ICP CCA724GKA100, CCA736GKA100, CCA748GKA100, CCA760GKA100, HCA724GKA100 Installation Guide
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INSTALLATION INSTRUCTIONS
R- 410A Two- Stage 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 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.
!
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.
!
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
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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 s lack 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.
CAUTION
421 01 1702 05 10/18/16
INSTALLA TION INSTRUCTIONS R- 410A Split System Air Conditioner
Figure 1 Connecting Tube Installation
Avoid contact between tubing and structureNOTE:
OUTDOOR WALL INDOOR WALL
CAULK
INSULATION
THROUGH THE WALL
HANGER STRAP
(AROUND VAPOR
TUBE ONLY)
1″ (25.4 mm)MIN.
SUSPENSION
LIQUID TUBE
VAPOR TUBE
JOIST
INSULATION
VAPOR TUBE
LIQUID TUBE
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.
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 s pecifications.
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
3/8- in. (9.53 mm) Dia.
Tiedown Knockouts in
Basepan(2) Places
Tie Down Knockouts
INSTALLATION
View From Top
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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
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.
2 421 01 1702 05
Unit
WARNING
UNIT BASE PAN
Dimension
31–1/2 X 31–1/2
(800 X 800)
35 X 35
(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
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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.
Specifications subject to change without notice.
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)
WARNING
INSTALLA TION INSTRUCTIONS R- 410A Split System Air Conditioner
beyond 80 ft/24.38 m, substantial capacity and performance
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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).
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
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
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.
Table 1 - Accessory Usage
REQUIRED FOR LOW AMBIENT
COOLING APPLICATIONS
Accessory
Crankcase Heater Yes Standard on some units Yes, standard on some units No
Compressor Start Assist Capacitor and Relay
Liquid Line Solenoid Valve No See Long Line Applications Guideline No
Support Feet Recommended No Recommended
Hard Shutoff 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 ft. (6.09 m) vertical differential, refer to Long Line Applications Guideline.
(Below 55F / 12.8C)
No No No
Yes (Standard with factory approved
indoor unit)
REQUIRED FOR LONG LINE
APPLICATIONS* (Over 80 ft. / 24.38 m)
Yes (Standard with factory approved in-
door unit)
Required for Sea Coast Applica-
tion (within 2 miles/3.22 km)
Yes (Standard with factory ap-
proved indoor unit)
Table 2 - Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters (In.)
RATED VAPOR
LIQUID
Connection and Tube
UNIT SIZE
*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.
Diameter
Install Liquid Line Filter Drier Indoor
Connection
Diameter
4. Connect and braze liquid refrigerant tube to the filter drier.
up to 80 ft. (24.38 m)*
Rated Tube
Diameter
!
CAUTION
Figure 3
Liquid Line Filter Drier
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.
421 01 1702 05 3
Specifications subject to change without notice.
Refrigerant Tubing Connection Outdoor
Connect vapor and liquid tubes to fittings on vapor and liquid
service valves (see Table 2.) Use refrigerant grade tubing.
INSTALLA TION INSTRUCTIONS R- 410A Split System Air Conditioner
Sweat Connection
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UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Service v alves 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.
CAUTION
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
BREAK VACUUM WITH DRY NITROGEN
BREAK VACUUM WITH DRY NITROGEN
Triple Evacuation Sequence
EVACUATE
WAIT
EVACUATE
WAIT
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
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM
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.
EVACUATE
CHARGE SYSTEM
Make Electrical Connections
5000
4500
4000
3500
3000
2500
2000
MICRONS
1500
1000
500
01234567
MINUTES
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
A95424
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.
4 421 01 1702 05
Specifications subject to change without notice.
!
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.
WARNING
INSTALLA TION INSTRUCTIONS R- 410A Split System Air Conditioner
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.
!
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.
WARNING
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
DISCONNECT
PER N. E. C. AND/OR
LOCAL CODES
FIELD POWER
WIRING
Line Power Connections
CONTACTO R
65F(18C). 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
OAT Thermistor must be locked
in place with spherical nib end facing
towards the front of the control box.
Outdoor Air Thermistor (OAT) Attachment
DX+ DX- C
FIELD GROUND
WIRING
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 DX- connections 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 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.
GROUND
LUG
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
liquidtubewiththeclipasshowninFig.8.
Figure 8
Outdoor Coil Thermistor (OCT) Attachment
OCT Thermistor must be
secured tight on the liquid tube.
Final Wiring Check
IMPORTANT: Check factory wiring and field wire c onnections 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
421 01 1702 05 5
Specifications subject to change without notice.
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.
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