigerant tube to the filter drier.

Figure 3					Liquid Line Filter Drier

Refrigerant Tubing Connection Outdoor

Connect vapor and liquid tubes to fittings on vapor and liquid service valves (see Table 2.) Use refrigerant grade tubing.

421 01 1702 05	Specifications subject to change without notice.	3

INSTALLATION INSTRUCTIONS

Sweat Connection

!CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

Service valves must be wrapped in a heatsinking material such as a wet cloth.

Service valves are closed from factory and ready for brazing. After wrapping service valve with a wet cloth, braze sweat connections using industry accepted methods and materials. Consult local code requirements. Refrigerant tubing and indoor coil are now ready for leak testing. This check should include all field and factory joints.

Evacuate Refrigerant Tubing and Indoor Coil

!CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

Never use the system compressor as a vacuum pump.

Refrigerant tubes 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 of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth. The deep vacuum method is the most positive way of assuring a system is free of air and liquid water. (See Fig. 4)

Figure 4				Deep Vacuum Graph
5000
4500
4000						LEAK IN
3500
						SYSTEM
3000
2500
MICRONS2000						VACUUM TIGHT
1500
						TOO WET
1000
						TIGHT
500
						DRY SYSTEM
0	1	2	3	4	5	6	7
			MINUTES

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 Fig.5 and proceed is as follows:

R- 410A Split System Air Conditioner

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 5.

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 5	Triple Evacuation Sequence

EVACUATE

BREAK VACUUM WITH DRY NITROGEN

WAIT

EVACUATE

BREAK VACUUM WITH DRY NITROGEN

WAIT

EVACUATE

CHECK FOR TIGHT, DRY SYSTEM (IF IT HOLDS DEEP VACUUM

CHARGE SYSTEM

Final Tubing Check

IMPORTANT: Check to be certain factory tubing on both indoor and outdoor unit has not shifted during shipment. Ensure tubes are not rubbing against each other or any sheet metal. Pay close attention to feeder tubes, making sure wire ties on feeder tubes are secure and tight.

Make Electrical Connections

!WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

Do not supply power to unit with compressor terminal box cover removed.

Be sure field wiring complies with local and national fire, safety, and electrical codes, and voltage to system is within limits shown on unit rating plate. Contact local power company for correction of improper voltage. See unit rating plate for recommended circuit protection device.

NOTE: Operation of unit on improper line voltage constitutes abuse and could affect unit reliability. See unit rating plate. Do not install unit in system where voltage may fluctuate above or below permissible limits.

NOTE: Use copper wire only between disconnect switch and unit.

1.Pull system down to 28 inches of mercury (711mm Hg) and NOTE: Install branch circuit disconnect of adequate size per NEC allow pump to continue operating for an additional 15 to handle unit starting current. Locate disconnect within sight from

minutes.

and readily accessible from unit, per Section 44014 of NEC.

4	Specifications subject to change without notice.	421 01 1702 05

INSTALLATION INSTRUCTIONS

Route Ground and Power Wires

Remove access panel to gain access to unit wiring. Extend wires from disconnect through power wiring hole provided and into unit control box.

!WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal injury or death.

The unit cabinet must have an uninterrupted or unbroken ground to minimize personal injury if an electrical fault should occur. The ground may consist of electrical wire or metal conduit when installed in accordance with existing electrical codes.

Connect Ground and Power Wires

Connect ground wire to ground connection in control box for safety. Connect power wiring to contactor as shown in Fig.6.

Figure 6	Line Power Connections

DISCONNECT

PER N. E. C. AND/OR LOCAL CODES

CONTACTOR

FIELD POWER

WIRING

FIELD GROUND

WIRING	GROUND
	LUG

Connect Control Wiring

This unit is capable of communication with an Observer Wall Control, or will operate using standard 24v 2- stage thermostat. Route 24v control wires through control wiring grommet and connect leads to control board. When an Observer Wall Control is available, connect DX+ and DXconnections only. If additional grounding is needed connect to C terminal. If a 2- stage thermostat is used, connect to the C, Y1, and Y2 connections. Refer to the wiring label for further clarification.

Use No. 18 AWG colorcoded, insulated (35_C minimum) wire. If thermostat is located more than 100 ft. (30.48 m) from unit, as measured along the control voltage wires, use No. 16 AWG colorcoded, insulated wire to avoid excessive voltage drop.

All wiring must be NEC Class 1 and must be separated from incoming power leads.

Use furnace transformer, fan coil transformer, or accessory transformer for control power, 24- v/40va minimum.

NOTE: Use of available 24- v accessories may exceed the minimum 40va power requirement. Determine total transformer load and increase the transformer capacity or split the load with an accessory transformer as required.

Final Wiring Check

IMPORTANT: Check factory wiring and field wire connections for secure and tight terminations. Check wire routing to ensure wires are not in contact with tubing, sheet metal, etc.

Compressor Crankcase Heater

When equipped with a crankcase heater, furnish power to heater a minimum of 24 hr before starting unit if ambient is less than

R- 410A Split System Air Conditioner

65 F (18 C). To furnish power to heater only, set thermostat to OFF and close electrical disconnect to outdoor unit.

A crankcase heater is required if refrigerant tubing is longer than 80 ft. (24.38 m). Refer to the Long Line Applications Guidelines.

Install Electrical Accessories

Refer to the individual instructions packaged with kits or accessories when installing.

Check OAT Thermistor and OCT Thermistor Attachments

Outdoor Air Temperature (OAT) Thermistor is factory installed by inserting the nibs on either sides of the thermistor body through a keyhole in the bottom shelf of the control box and locking it in place by turning it 90 degrees, such that the spherical end of a nib faces the front of the control box.

Check to make sure the OAT is locked in place. See Fig. 7.

Figure 7 Outdoor Air Thermistor (OAT) Attachment

OAT Thermistor must be locked

in place with spherical nib end facing towards the front of the control box.

DX+ DX- C

The Outdoor Coil Temperature (OCT) Thermistor is factory installed on the liquid tube between the coil assembly and the liquid service valve. See Fig. 8.

Check to make sure the thermistor is securely attached on the liquid tube with the clip as shown in Fig. 8.

Figure 8 Outdoor Coil Thermistor (OCT) Attachment

OCT Thermistor must be secured tight on the liquid tube.

Airflow Setup with Observer Communicating Furnace or Fan Coil

When using an Observer Communicating Wall Control and communicating indoor equipment, airflow is automatically selected based on equipment size. See Observer Wall Control Installation Instructions and indoor specification sheet for available adjustments.

421 01 1702 05	Specifications subject to change without notice.	5