International Comfort Products CSA6, HSA6, TSA6 Installation Manual
INSTALLATION INSTRUCTIONS
R−410A Split System Air Conditioner
CSA6, HSA6, TSA6
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 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 03 02/11/15
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
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
OUTDOOR WALL INDOOR WALL
HANGER STRAP
(AROUND VAPOR
1″ (25.4 mm)MIN.
Connecting Tube Installation
Avoid contact between tubing and structureNOTE:
CAULK
INSULATION
THROUGH THE WALL
TUBE ONLY)
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.
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.
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.
!
WARNING
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.
2 421 01 5104 03
Specifications subject to change without notice.
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
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
WARNING
CAUTION
Indoor Unit
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
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.
421 01 5104 03 3
Specifications subject to change without notice.
(Below 555F / 12.85C)
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
APPLICATIONS* (Over 80 ft. / 24.38 m)
Yes Yes
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
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
Install Liquid Line Filter Drier Indoor
Connection
Diameter
Evacuate Refrigerant Tubing and Indoor Coil
up to 80 ft. (24.38 m)*
Rated Tube
Diameter
!
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 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.
CAUTION
!
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.
CAUTION
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
5000
4500
4000
3500
3000
2500
2000
MICRONS
1500
1000
500
01234567
Deep Vacuum Graph
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
MINUTES
A95424
Final Tubing Check
IMPORTANT: Check to be certain factory tubing on both
indoor and outdoor unit has not shifted during shipment.
Ensure tubes are not rubbing against each other or any
sheet metal. Pay close attention to feeder tubes, making sure
wire ties on feeder tubes are secure and tight.
Make Electrical Connections
!
WARNING
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.
4 421 01 5104 03
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.
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner
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.
!
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
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
DISCONNECT
PER N. E. C. AND/OR
LOCAL CODES
FIELD POWER
WIRING
FIELD GROUND
WIRING
Line Power Connections
CONTACTOR
GROUND
LUG
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
DX+ DX- C R
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 5
Specifications subject to change without notice.
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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