ICP CSA618GKA100, CSA624GKA100, CSA630GKA100, CSA636GKA100, CSA642GKA100 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 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 per-

sonal 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 discon-

nect switch. Lock out and tag switch with a suit-

able warning label.

CUT HAZARD

Failure to follow this caution may result in per-

sonal injury Sheet metal parts may have sharp edges or burrs.

Use care and wear appropriate protective clothing

and gloves when handling parts.

421 01 5104 03 02/11/15

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.

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

Figure 1 _ Connecting Tube Installation

NOTE: Avoid contact between tubing and structure

THROUGH THE WALL

SUSPENSION

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

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.

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 specificationssubjecttochangewithout notice. 421 01 5104 03

Forhurricanetiedowns- contactyourlocaldistributorfor

detailsandPE(ProfessionalCertification),ifrequiredbylocal authorities.

Make Piping Connections

Onrooftopapplications,mountonlevelplatformorframe.

Placeunitabovea load-bearingwallandisolateunitand

tubingsetfromstructure.Arrangesupportingmembersto adequatelysupportunitandminimizetransmissionof vibrationtobuilding.Consultlocalcodesgoverningrooftop

applications.

Roofmountedunitsexposedtowindsmayrequirewind

baffles.ConsulttheLow-Ambientpressureswitchinstallation

instructionsforwindbaffleconstruction.

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.

NOTE:Unitmustbe levelto 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 J Tie Down Knockouts

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

Basepan(2) Places

View From Top

UNIT BASE PAN

Dimension

31-1/2 X 31-1/2

35 X 35

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

TIEDOWN KNOCKOUT LOCATIONS in. (mm)

A B C

9-1/8 (231.8) 6-9/16 (166,7) 24-11/16 (627.1) 9-1/8 (231.8) 6-9/16 (166,7) 28-7/16 (722,3)

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).

Table 1 - Accessory Usage

REQUIRED FOR LOW-AMBIENT

COOLING APPLICATIONS

Accessory APPLICATIONS* (Over 80 ft. / 24.38 m)

Crankcase Heater Yes Compressor Start Assist Capacitor and Relay Yes

Evaporator Freeze Thermostat No Liquid Line Solenoid Valve See Long Line Applications Guideline

Low-ambient Pressure Switch No

Support Feet No Thermal Expansion Valve (TXV) Yes

Hard Shutoff

Winter Start Control 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 55°F / 12,8°C)

Recommended

421 01 5104 03 Specifications subject to change without notice. 3

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.

REQUIRED FOR LONG LINE

Yes Yes

Yes

Yes Yes

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

RATED VAPOR

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

UNIT SIZE Diameter Diameter Diameter

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.

Install Liquid Line Filter Drier Indoor Evacuate Refrigerant Tubing and Indoor Coil

Connection and Tube Connection Rated Tube

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

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. 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

SYSTEM

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

0 1 2 3 4 5 6 7

MINUTES

Final Tubing Check

VACUUM TIGHT

TOO WET TIGHT

DRY SYSTEM

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

UNIT DAMAGE HAZARD

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

sheet metal. Pay close attention to feeder tubes, making sure wire ties on feeder tubes are secure and tight.

Make Electrical Connections

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. ELECTRICAL SHOCK HAZARD After wrapping service valve with a wet cloth, braze sweat Failure to follow this warning could result in personal

connections using industry accepted methods and materials, injury or death. Consult local code requirements. Refrigerant tubing and

indoor coil are now ready for leak testing. This check should

Do not supply power to unit with compressor terminal box

include atl field and factory joints, cover removed.

4 Specifications subject to change without notice. 421 01 5104 03

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.

ELECTRICALSHOCKHAZARD

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

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.

A crankcase heater is required for low-ambient cooling or if 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.

Connect ground wire to ground connection in control box for safety. Connect power wiring to contactor as shown in Fig. 5.

Figure 5 J Line Power Connections

DISCONNECT PERN. E. C.AND/OR

LOCALCODES

FIELD POWER O

CONTACTOR

FIELD GROUND

WIRING j GROUND

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.

421 01 5104 03

LUG

Specifications subject to change without notice. 5

Check to make sure the OAT is locked in place. See Fig. 6.

Figure 6 J Outdoor Air Thermistor (OAT) Attachment

OAT Thermistor must be locked in place with spherical nib end facing towards

the front of the control box .................... \\\

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.

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