ICP T4H418GKD100, T4H424GKD100, T4H430GKD100, T4H436GKD100, T4H442GKD100 Installation Guide

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:

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

Inspect New Unit ............................... 2

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

Location ....................................... 2

Clearances ................................. 2 - 3

Unit Support ................................... 4

Refrigeration System ........................ 5 - 9

Electrical Wiring ............................ 9 - 10

Defrost System ............................... 11

Start-up Procedure ............................ 11

Refrigerant Charge ........................ 12 - 13

Sequence of Operation ......................... 14

Troubleshooting ............................... 14

Maintenance .................................. 14

Comfort Alert TM Diagnostics Codes .............. 15

R-410A Quick Reference Guide ................. 16

DEATH, PERSONAL INJURY, AND/OR PROPERTY
DAMAGE HAZARD

Failure to carefully read and follow this warning

could result in equipment malfunction, property
damage, personal injury and/or death.

Installation or repairs made by unqualified per-
sons could result in equipment malfunction, prop-
erty damage, personal injury and/or death.

The information contained in this manual is in-
tended for use by a qualified service technician fa-

miliar with safety procedures and equipped with
the proper tools and test instruments.

Installation must conform with local building
codes and with the National Electrical Code

NFPA70 current edition or Canadian Electrical
Code Part 1 CSA C.22.1.

428 01 5102 00 Aug 2008

INSPECT NEW UNIT

After uncrating unit, inspect thoroughly for hidden company immediately and file a concealed damage
damage. If damage is found, notify the transportation claim.

SAFETY CONSIDERATIONS

Consult a qualified installer, service agency, or the
dealer/distributor for information and assistance. The

qualified installer must use factory authorized kits and
accessories when modifying this product. Refer to the

individual instructions packaged with the kit or accessory

when installing.
The weight of the product requires careful and proper

handling procedures when lifting or moving to avoid
personal injury. Use care to avoid contact with sharp or

pointed edges.
Follow all safety codes. Wear safety glasses, protective

clothing, and work gloves. Use a heat sinking material -
such as a wet rag - during brazing operations. Keep a fire

extinguisher available. Consult local codes and the

National Electric Code (NEC) for special requirements.
Improper installation, adjustment, alteration, service or

maintenance can void the warranty.

ELECTRICAL SHOCK HAZARD

Failure to turn off the main (remote) electrical dis-
connect device could result in personal injury or

death.

Before installing, modifying or servicing system,
turn OFF the main (remote) electrical disconnect
device. There may be more than one disconnect
device. Lock out and tag switch with a suitable
warning label.

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in proper-
ty damage

R-410A systems operate at higher pressures than

R-22 systems. When working with R-410A sys-
tems, use only service equipment and replace-

ment components specifically rated or approved
for R-410A service.

LOCATION

Check local codes for regulations concerning zoning,

noise, platforms, and other issues.
Locate unit away from fresh air intakes, vents, or

bedroom windows. Noise may carry into the openings

and disturb people inside.

Locate unit in a well drained area, or support unit high

enough so that water runoff will not enter the unit.

Locate unit away from areas where heat, lint, or exhaust

fumes will be discharged onto unit (as from dryer vents).

CLEARANCES

Nominal minimum clearances are 48 inches (1.2m)
above unit for discharge air and 18 inches (457mm) on
each side of the coil for intake air. Clearance on any one
side of the coil (normally between unit and structure) may

be reduced to 6 inches (152mm). Nominal minimum
clearances are based on a solid parallel object such as a
wall or roof overhang.

The clearance may be reduced for a single object with
small surface area, such as the end of a wall, outside
corner of a wall, fence section, post, etc. As a general

rule, the minimum clearance from the unit should equal
the width of the object. For example, a 6 inch (152mm)
fence post should be a minimum of 6 inches (152mm)

from the unit.

Locate unit away from recessed or confined areas where
recirculation of discharge air may occur (refer to

CLEARANCES section of this document).
Roof-top installation is acceptable providing the roof will

support the unit and provisions are made for water
drainage and noise/vibration dampening.

NOTE: Roof mounted units exposed to wind may require
wind baffles. Consult the manufacturer for additional

information.

Do not install unit under roof overhangs unless gutters are
present. A minimum vertical clearance of 48 inches
(1.2m) is required to the overhang.

Inside corner locations on single story structures require

evaluation. Large overhanging soffits may cause air
recirculation in a corner area even though recommended

minimum clearances are maintained. As a guide, locate
the unit far enough out so that half of the discharge grille is

out from under the soffit.
When placing two or more units side-by-side, provide a

minimum of 18 inches (457mm) between units.
Provide minimum service clearance of 24 inches

(610mm) from control box corner and side service panel.
Refer to Figure 1.

2 428 01 5102 00

Figure1 _ Clearances (various examples)

liiii !!i,!i

,,

(152mm)

24"

(610mm)

Service

18"

(457mm)

18"

(457mm)

18"

(457mm)

24" i

(610mm)
Service _;

8"

152ram)

18"

(457mm)

24"

(610mm) I

Service L_"

(6lOre.m) i

,,

(152mm)

(102mm)

24" i

4"

f

18"

(152mm)

(102mm)

wide fence

(610mm)

Service

24" Jr

,,

(152mm)

24"

(610mm)

18"

(457mm)

Service

6"

,,

(152mm)

Post

(610mm)

Service

f

24" __

18"

(457mm)

18"

(457mm)

18"

(457mm)

(457mm)

I 18"

428 01 5102 O0 3

UNIT SUPPORT

NOTE: Unit must be level + 2 degrees {% inch rise or fall

per foot of run (10mm rise or fall per 305 mm of run) } or
compressor may not function properly.

A. GROUND LEVEL INSTALLATION
The unit must be level and supported above grade by

beams, platform, or a pad. Platform or pad can be of open or
solid construction but should be of permanent materials
such as concrete, bricks, blocks, steel, or pressure- treated
timbers approved for ground contact. Soil conditions must

be considered so that the platform or pad does not shift or
settle and leave the unit partially supported. Minimum pad

dimensions are shown in Figure 2.

If beams or an open platform are used for support, it is

recommended that the soil be treated or area be graveled
to reduce the growth of grasses and weeds.

To minimize vibration or noise transmission, it is

recommended that supports not be in contact with the

building structure. However, slabs on grade constructions
with an extended pad are normally acceptable.

PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property damage.

Top surface of platform must be above estimated snow-
fall level to prevent snow blocking coil and to allow water

melt to drain from unit.

B. ROOF TOP INSTALLATION

This type of installation is not recommended on wood
frame structures where low noise levels are required.

Supporting structure or platform for the unit must be level.

If installation is on afiat roof, locate unit minimum 6 inches

(152mm) above roof level.

Place the unit over one or more load bearing walls. If there
are several units, mount them on platforms that are

self-supporting and span several load bearing walls. These
suggestions are to minimize noise and vibration
transmission through the structure. If the structure is a home

or apartment, avoid locating the unit over bedrooms or study.

NOTE: When unit is to be installed on a bonded
guaranteed roof, a release must be obtained from the

building owner to free the installer from all liabilities.
C. FASTENING UNIT DOWN

If conditions or local codes require the unit be attached in

place, remove the knockouts in the base pan and install
tie down bolts through the holes (refer to Figure 2).

Contact local distributor for hurricane hold-down details and
the RE. (Professional Engineer) certification, when required.

I

Figure 2 J Tie Down Knockouts

%" (10rnrn) dia. Tie Down Knockouts [ View From Top
In Base Pan (2 places)

Base

Pan

Depth

o o

A

Base Pan Width

Inches (mm)

Base Pan

Width x Depth

23 x 23

(584 x 584)

25%6 x 25%6

(652 x 652)

31YBx 31Y8

(791 x 791)

3415_6x 3415_6

(887 x 887)

Tie Down

Knockouts

A B C

73_ 47_6 18

(197) (113) (457)

9_6 47_6 21¼

(230) (113) (540)

9_e 6Y2 24%

(230) (165) (625)

9_e 6Y2 287_6

(230) (165) (722)

Minimum

MountingPad

Dimensions

23 x 23

(584 x 584)

26 x 26

(660 x 660)
31Y2x 31Y2

(800 x 800)

35 x 35

(889 x 889)

PROPERTY DAMAGE HAZARD
Failuretofollow thiscautionmayresultinpropertydamage.

Inadequate unit support may cause excessive vibration,
noise, and/or stress on the refrigerant lines, leading to re-

frigerant line failure.

4 428 01 5102 00

REFRIGERATION SYSTEM

A. COMPONENT MATCHES

Check to see that the proper system components are in

place, especially the indoor coil.

R-410A outdoor units can only be used with R-410A
specific indoor coils. If there is a refrigerant mis-match,

consult the indoor coil manufacturer to determine if a

refrigerant conversion kit is available for the indoor coil.
This outdoor unit is designed for use only with indoor coils

that utilize a TXV refrigerant metering device. If any other
type of metering device is installed on the indoor coil,

consult the indoor coil manufacturer to determine ifa TXV
conversion kit is available.

When installing a TXV on an indoor coil, follow the

instructions provided with the new TXV.
A typical TXV installation is shown in Figure 3.

PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product

damage.
Indoor coil and outdoor unit must be listed as a

certified combination (match) in the ARI Unitary
Directory of Certified Products.
Indoor coil must have R-410A specific, TXV refrig-

erant metering device.

B. REFRIGERANT LINE SETS

The refrigerant line set must be properly sized to assure
maximum efficiency and proper oil circulation.

Refer to Product Specifications and Long Line
Applications Guideline for line set sizing.

NOTE: Total line set length must not exceed 200 feet
(61m).

NOTE: A crankcase heater must be used when the
refrigerant line length exceeds 80 feet (24.4m).

If outdoor unit is more than 10 feet (3m) higher than the

indoor coil, refer to the Long Line Applications Guideline
for instructions.

NOTE: When the outdoor unit is higher than the indoor
coil, the vertical separation must not exceed 100 feet
(30m).

NOTE: When the outdoor unit is lower than the indoor
coil, the vertical separation must not exceed 50 feet

(15.2m).

If it is necessary to add refrigerant line in the field, use
dehydrated or dry, sealed, deoxidized, copper
refrigeration tubing. Do not use copper water pipe.

Do not remove rubber plugs or caps from copper tubing
until connections are ready to be made.

Be extra careful when bending refrigeration tubing.
Tubing can "kink" easily, and if this occurs, the entire
length of tubing must be replaced.

Figure 3 _ Typical TXV Installation

EQUALIZER

TUBE

SENSING SUCTION
BULB TUBE

LIQUID

TUBE

TXV

SENSING BULB

STRAP

(EITHE_

PERSONAL INJURY HAZARD
Failure to relieve system pressure could result in

personal injury and/or death.
Relieve pressure and recover all refrigerant before

servicing existing equipment, and before final unit
disposal. Use all service ports and open all flow-
control devices, including solenoid valves.

UNIT OPERATION HAZARD
Failure to follow this caution may result in improp-

er product operation.

Do not leave system open to atmosphere any lon-

ger than absolutely required for installation. Inter-

nal system components - especially refrigerant
oils - are extremely susceptible to moisture con-
tamination. Keep ends of tubing sealed during

installation until the last possible moment.

8 O'CLOCK

428 01 5102 00 5

4 O'CLOCK

C. ROUTING AND SUSPENDING REFRIGERANT

LINES

Run refrigerant lines as straight and direct as possible,

avoiding unnecessary bends and turns. Always insulate
the entire suction line. Both lines should be insulated

when routed through an attic or when routed through an

underground raceway.

When routing refrigerant lines through a foundation or
wall, do not allow refrigerant lines to come in direct
contact with the building structure. Make openings large

enough so that lines can be wrapped with extra insulation.

Fill all gaps with RTV caulk. This will prevent noise

transmission between the tubing and the foundation or
wall.

Along floor or ceiling joists, suspend refrigerant lines so
that they do not contact the building structure, water
pipes, or ductwork. Use insulated or suspension type
hangers. Metal straps must be at least 1" (25mm)wide to
avoid cutting into the tube insulation. Keep the liquid and
suction lines separate. Refer to Figure 4.

Figure 4

OUTDOOR WALL's, INDOAORWAL_7

-- L_N SULATION ____/_]- SUCTION TUBE

l

I_CAU LK_[-F[_ V_R-,_"

_ LIQUID TUBE

THROUGH THE WALL

Routing and Suspending Refrigerant Lines

UNIT OPERATION HAZARD
Failure to follow this caution may result in improp-

er product operation.

Do not bury more than 36" (lm) of line set under-
ground. Refrigerant may migrate to cooler buried

section during extended periods of unit shut-

down, causing refrigerant slugging and possible
compressor damage at start-up.

If ANY section of the line set is buried under-
ground, provide a minimum 6" (152mm) vertical

rise at the service valve.

HANGER STRAP

(AROUND SUCTION _,_ --

TUBE ONLY) "_'

h

1" (25mm) MIN -_.,,-I I_

SUSPENSION

Figure 5

Liquid Line Filter-Drier

lf JOiST

LIQUID TUBE

Installed at Indoor Coil

D. OUTDOOR UNIT HIGHER THAN INDOOR UNIT

Proper oil return to the compressor should be maintained
with suction gas velocity. If velocities drop below 1500
fpm (feet per minute), oil return will be decreased. To

maintain suction gas velocity, do not upsize vertical
suction risers.

E. LIQUID LINE FILTER-DRIER

Outdoor units are shipped with an appropriate filter-drier
for installation in the liquid line. Leave the plugs in the tube
ends until the filter-drier is installed. The optimal location
for the filter-drier is close to the indoor coil. Heat pump
filter-driers are "bi-flow" type. Either end can be pointed
towards indoor coil. Refer to Figure 5.

6 428 01 5102 00

F. SERVICEVALVES

Service valves are closed and plugged from the factory.
Outdoor units are shipped with a refrigerant charge
sealed in the unit. Leave the service valves closed until all

other refrigerant system work is complete or the charge
will be lost. Leave the plugs in place until line set tubing is

ready to be inserted.

Heat pumps require a piston metering device in the liquid
service valve for proper heating operation. Piston is

shipped in the piston body of the liquid service valve,
temporarily held in place with a plastic cap. Do not remove

the plastic cap until line set tubing is ready to be installed.

Refer to Figure 6 and follow these steps for piston

installation:

1. Remove plastic cap holding piston in piston body of
liquid service valve.

2. Check that piston size (stamped on side of piston)
matches with number listed on unit rating plate.

Return piston to piston body of liquid service valve
(either direction).

3. Find plastic bag taped to unit containing copper
adapter tube, brass nut, and plastic washer.

4. Install plastic washer in the seat inside piston body.

5. Fit brass nut onto adapter tube and install tube
onto liquid service valve. Tighten nut finger tight,

then wrench additional 1/2turn only. Over tightening
may damage the plastic washer.

Service valve bodies are brass and suction tube stub is
copper.

Figure 6 Liquid Service Valve with Piston

and Adapter Tube

G. BRAZING CONNECTIONS
NOTE:

For Liquid Service Valve - Braze lineset to adapter tube
BEFORE bolting adapter to valve. This helps prevent
overheating and damage to plastic washer or o-ring.

For Vapor Service Valve - remove valve core from
schrader port on both Service Valves BEFORE brazing.
This helps prevent overheating and damage to valve
seals (refer to Figure 6). Replace valve core when brazing
is completed.

FIRE HAZARD
Failure to remove refrigerant and oil charge before

brazing could result in personal injury, death, and/

or property damage.

Refrigerant and oil mixture could ignite and burn

as it escapes and contacts brazing torch. Make
sure the refrigerant charge is properly removed

from both the high and low sides of the system be-
fore brazing any component or lines.

Clean line set tube ends with emery cloth or steel brush.
Remove any grit or debris.

Insert line set tube ends into service valve tube stubs.
Apply heat absorbing paste or heat sink product between

service valve and joint. Wrap service valves with a heat
sinking material such as a wet cloth.

Braze joints using a SiI-Fos or Phos-copper alloy.

BRASS NUT

_/'/_-"'-" ADAPTER TUBE

_ PLASTIC WASHER

LIQUID SERVICEVALVE-''''_ ... /

Vapor Service Valve

I_ /..,,,.--SE RVIC E VALVE

VALVE CORE X

PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product

damage.

Braze with SiI-Fos or Phos-copper alloy on cop-
per-to-copper joints and wrap a wet cloth around
rear of fitting to prevent damage to TXV.

428 01 5102 00 7

H. EVACUATING LINE SET AND INDOOR COIL

The unit is shipped with a factory refrigerant charge. The

liquid line and suction line service valves have been

closed after final testing at the factory. Do not disturb
these valves until the line set and indoor coil have been

evacuated and leak checked, or the charge in the unit

may be lost.
NOTE: Do not use any portion of the factory charge for

purging or leak testing. The factory charge is for filling the

system only after a complete evacuation and leak check

has been performed.

PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product

damage.
Never use the outdoor unit compressor as a vacu-

um pump. Doing so may damage the compressor.

Line set 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 to 500 microns and a vacuum
gauge capable of accurately measuring this vacuum

level. The deep vacuum method is the most positive way
of assuring a system is free of air and water.

Watch the vacuum gauge as the system is pulling down.
The response of the gauge is an indicator of the condition
of the system (refer to Figure 7).

With no leaks in the system, allow the vacuum pump to

run for 30 minutes minimum at the deep vacuum level.

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. 8 and proceed is as

follows:

.

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 8.

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 8

BREAKVACUUM WITH DRYNITROGEN

IBREAK VACUUM WITH DRYNITROGEN

Triple Evacuation Sequence

IEVACUATE ]

1

IEVACUATE l

I

1

Figure 7

5000
4500

4000
3500

3000
2500

o

2000

1500
1000

500

8 428 01 5102 00

J Deep Vacuum Gauge Responseand System Conditions

TOO WE1
TIGHT

DRY SYSTEM

1 2 3 4 5 6 7

MINUTES

CHECK FOR TIGHT, DRYSYSTEM

(IF IT HOLDS DEEP VACUUM'

I CHARGE SYSTEM

1

I. OPENINGSERVICEVALVES

Outdoor units are shipped with a refrigerant charge
sealed in the unit. Opening the service valves releases

this charge into the system.

NOTE: Open the Suction service valve first. If the Liquid

service valve is opened first, oil from the compressor may

be drawn into the indoor coil TXV, restricting refrigerant

flow and affecting operation of the system.

Remove Suction service valve cap and insert a hex
wrench into the valve stem. Hold the valve body steady
with an end-wrench and back out the stem by turning the

hex wrench counterclockwise. Turn the stem until it just
contacts the rolled lip of the valve body.

ELECTRICAL WIRING

ELECTRICAL SHOCK HAZARD
Failure to turn off the main (remote) electrical dis-

connect device could result in personal injury or
death.

Before installing, modifying or servicing system,

turn OFF the main (remote) electrical disconnect

device. There may be more than one disconnect
device.

Supply voltage must be 208/230 volts (197 volt minimum
to 253 volts maximum) 60 Hz single phase.

Outdoor units are approved for use with copper
conductors only. Do not use aluminum wire.

Refer to unit rating plate for minimum circuit ampacity and
circuit protection requirements.

Grounding

Permanently ground unit in accordance with the National

Electrical Code and local codes or ordinances. Use a
copper conductor of the correct size from the grounding

lug in control box to a grounded connection in the service

panel or a properly driven and electrically grounded
ground rod.

Wiring Connections

Make all outdoor electrical supply (Line Voltage)
connections with raintight conduit and fittings. Most
codes require a disconnect switch outdoors within sight of
the unit. Consult local codes for special requirements.

After the refrigerant charge has bled into the system,
open the Liquid service valve.

NOTE: These are not back-seating valves. It is not
necessary to force the stem tightly against the rolled lip.

The service valve cap is a primary seal for the valve and
must be properly tightened to prevent leaks. Make sure
cap is clean and apply refrigerant oil to threads and
sealing surface on inside of cap.

Tighten cap finger tight and then tighten additional Y6of a
turn (1 wrench flat) to properly seat the sealing surfaces.

J. GAUGE PORTS

Check for leaks at the schrader ports and tighten valve
cores if necessary. Install plastic caps finger tight.

Route electrical supply (Line Voltage) wiring through
knockout hole in bottom of Control Box. Connect wires to

Contactor and Ground Lug according to Wiring Diagram
on unit. Refer to Figure 9.

Route thermostat wiring through rubber grommet in
bottom of Control Box. Low voltage lead wires are
provided in the control box for connection to thermostat
wires (use wire nuts). Refer to Wiring Diagram on unit and

Figure 10 for low voltage wiring examples.

NOTE: Use No. 18 AWG (American Wire Gage)
color-coded, insulated (35 °C minimum) wire. If

thermostat is located more than 100 feet (30.5 m) from
unit as measured along the control voltage wires, use No.

16 AWG color-coded wires to avoid excessive voltage

drop.

Figure 9

DISCONNECT

PER NEC AND/OR

LOCAL CODES

FIELD POWER

WIRING L2

FIELD GROUND

Electrical Supply (Line Voltage)

Connections

CONTACTOR

L1

11 o

-® ®

-® ®

23 or 13

-®

WIRING I

GROUND

LUG

428 01 5102 00 9

Figure10

THERMOSTAT
SUBBASE

i

D .......

[]

TypicalThermostat(ControlCircuit)Connections

NOTE: WHEN USING OUTDOOR THERMOSTATS, W 2 MUST BE ENERGIZED WHEN REQUESTING SUPPLEMENTAL HEAT.
SYSTEMS WITH ONE OUTDOOR THERMOSTAT SYSTEMS WITH TWO OUTDOOR THERMOSTATS

INDOOR

SPLICE
CONNECTION

/vw,\

OUTDOOR DEFROST THERMOSTAT INDOOR OUTDOOR DEFROST
SPLICE BOARD SUBBASE SPLICE SPLICE BOARD

CON OT:I"CON ITO __-- I ODTII_

_ .......

[]

E_ .......

i....... i

lo-1 ........

I

REMOVE WIRES FROM CRIMP NUT IN INDOOR FAN COIL WHEN INSTALLING OUTDOOR THERMOSTATS.

SYSTEMS WITHOUT OUTDOOR THERMOSTATS

THERMOSTAT

SUBBASE

D .....

D .....

[]

D .....

D .....

INDOOR OUTDOOR

SPLICE SPLICE

CONNECTION CONNECTION

I _ _ _ I

/VV _ \

I _ X _ I

...... j/Z__

j/Z__ _

-0

-0

4

DEFROST

BOARD

f_

O=r¸ ! iO

G

G

24-V FACTORY WIRING

24-V FIELD WIRING

FIELD SPLICE CONNECTION

OUTDOOR THERMOSTAT

EMERGENCY HEAT RELAY

SUPPLEMENTAL HEAT RELAY

LEGEND

[]

D .....

E_ .....

.... X

10 428 01 5102 00

-0

4

/

DEFROST SYSTEM

A. DEFROST THERMOSTAT

The defrost thermostat is factory installed on a short tube
stub extending from the coil end plate. Refer to Figure 11

and confirm that the thermostat is securely fastened in

alace on the tube stub.

Figure 11

Defrost Thermostat

TUBE

f TUBE STUB

6. When you hear reversing valve change position,
remove screwdriver immediately; otherwise,

control will terminate normal 10-minute defrost
cycle in approximately 2 seconds.

NOTE: Length of defrost cycle is dependent upon length
of time it takes to remove screwdriver from test pins after

reversing valve has shifted.

7. Unit will remain in defrost for remainder of
defrost-cycle time or until defrost thermostat

reopens at approximately 65°F (18°C) coil
temperature of liquid line.

8. Turn off power to outdoor unit and reconnect

fan-motor lead to OF2 on control board (refer to

Figure 12).

COIL

DEFROST
THERMOSTAT

B. DEFROST CONTROL BOARD

The defrost board is a time/temperature control which

includes a fleld-selectable time period between defrost

cycles of 30, 60, or 90 minutes (quick-connects located
at board edge, factory set at 90 minutes).

Defrost mode is identical to cooling mode except that

outdoor-fan motor stops and second-stage heat is
turned on to continue warming conditioned space.

Initially, the defrost cycle timer starts when the contactor

is energized and a 24 VAC signal is present on the T1
terminal. Then the defrost cycle begins when the defrost
thermostat is closed and the cycle timer times out (30, 60,

90 or minutes).
To initiate a forced defrost cycle, the defrost thermostat

must be closed. This can be accomplished as follows:

1. Turn off power to outdoor unit.

2. Disconnect outdoor fan-motor lead from OF2 on
control board (refer to Figure 12). Tape lead to

prevent grounding.

3. Restart unit in heating mode, allowing frost to
accumulate on outdoor coil.

4. After a few minutes in heating mode, liquid line
temperature should drop below closing point of

defrost thermostat, approximately 32° F (0°C).

5. Short between speed-up terminals with a
fiat-bladed screwdriver (refer to Figure 12). This

reduces the timing sequence to 7, 14, or 21
seconds (30, 60, or 90 minute defrost selection,

respectively).

START-UP PROCEDURE

1. Set indoor thermostat selector switch to OFF,

2. Turn ON all electrical disconnect devices.

3. If unit has a crankcase heater, energize the heater
and wait 24 hours before proceeding.

Figure 12 [

C_:_ US O1

H9C1(_<

F1 K1 _ }0

OF2

Ct9 C9

C1

oooo Y0

TI CC O I

4. Set indoor thermostat at desired temperature. Be
sure setpoint is below indoor ambient temperature
to call for cooling, or above indoor ambient to call

for heating.

5. Set indoor thermostat selector switch to COOL or
HEAT. Operate unit for minimum 15 minutes, then

check the system refrigerant charge.

Defrost Control Board

1-1

30 60 90

P1 J1

428 01 5102 00 11

REFRIGERANT CHARGE

A. COOLING MODE

Outdoor units are shipped with a refrigerant charge to

match a specific indoor coil and 15 feet (4.6m) of
refrigerant line. If shorter or longer refrigerant lines or a

different indoor coil are used, the charge will have to be
adjusted.

For different line lengths, add or remove charge based on

0.6 ounces (17g) charge per foot (305mm) of difference.
For example, a 25 foot (7.6m) line set is 10 feet (3m)
longer than the specified 15 feet (4.6m). Add 0.6 ounces

(17g) charge for each of the extra 10 feet (3m):
10 x 0.6 = 6.0 ounces additional charge

(3m x 17g = 51g additional charge)

This outdoor unit is designed for use only with indoor coils
that utilize a TXV refrigerant metering device. With an

indoor TXV, use the subcooling method to make final

charge adjustments:

NOTE: Only use subcooling charging method when

• outdoor ambient temperature is between 70°F and 100°F
(21°C and 38°C)

• indoor temperature is between 70° and 80°F (21 °C and

27°C)

• line set is less that 80 feet (24.4m).

1. Operate unit a minimum of 15 minutes before
checking charge.

NOTE: If outdoor unit has a 2-speed fan motor,
motor will operate in low speed when outdoor

ambient temperature is below 82°F (28°C). Pull
one of the yellow low voltage wires off the fan

control and the unit will default to high speed fan for
servicing. Reconnect wire after servicing.

2. Measure liquid service valve pressure by attaching
an accurate gauge to service port.

3. Measure liquid line temperature by attaching an
accurate thermistor type sensor or electronic

thermometer to liquid line near outdoor coil.

4. Refer to unit rating plate for required subcooling
temperature.

5. Refer to Figure 13. Find the required liquid line
temperature where the rating plate subcooling

temperature intersects measured liquid service
valve pressure.

6. If the measured liquid line temperature is higher
than the chart number, add refrigerant to lower the

measured temperature.
NOTE: When adding refrigerant, charge in liquid

form, using a flow restricting device, into the

suction port.
If the measured liquid line temperature is lower

than the chart number, reclaim refrigerant to raise
the measured temperature.

Tolerance is + 3° F (+1.7°C).

B. HEATING MODE
To check system operation during heating cycle, refer to

the Tech Label on outdoor unit. This chart indicates
whether a correct relationship exists between system

operating pressure and air temperature entering indoor
and outdoor units. If pressure and temperature do not

match on chart, system refrigerant charge may not be
correct. Do not use chart to adjust refrigerant charge.

NOTE: When charging is necessary during heating
season, charge must be weighed in accordance with unit

rating plate +0.6 ounces per foot of 3/8inch liquid line
above or below 15 feet respectively (+17g per 305mm of

10mm liquid line above or below 4.6m respectively).

12 428 01 5102 00

Figure13

oF

Measured Liquid

Pressure (psig)

251 78 76 74 72 70 68
259 80 78 76 74 72 70

266 82 80 78 76 74 72
274 84 82 80 78 76 74

283 86 84 82 80 78 76
291 88 86 84 82 80 78
299 90 88 86 84 82 80

308 92 90 88 86 84 82
317 94 92 90 88 86 84
326 96 94 92 90 88 86

335 98 96 94 92 90 88
345 1O0 98 96 94 92 90
364 104 102 1O0 98 96 94

374 106 104 102 1O0 98 96
384 108 106 104 102 1O0 98
395 110 108 106 104 102 100

406 112 110 108 106 104 102
416 114 112 110 108 106 104

427 116 114 112 110 108 106
439 118 116 114 112 110 108

450 120 118 116 114 112 110
462 122 120 118 116 114 112
474 124 122 120 118 116 114

6

Rating Plate (required) Subcooling Temperature °F (°C)

°F F °F (i ............................................

8 10 ...........................................12 .....................................................................................

R-410A Required Liquid Line Temperature °F (°C)

°

428 01 5102 O0 13

SEQUENCE OF OPERATION

A. COOLING MODE

On a call for cooling, the thermostat makes circuits R-O,

R-Y, and R-G. Circuit R-O energizes reversing valve,

switching it to cooling position. Circuit R-Y energizes
contactor, starting outdoor fan motor and compressor.

Circuit R-G energizes indoor unit blower relay, starting

indoor blower motor.

When thermostat is satisfied, its contacts open,
de-energizing contactor and blower relay. Compressor

and motors stop.

NOTE: If indoor unit is equipped with a time-delay relay

circuit, the blower runs an additional length of time to

increase system efficiency. (Applies to both cooling and
heating modes.)

TROUBLESHOOTING

Some models are factory equipped with the Comfort
Alert TM Diagnostics device in the control box (refer to

Figure 14). Comfort Alert provides around-the-clock
monitoring for common electrical problems, compressor

defects, and broad system faults. Iftrouble is detected, an
alert code is displayed with a flashing LED indicator. Alert

codes are listed in Figure 15.
The device is factory wired and requires no

modification. Low voltage lead wires are provided in the

control box for connection to thermostat wires (use wire

nuts).

The Comfort Alert device operates by monitoring the
compressor power leads and the thermostat demand
signal (Y terminal). It draws constant 24 VAC power at the

R and C terminals.

B. HEATING MODE

On a call for heating, the thermostat makes circuits R-Y
and R-G (circuit R-O is NOT made, and the reversing

valve stays in the de-energized, heating position). Circuit
R-Y energizes contactor, starting outdoor fan motor and

compressor. Circuit R-G energizes indoor blower relay,
starting blower motor. If the room temperature continues

to fall, circuit R-W2 is made through the second-stage
room thermostat bulb. Circuit R-W2 energizes a

sequencer, bringing on the first bank supplemental
electric heat and providing electrical potential to the

second heater sequencer (if used). If outdoor
temperature falls below the setting of the outdoor

thermostat (field-installed option), contacts close to
complete the circuit and bring on the second bank of

supplemental electric heat.
When the thermostat is satisfied, its contacts open,

de-energizing contactor, blower relay, and sequencer.
Compressor, motors, and heaters stop.

Figure 14

Comfort Alert TM Diagnostics

(some models)

. Compressor Wires

___ough Holes (3)

R

IJ !_ _ "Power" LED

_ C __ Thermostat Demand

['"1 _:!/:s I_ 24 VAC Common

MAINTENANCE

Condensate Drain

During the cooling season, check monthly for free flow of

drainage and clean if necessary.
Cleanliness
These tips will help keep the air conditioner looking better

and working more efficiently:

1. Free flow of air is essential. Keep fences, shrubs,
trash cans, and other obstructions at least 18

inches (457mm) from all coil inlets.

14 428 01 5102 00

,

Keep the coil free of grass clippings, leaves,

weeds, and other debris.

NOTE: Coil may occasionally require cleaning with
a liquid solution. The coil must be cold when

cleaning. Use an alkaline based cleaner only.
Cleaning a hot coil or using an acid based cleaner

will remove the paint from the fins and may clog the

coil.

,

Never use a weather cover over the outdoor unit
unless it is a ventilated type or made of breathable

fabric that will allow moisture to evaporate rapidly.
A cover that holds moisture in the unit will cause

more rust build-up and damage than normal
exposure to weather.

Figure15

StatusLED

Green"POWER"

Red "TRIP"

Yellow "ALERT"

Flash Code 1

Yellow "ALERT"

Flash Code 2

Yellow "ALERT"

Flash Code 3

Yellow "ALERT"

Flash Code 4

Yellow "ALERT"

Flash Code 5

Yellow "ALERT" Open Start Circuit 1. Run capacitor has failed

Flash Code 6 Current only in run circuit 2. Open circuit in compressor start wiring or connections

Yellow "ALERT" Open Run Circuit 1. Open circuit in compressor run wiring or connections

Flash Code 7 Current only in start circuit 2. Compressor run winding is damaged

Yellow "ALERT" Welded Contactor 1. Compressor contactor has failed closed

Flash Code 8 Compressor always runs 2. Thermostat demand signal not connected to module

Yellow "ALERT" Low Voltage 1. Control circuit transformer is overloaded

Flash Code 9 Control circuit < 17VAC 2. Low line voltage (contact utility if voltage at disconnect is low)

• Flash Code number corresponds to a number of LED flashes, followed by a pause and then repeated.

• TRIP and ALERT LEDs flashing at same time means control circuit voltage is too low for operation.

• Reset ALERT Flash code by removing 24VAC power from module.

• Last ALERT Flash code is displayed for 1 minute after module is powered on.

Status LED Description

Module has power
Thermostat demand signal
Y1 is present, but the com-
pressor is not running

Long Run Time
Compressor is running ex-
tremely long run cycles

System Pressure Trip
Discharge or suction pres-

sure out of limits or com-
pressor overloaded

Short Cycling
Compressor is running only
briefly 3.

Locked Rotor

Open Circuit

Comfort Alert TM

Supply voltage is present at module terminals

1. Compressor protector is open

2. Outdoor unit power disconnect is open

3. Compressor circuit breaker or fuse(s) is open

4. Broken wire or connector is not making contact

5. Low pressure switch open if present in system

6. Compressor contactor has failed open

1. Low refrigerant charge

2. Evaporator blower is not running

3. Evaporator coil is frozen

4. Faulty metering device

5. Condenser coil is dirty

6. Liquid line restriction (filter drier blocked if present in system)

7. Thermostat is malfunctioning

1. High head pressure

2. Condenser coil poor air circulation (dirty, blocked, damaged)

3. Condenser fan is not running

4. Return air duct has substantial leakage

5. If low pressure switch present in system, check Flash Code 1
information

1. Thermostat demand signal is intermittent

2. Time delay relay or control board defective

If high pressure switch present go to Flash Code 2 informa-

tion

4. If low pressure switch present go to Flash Code 1 informa-
tion

1. Run capacitor has failed

2. Low line voltage (contact utility if voltage at disconnect is low)

3. Excessive liquid refrigerant in compressor

4. Compressor bearings are seized

1. Outdoor unit power disconnect is open

2. Compressor circuit breaker or fuse(s) is open

3. Compressor contactor has failed open

4. High pressure switch is open and requires manual reset

5. Open circuit in compressor supply wiring or connections

6. Unusually long compressor protector reset time due to ex-
treme ambient temperature

7. Compressor windings are damaged

3. Compressor start winding is damaged

Diagnostics (some models)

Status LED Troubleshooting Information

428 01 5102 00 15

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.

International Comfort Products, LLC

16 Lewisburg, TN 37091 USA 428 01 5102 00