ICP CCA924GKA100, CCA936GKA100, CCA948GKA100, CCA960GKA100, HCA924GKA100 Installation Guide

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Theseinstructionsmustbereadand understoodcompletelybeforeattemptinginstallation.

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

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

Installation Recommendations ................... 2

Installation ..................................... 2

Start-up Procedure ............................. 7

System Functions & Sequence of Operation ....... 7

Troubleshooting ................................ 8

Status Codes ................................. 11

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

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 warn-

ing label.

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.

421 01 1702 04 03/16/15

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service,

maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or

property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The

qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual

instructions packaged with the kits or accessories when installing. Follow all safety codes. Wear safety glasses, protective clothing,

and work gloves. Use quenching cloth for brazing operations.

Have fire extinguisher available. Read these instructions

thoroughly and follow all warnings or cautions included in

literature and attached to the unit. Consult local building codes

and current editions of the National Electrical Code ( NEC ) NFPA

70. In Canada, refer to current editions of the Canadian electrical code CSA 22.1.

Figure 1 [ Connecting Tube Installation

NOTE: Avoid contact between tubing and structure

THROUGH THE WALL

SUSPENSION

Recognize safety information. This is the safety-alert 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 safety-alert 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.

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.

When passing refrigerant tubes through the wall, seal

opening with RTV or other pliable silicon-based caulk. (See Fig. 1.)

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

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.)

Ensure that tubing insulation is pliable and completely

surrounds vapor tube.

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.

Outdoor unit contains system refrigerant charge for operation with AHRI rated indoor unit when connected by 15 ft. (4.57 m) of

field-supplied 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 liquid-line size is 3/8-in. OD for all

residential applications including long line. IMPORTANT: Always install the factory-supplied liquid-line filter

drier. Obtain replacement filter driers from your distributor or branch.

INSTALLATION

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 presate literature. There

can be no deviation.

Check Equipment and Job Site Unpack Unit

Move to final location. Remove carton taking care 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.

2 specificationssubjectto change without notice. 421 01 1702 04

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 load-bearing 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 Low-Ambient 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 30 in. (762 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 [

3/8--in. (9.53 ram) Dia. Tiedown Knockouts in

Basepan(2) Places

Tie Down Knockouts

View From Top

UNIT BASE PAN TIEDOWN KNOCKOUT LOCATIONS in. (mm)

Dimension A B C

31-1/2 X 31-1/2

(800 X 800) 9-1/8 (231,8) 6-9/16 (166,7) 24-11/16 (627.1)

35 X 35

(889 X 889) 9-1/8 (231,8) 6-9/16 (166,7) 28-7/16 (722,3)

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).

17 SEER 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.

19 SEER product is not approved for low ambient cooling

applications.

This unit is not approved for low ambient cooling applications.

Make Piping Connections

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 flow-control devices, including solenoid valves.

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 field-supplied refrigerant grade

tubing of correct size and condition. For tubing requirements beyond 80 ft/24.38 m, substantial capacity and performance

losses can occur. Following the recommendations in the Long Line Applications Guideline for Split-System 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 buried-line 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

connected by 15 ft. (4.57 m) of field-supplied or factory-accessory tubing, and factory supplied filter drier. Check

refrigerant charge for maximum efficiency.

421 01 1702 04 specificationssubjectto change without notice. 3

Table1- AccessoryUsage

REQUIREDFORLOWAMBIENT

COOLINGAPPLICATIONS

(17SEERProductOnly) REQUIREDFORLONGLINE Requiredfor Sea CoastApplica-

Accessory (Below55°F / 12,8°C) APPLICATIONS*(Over80 ft. / 24,38 m) tion (within2 miles/3,22 km)

Crankcase Heater Yes Standardon some units Yes,standard on some units No

Compressor StartAssist Ca- pacitorand Relay

LiquidLineSolenoid Valve No See Long LineApplications Guideline No

Support Feet Recommended No Recommended

HardShutoff TXV 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 ff, (6.09 m) vertical differential, refer to Long Line Applications Guideline.

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

UNIT SIZE Diameter Diameter Diameter

"0A724 3/8 3/4 3/4 "0A924 3/8 7/8 7/8

"0A736, "0A936 3/8 7/8 7/8

"0A748, "0A948 3/8 7/8 1-1/8 "0A760, "0A960 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 Refrigerant Tubing Connection Outdoor

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 heat-sinking 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 J Liquid Line Filter Drier

Yes(Standardwith factory approved Yes (Standardwithfactory approved in- Yes (Standardwith factoryap-

No No No

indoorunit) door unit) provedindoor unit)

RATEDVAPOR

LIQUID up to 80ft, (24,38 m)*

Connectionand Tube Connection RatedTube

Connect vapor and liquid tubes to fittings on vapor and liquid

service valves (seeTable 2.) Userefrigerant grade tubing. Sweat Connection

UNIT DAMAGE HAZARD

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

Service valves must be wrapped in a heat-sinking 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

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.

4 specificationssubjectto change without notice. 421 01 1702 04

Refrigeranttubesandindoorcoilshouldbeevacuatedusingthe recommendeddeepvacuummethodof 500microns.Ifdeep

vacuum equipmentis notavailable,thealternatetriple evacuationmethodmaybeusedbyfollowingthespecified

procedure.Ifvacuummustbeinterruptedduringtheevacuation procedure,alwaysbreakvacuumwithdrynitrogen.

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 5 _ Triple Evacuation Sequence

EVACUATE

BREAK VACUUM WITH DRY NITROGEN

WAIT

EVACUATE

BREAK VACUUM WITH DRY NITROGEN

Figure 4 [ Deep Vacuum Graph

SYSTEM

VACUUM TIGHT TOO WET

TIGHT 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:

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.

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.

WAIT

EVACUATE

CHECK FOR TIGHT, DRY SYSTEM I

(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

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. NOTE: Install branch circuit disconnect of adequate size per NEC

to handle unit starting current. Locate disconnect within sight from and readily accessible from unit, per Section 440-14 of NEC.

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.

421 01 1702 04 Specifications subject to change without notice. 5

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