INSTALLATION INSTRUCTIONS
R−410A Split System Air Conditioner
CSA6, HSA6, TSA6
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
Safety Considerations 2...........................
Installation Requirements 2........................
Installation 2.....................................
Start−up Procedure 7.............................
General Sequence of Operation 8..................
Control Functions & Sequence of Operation 8........
Troubleshooting 9................................
Status Codes 10.................................
!
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.
!
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.
WARNING
CAUTION
421 01 5104 02 6/14/13
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical
shock, or other conditions which may cause death, personal
Figure 1
Connecting Tube Installation
Avoid contact between tubing and structureNOTE:
OUTDOOR WALL INDOOR WALL
CAULK
LIQUID TUBE
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
INSULATION
THROUGH THE WALL
HANGER STRAP
(AROUND VAPOR
TUBE ONLY)
VAPOR TUBE
JOIST
INSULATION
VAPOR TUBE
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
1″ (25.4 mm)MIN.
SUSPENSION
LIQUID TUBE
Code ( NEC ) NFPA 70. In Canada, refer to current editions
of the Canadian electrical code CSA 22.1.
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.
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
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 silicon−based 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.
2 421 01 5104 02
Specifications subject to change without notice.
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 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.
!
WARNING
INSTALLATION INSTRUCTIONS 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 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 mm) Dia.
Tiedown Knockouts in
Basepan(2) Places
UNIT BASE PAN
Dimension
31–1/2 X 31–1/2 9–1/8 (231.8) 6–9/16 (166.7) 24–11/16 (627.1)
35 X 35 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.
TIEDOWN KNOCKOUT LOCATIONS in. (mm)
Tie Down Knockouts
View From Top
A B C
Operating Ambient
The minimum outdoor operating ambient in cooling mode is
55°F (12.78_C) without low ambient cooling enabled, and the
maximum outdoor operating ambient in cooling mode is
125°F (51.67_C).
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.
WARNING
CAUTION
421 01 5104 02 3
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
Table 1 − Accessory Usage
REQUIRED FOR LOW−AMBIENT
COOLING APPLICATIONS
Accessory
Crankcase Heater Yes Yes
Compressor Start Assist Capacitor and Relay Yes Yes
Evaporator Freeze Thermostat Yes No
Liquid Line Solenoid Valve No See Long Line Applications Guideline
Low−ambient Pressure Switch Yes No
Support Feet Recommended No
Thermal Expansion Valve (TXV)
Hard Shutoff
Winter Start Control Yes 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.
(Below 555F / 12.85C)
Yes Yes
REQUIRED FOR LONG LINE
APPLICATIONS* (Over 80 ft. / 24.38 m)
Table 2 − Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters (In.)
RATED VAPOR
LIQUID
Connection and Tube
UNIT SIZE
18, 24, 30, 3/8 3/4 3/4
36, 42, 48 3/8 7/8 7/8
60 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.
Diameter
Connection
Diameter
up to 80 ft. (24.38 m)*
Rated Tube
Diameter
4 421 01 5104 02
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
Install Liquid Line Filter Drier Indoor
!
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
CAUTION
Liquid Line Filter Drier
Refrigerant tubes and indoor coil should be evacuated using
the recommended deep vacuum method of 500 microns. An
alternate triple evacuation method may be used. See triple
evacuation method in Service Manual.
IMPORTANT: Always break a 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
3500
3000
2500
2000
MICRONS
1500
1000
500
01234567
MINUTES
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
A95424
Final Tubing Check
IMPORTANT: Check to be certain factory tubing on both
indoor and outdoor unit has not shifted during shipment.
Refrigerant Tubing Connection Outdoor
Connect vapor tube to fitting on outdoor unit vapor service
valves (see Table 2.) Connect and braze the 3/8” coupling
(provided with the filter drier) to the liquid service valve and
connect and braze the liquid tubing to the other end of this
coupling. Use refrigerant 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.
CAUTION
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.
421 01 5104 02 5
CAUTION
Specifications subject to change without notice.
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.
WARNING
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
A crankcase heater is required for low−ambient cooling or if
!
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. 5.
Figure 5
DISCONNECT
PER N. E. C. AND/OR
LOCAL CODES
FIELD POWER
WIRING
Line Power Connections
CONTACTOR
refrigerant tubing is longer than 80 ft. (24.38 m). Refer to the
Long Line Applications Guideline − Residential Split−System
Air Conditioners and Heat Pumps Using R−410A Refrigerant.
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. 6.
Figure 6
OAT Thermistor must be locked in place
with spherical nib end facing towards
the front of the control box
Outdoor Air Thermistor (OAT) Attachment
FIELD GROUND
WIRING
GROUND
LUG
Connect Control Wiring
Route 24−v control wires through control wiring grommet and
connect leads to control wiring. (See Fig. 10 & Fig. 11)
Use No. 18 AWG color−coded, 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 color−coded, 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/40−va minimum.
NOTE: Use of available 24−v accessories may exceed the
minimum 40−va 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 to ensure terminations are secured properly.
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. To furnish
power to heater only, set thermostat to OFF and close
electrical disconnect to outdoor unit.
DX+ DX- C R
The Outdoor Coil Temperature (OCT) Thermistor is factory
installed on the liquid tube between the coil assembly and the
liquid service valve. See Fig. 7.
Check to make sure the thermistor is securely attached on
the liquid tube with the clip as shown in Fig. 7.
Figure 7
Outdoor Coil Thermistor (OAT) Attachment
OCT Thermistor must be
secured tight on the liquid tube.
6 421 01 5104 02
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
Start−Up
!
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this caution may result in minor personal
injury, equipment damage or improper operation.
To prevent compressor damage or personal injury,
observe the following:
S Do not overcharge system with refrigerant.
S Do not operate unit in a vacuum or at negative
pressure.
S Do not disable low pressure switch in scroll compressor
applications.
S Dome temperatures may be hot.
!
PERSONAL INJURY HAZARD
Failure to follow this caution may result in personal injury.
Wear safety glasses, protective clothing, and gloves
when handling refrigerant and observe the following:
S Front seating service valves are equipped with
Schrader valves.
!
ENVIRONMENTAL HAZARD
Failure to follow this caution may result in environmental
damage.
Federal regulations require that you do not vent refrigerant
to the atmosphere. Recover during system repair or final
unit disposal.
Follow these steps to properly start up the
system:
1. After system is evacuated, fully open liquid and vapor
service valves.
2. Unit is shipped with valve stem(s) front seated (closed)
and caps installed.
Replace stem caps after system is opened to
refrigerant flow. Replace caps finger−tight and tighten
with wrench an additional 1/12 turn
3. Close electrical disconnects to energize system.
4. Set room thermostat at desired temperature. Be sure
set point is below indoor ambient temperature.
5. Set room thermostat to COOL and fan control to ON or
AUTO mode, as desired. Operate unit for 15 minutes.
Check system refrigerant charge.
CAUTION
CAUTION
CAUTION
Check Charge
Factory charge amount and desired subcooling are shown
on unit rating plate. Charging method is shown on information
plate inside unit. To properly check or adjust charge,
conditions must be favorable for subcooling charging.
Favorable conditions exist when the outdoor temperature is
between 70_F and 100_F (21.11_C and 37.78_C), and the
indoor temperature is between 70_F and 80_F (21.11_C and
26.67_C). Follow the procedure below:
421 01 5104 02 7
Specifications subject to change without notice.
Unit is factory charged for 15ft (4.57 m) of lineset. Adjust
charge by adding or removing 0.6 oz/ft of 3/8 liquid line
above or below 15ft (4.57 m) respectively.
For standard refrigerant line lengths (80 ft/24.38 m or less),
allow system to operate in cooling mode at least 15 minutes.
When operating with the Observer Wall Control in
communicating mode, make sure that indoor airflow is set to
“efficiency” during charging. If conditions are favorable, check
system charge by subcooling method. 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 (26.67_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 (26.67_C) before attempting to
check system charge by subcooling method as described
above.
If the indoor temperature is below 70_F (21.11_C), or the
outdoor temperature is not in the favorable range, adjust
charge for line set length above or below 15ft (4.57 m) 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 ft (24.38 m) or greater than
20 ft (6.10 m) vertical separation, See Long Line Applications
Guideline for special charging requirements.
Major Components
Control Board
The AC control board controls the following functions:
S Compressor contactor operation
S Outdoor fan motor operation
S Compressor external protection
S Pressure switch monitoring
S Time Delays
Field Connections
When using communicating control, 4 field wires are required
to be connected to the factory wires already wired to the
DX+DX−C R terminal (see Fig. 10). Unit as provided by
manufacturer is set up for communicating control.
When used with a standard non−communicating thermostat,
it is recommended to use 3 thermostat control wires to be
connected to R, Y and C. When using 3 wires, all diagnostic
and time delay features are enabled (See Fig. 11).
Disconnect factory provided wires from DX+, DX−, C & R
terminals. Using factory provided wires, connect to R, C, and
Y on the control board for 3 wire thermostat control. Connect
field 24V wires to factory provided wires now connected to R,
C, and Y and cap both sides or remove unused factory
provided wires.
When only 2 thermostat control wires are available, units will
function, but some control features are lost. (See Fig. 12).
With only 2 wires connected, the circuit board will be
powered down whenever there is no call for cooling, and the
following will result:
S Compressor time delay is reduced from 5 minutes to 10
seconds
S When the thermostat is not calling for cooling, the amber
status light will be off, and no diagnostics codes will be
available
S All system counters will be reset on each new call for
cooling
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
Disconnect factory provided wires from DX+, DX−, C and R
terminals. Using factory provided wires, connect to C and Y
on the control board for 2 wire thermostat control. A field
installed jumper wire is also required between R and Y (See
Fig. 12). Connect field 24V wires to factory provided wires
now connected to C and Y and cap both sides or remove
unused factory provided wires.
Compressor Internal Relief
The compressor is protected by an Internal Pressure Relief
(IPR) which relieves discharge gas into the compressor shell
when differential between suction and discharge pressure
exceeds 550−625 psi. The compressor is also protected by
an internal overload attached to motor windings.
GENERAL SEQUENCE OF OPERATION
STANDARD THERMOSTAT
Turn on power to indoor and outdoor units. Transformer is
energized.
On a call for cooling, thermostat makes circuits R−Y and
R−G. Circuit R−Y energizes contactor, starting outdoor fan
motor and compressor circuit. R−G energizes indoor unit
blower relay, starting indoor blower motor on high speed.
NOTE: To achieve the rated system performance, the indoor
unit or the thermostat must be equipped with a time delay
relay circuit.
When thermostat is satisfied, its contacts open,
de−energizing contactor and blower relay. Compressor and
motors stop. If indoor unit is equipped with a time−delay relay
circuit, the indoor blower will run an additional 90 sec to
increase system efficiency.
CONTROL FUNCTIONS
AND SEQUENCE OF OPERATION
The outdoor unit control system has special functions. The
following is an overview of the control functions.
SEQUENCE OF OPERATION
Cooling Operation
This product utilizes either a standard indoor thermostat or
Observer t Communicating Wall Control. With a call for
cooling, the outdoor fan and compressor are energized.
When the cooling demand is satisfied, the compressor and
fan will shut off.
NOTE: The outdoor fan motor will continue to operate for one
minute after compressor shuts off, when the outdoor ambient
is greater than or equal to 100_F (37.78_C).
Communication and Status Function Lights
Green Communications (COMM) Light (Communicating
Control only):
A green LED (COMM light) on the outdoor board indicates
successful communication with the other system products.
The green LED will remain OFF until communications is
established. Once a valid command is received, the green
LED will turn ON continuously. If no communication is
received within 2 minutes, the LED will be turned OFF until
the next valid communication.
8 421 01 5104 02
Specifications subject to change without notice.
Amber Status Light
An amber colored STATUS light is used to display the
operation mode and fault codes as specified in the
troubleshooting section. See Table 3 for codes and
definitions.
NOTE: Only one fault code will be displayed on the outdoor
unit control board (the most recent, with the highest priority).
Crankcase Heater Operation
The crankcase heater (when applicable) is energized during
the off cycle below 65_F (37.78_C)
Outdoor Fan motor Operation
The outdoor unit control energizes outdoor fan any time the
compressor is operating. The outdoor fan remains energized
for 15 minutes if a pressure switch or compressor thermal
protector should open. Outdoor fan motor will continue to
operate for one minute after the compressor shuts off when
the outdoor ambient is greater than or equal to 100_F
(37.78_C).
Time Delays
The unit time delays include:
S Five minute time delay to start cooling operation when
there is a call from the thermostat or communicating wall
control.
S When operating the unit with 2 wires, this delay is
shortened to 10 seconds.
S Five minute compressor recycle delay on return from a
brown out condition
S Two minute time delay to return to standby operation from
last valid communications (with communicating only)
S One minute time delay of outdoor fan at termination of
cooling mode when outdoor ambient is greater than or
equal to 100_F (37.78_C).
Utility Interface
With Non−Communicating Thermostats
Utility curtailment will only work when the unit is operating
with a non−communicating thermostat.
When the utility curtailment interface is applied with a
non−communicating thermostat, the utility relay should be
wired in series with the Y input.
Low Ambient Cooling
When this unit is required to operate below 55_F (12.78_C) to
a minimum of 0 _F ( −17.78 _C) outdoor temperature,
provisions must be made for low ambient operation.
Low ambient applications require the installation of
accessory kits:
S Low Ambient Pressure Switch Kit
S Evaporator Freeze Thermostat
S Hard Start kit
S Crankcase Heater
Support feet are recommended for low ambient cooling. See
Product Specification sheet for kit part numbers on
appropriate unit size and series unit.
For low ambient cooling with the Observer
Communicating Wall Control the cooling lockout must be
set to “Off” in the Wall Control setup.
Liquid Line Solenoid
When operating in communicating mode the standard
thermostat terminals will not function. A terminal on the
non−communicating thermostat bus labeled “LS” on the AC
control board is provided for wiring liquid line solenoids when
in communicating mode. For operation in communicating
mode wire solenoid valve kit NASA401LS across LS and C
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
terminals . For operation in non−communicating mode wire
solenoid valve kit NASA401LS across C and Y terminals.
421 01 5104 02 9
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
TROUBLESHOOTING
SYSTEMS COMMUNICATION FAILURE
If communication between outdoor unit, control board, and
indoor wall control has failed, the control will flash the
appropriate fault code. (See table 3) Check the wiring to the
wall control, indoor and outdoor units.
PRESSURE SWITCH PROTECTION
The outdoor unit is equipped with high− and low−pressure
switches. If the control senses the opening of a high or
low−pressure switch, it will de−energize the compressor
contactor, keep the outdoor fan operating for 15 minutes and
display the appropriate fault code. (See table 3)
After a 15 minute delay, if there is still a call for cooling, and
the LPS or HPS is reset, the compressor contactor is
energized. If the LPS or HPS has not closed after a 15
minute delay, the outdoor fan is turned off. If the open switch
closes anytime after the 15−minute delay, then the unit will
resume operation with a call for cooling.
If the LPS or HPS trips for five consecutive cycles, then unit
operation is locked out for 4 hours and the appropriate fault
code (See table 3) is displayed.
In the event of a high−pressure switch trip or high−pressure
lockout, check the refrigerant charge, outdoor fan operation
and outdoor coil for airflow restrictions.
In the event of a low−pressure switch trip or low−pressure
lockout, check the refrigerant charge and indoor airflow.
CONTROL FAULT
If the outdoor unit control board has failed, the control will
flash the appropriate fault code. (See table 3) The control
board should be replaced.
24V BROWN OUT PROTECTION
If the control voltage is less than 15.5volts for at least 4
seconds, the compressor contactor and fan relay are
de−energized. Compressor and fan operation are not
allowed until control voltage is a minimum of 17.5volts. The
control will flash the appropriate fault code. (See table 3)
Verify the control voltage is in the allowable range of
18−30volts.
COMPRESSOR VOLTAGE SENSING
The input terminals labeled VR and VS on the control board
(see Fig. 9) are used to detect compressor voltage status,
and alert the user of potential problems. The control
continuously monitors the high voltage on the run capacitor
of the compressor motor. Voltage should be present any time
the compressor contactor is energized, and voltage should
not be present when the contactor is de−energized.
COMPRESSOR THERMAL CUTOUT OR LOSS OF
230V POWER
If the control senses the compressor voltage after start−up,
and is then absent for 10 consecutive seconds while cooling
demand exists, it will de−energize the compressor contactor,
keep the outdoor fan operating for 15 minutes (if 230v power
present) and display the appropriate fault code. (See table 3)
Possible causes are compressor internal overload trip or loss
of high voltage (230V) to compressor without loss of control
voltage.
After a 15 minute delay, if there is still a call for cooling, the
compressor contactor is energized. If the thermal protector
has not re−set, the outdoor fan is turned off. If the call for
cooling continues, the control will energize the compressor
contactor every 15 minutes. If the thermal protector closes,
10 421 01 5104 02
Specifications subject to change without notice.
(at the next 15 minute interval check), the unit will resume
operation.
If the thermal cutout trips for three consecutive cycles, then
unit operation is locked out for 4 hours and the appropriate
fault code (See Table 3) is displayed.
CONTACTOR SHORTED DETECTION
If there is compressor voltage sensed when there is no
demand for compressor operation, the contactor may be
stuck closed. The control will flash the appropriate fault
code. Check the contactor and control box wiring.
NO 230V AT COMPRESSOR
If the compressor voltage is not sensed when the
compressor should be starting, the contactor may be stuck
open or the unit disconnect or circuit breaker may be open.
The control will flash the appropriate fault code. Check the
contactor, unit disconnect or circuit breaker and control box
wiring.
TEMPERATURE THERMISTORS
Thermistors are electronic devices which sense temperature.
As the temperature increases, the resistance decreases.
Thermistors are used to sense outdoor air (OAT) and coil
temperature (OCT).
If the outdoor air or coil thermistor should fail, the control will
flash the appropriate fault code. (See table 3).
IMPORTANT: The outdoor air thermistor and coil thermistor
are factory mounted in the correct locations. Do not re−locate
thermistor sensors.
THERMISTOR SENSOR COMPARISON
The control continuously monitors and compares the outdoor
air temperature sensor and outdoor coil temperature sensor
to ensure proper operating conditions. The comparison is, if
the outdoor air sensor indicates ≥10_F (≥ −12.22_C) warmer
than the coil sensor (or) the outdoor air sensor indicates
≥20_F (≥ −6.67_C) cooler than the coil sensor, the sensors
are out of range.
If the sensors are out of range, the control will flash the
appropriate fault code. (See Table 3).
FAILED THERMISTOR DEFAULT OPERATION
Factory defaults have been provided in the event of failure of
outdoor air thermistor and/or coil thermistor.
Thermistor Curve: The resistance vs. temperature chart
shown in Figure 8 enables the technician to check the
outdoor air and outdoor coil thermistors for proper resistance.
Unplug the thermistor assembly from the circuit board and
measure resistance across each thermistor. For example, if
the outdoor temperature is 60_F (15.56_C), the resistance
reading across the outdoor air thermistor should be around
16,000 Ohms.
STATUS CODES
Table 3 shows the status codes flashed by the amber status
light. Most system problems can be diagnosed by reading
the status code as flashed by the amber status light on the
control board.
The codes are flashed by a series of short and long flashes
of the status light. The short flashes indicate the first digit in
the status code, followed by long flashes indicating the
second digit of the error code. The short flash is 0.25 second
ON and the long flash is 1.0 second ON. Time between
flashes is 0.25 second. Time between short flash and first
long flash is 1.0 second. Time between code repeating is 2.5
seconds with LED OFF.
Count the number of short and long flashes to determine the
appropriate flash code. Table 3 gives possible causes and
actions related to each error.
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
Example: 3 short flashes followed by 2 long flashes indicates
a 32 code. Table 3 shows this to be low pressure switch
open.
Table 3 − Status Codes
OPERATION FAULT
Standby – no call
for unit operation
Standby – no call
for unit operation
Cooling Operation None 1, pause Normal operation
Outdoor Air Temp Sensor
Outdoor Coil Sensor Fault 55 Coil sensor not reading or out of range. Ohm out sensor and check wiring
None On solid, no flash Normal operation − with communicating Control
None Off
System Communications
Failure
High Pressure
Switch Open
Low Pressure
Switch Open
Control Fault 45
Brown Out
(24 v)
Fault
Thermistors out
of range
Thermal Cutout 72
Contactor Shorted 73
No 230V at
Compressor
Thermal Lockout 82
Low Pressure Lockout 83
High Pressure
Lockout
AMBER LED
FLASH CODE
Normal operation − No call for cooling with 2−wire connection or indoor unit not pow-
ered.
16
31
32 Low pressure switch trip. Check refrigerant charge and indoor air flow
46
53 Outdoor air sensor not reading or out of range. Ohm out sensor and check wiring
56
74
84
Communication with wall control lost. Check wiring to wall control, indoor and outdoor
units
High pressure switch trip. Check refrigerant charge, outdoor fan operation and coils
for airflow restrictions.
Outdoor unit control board has failed. Control board needs to be replaced.
The control voltage is less than 15.5v for at least 4 seconds. Compressor and fan
operation not allowed until control voltage is a minimum of 17.5v. Verify control voltage.
Improper relationship between coil sensor and outdoor air sensor. Ohm out sensors
and check wiring.
Compressor voltage sensed after start−up, then absent for 10 consecutive seconds
while cooling demand exists. Possible causes are internal compressor overload trip or
loss of high voltage to compressor without loss of control voltage. The control will
continue fan operation and wait 15 minutes to attempt a restart. Fault will clear when
restart is successful, or low voltage power is cycled.
Compressor voltage sensed when no demand for compressor operation exists. Contactor may be stuck closed or there is a wiring error.
Compressor voltage not sensed when compressor should be starting. Disconnect may
be open or contactor may be stuck open or there is a wiring error.
Thermal cutout occurs in three consecutive cycles. Unit operation locked out for 4
hours or until 24v power recycled.
Low pressure switch trip has occurred during 3 consecutive cycles. Unit operation
locked out for 4 hours or until 24v power recycled.
High pressure switch trip has occurred during 3 consecutive cycles. Unit operation
locked out for 4 hours or until 24v power recycled.
Possible Cause and Action
Figure 8 Resistance vs Temperature Chart
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THERMISTOR CURVE
90
80
70
60
50
40
30
20
RESISTANCE (KOHMS)
10
0
0
(-17.77)
20
(-6.67)
Specifications subject to change without notice.
40
(4.44)
TEMPERATURE °F (°C)
60
(15.56)
80
(26.67)
100
(37.78)
120
(48.89)
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
Figure 9 Single Stage Control Board
12 421 01 5104 02
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
Figure 10
Wall Control
DX+
DX−
C
R
S1
S2
Figure 11
Optional Remote
Room Sensor
Observer Communicating Wall Control Four−Wire Connection Wiring Diagrams
(See Thermostat Installation Instructions for specific unit combinations)
Variable Speed
Green
Yellow
White
Red
Humidifier
Connection
Furnace/Fan Coil
DX+
DX−
C
R
HUM
COM
Green
Yellow
White
Red
Outdoor
DX+
DX−
C
R
LEGEND
24V FACTORY WIRING
24V FIELD WIRING
FIELD SPLICE CONNECTION
Non−Communicating Standard Thermostat 3−Wire 24V Circuit Connections
(See Thermostat Installation Instructions for
Specific Unit combinations)
LEGEND
24−V FACTORY WIRING
24−V FIELD WIRING
FIELD SPLICE CONNECTION
!
CAUTION
ELECTRICAL OPERATION HAZARD
Failure to follow this caution may result in
equipment damage or improper operation.
A minimum of three wire thermostat wiring is
required for the system to operate.
421 01 5104 02 13
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
Figure 12
A/C THERMOSTAT
24VAC HOT
24VAC COM
HEAT STAGE 1
HEAT STAGE 2
INDOOR FAN
R
C
W/W1
Y/Y2
G
Non−Communicating Standard Thermostat
NOTE: Wiring must conform to NEC or local codes.
2−Wire 24V Circuit Connections
TPPICAL FURNACE
OR
FAN COIL
R
C
W
Y
G
LEGEND
24V FACTORY WIRING
24V FIELD WIRING
FIELD SPLICE CONNECTION
AIR CONDITIONER
R
C
Y
FIEL INSTALLED JUMPER WIRE
Figure 13 Non−Communicating Indoor with Observer Communicating Wall Control
Wall
Control
DX+
R
C
DX-
C
R
W2
Y/Y2
G
Non-Communicating
Indoor
NOTE: This installation requires the daughter board
accessory, NAXA00101DB.
NOTE: This installation does not allow for communicating
feature functionality.
Green
Red
White
Yellow
NAXA00101DB
DX+
R
C
DX-
C
R
W2
Y
G
O
OAT
Communicating
Outdoor
C
R
Y
OAT
Sensor
14 421 01 5104 02
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
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.
421 01 5104 02 15
Specifications subject to change without notice.
Copyright 2013 International Comfort Products
Lewisburg, TN 37091 USA
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