INSTALLATION INSTRUCTIONS
r
R−410A Two−Stage Split System Air Condi t i one
Product Family: H4A6, C4A6, T4A6
H4A8, C4A8, T4A8
These instructions must be read and understood completely before attempting installation.
Safety Labeling and Signal Words
DANGER, WARNING, CAUTION, and
NOTE
The signal words DANGER, WARNING,
CAUTION, and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is
only used on product labels to signify an immediate
hazard. The signal words WARNING, CAUTION,
and NOTE will be used on product labels and
throughout this manual and other manuals that may
apply to the product.
DANGER − Immediate hazards which will result in
severe personal injury or death.
WARNING − Hazards or unsafe practices which
could result in severe personal injury or death.
CAUTION − Hazards or unsafe practices which
may result in minor personal injury or product or
property damage.
NOTE − Used to highlight suggestions which
will result in enhanced installation, reliability, or
operation.
Signal Words in Manuals
The signal word WARNING is used throughout this
manual in the following manner:
WARNING
!
The signal word CAUTION is used throughout this
manual in the following manner:
!
Signal Words on Product Labeling
Signal words are used in combination with colors
and/or pictures on product labels.
WARNING
CAUTION
TABLE OF CONTENTS
Inspect New Unit 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Considerations 2. . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearances 2 − 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Support 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration System 4 − 8. . . . . . . . . . . . . . . . . . . . . . . .
Electrical Wiring 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Airflow Selection 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start−up Procedure 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Charge 9 − 10. . . . . . . . . . . . . . . . . . . . . . . . .
Sequence of Operation 10. . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Operation 11. . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 11 − 12. . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostics 13 − 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R−410A Quick Reference Guide 15. . . . . . . . . . . . . . . . .
!
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 persons could result in equipment malfunction, property damage, personal injury and/or death.
The information contained in this manual is intended for use by a qualified service technician familiar 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.
WARNING
421 01 6002 01 Oct 2009
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
INSPECT NEW UNIT
After uncrating unit, inspect thoroughly for hidden
damage. If damage is found, notify the transportation
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.
company immediately and file a concealed damage
claim.
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in per-
sonal 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 systems, use only service equipment and replacement components specifically rated or approved
for R−410A service.
WARNING
CAUTION
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.
2 421 01 6002 01
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
Figure 1 Clearances (various examples)
24”
(610mm)
Service
Wall
6”
(152mm)
18”
(457mm)
Wall
6”
(152mm)
18”
(457mm)
18”
(457mm)
Wall
24”
(610mm)
Service
Wall
6”
(152mm)
18”
(457mm)
Wall
6”
(152mm)
24”
(610mm)
Service
18”
(457mm)
24”
(610mm)
Service
4”
(102mm)
(457mm)
18”
(152mm)
18”
(102mm)
wide fence
Wall
24”
(610mm)
Service
4”
24”
(610mm)
Service
18”
(457mm)
18”
(457mm)
6”
(152mm)
6”
(152mm)
Post
24”
(610mm)
Service
18”
(457mm)
421 01 6002 01 3
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
UNIT SUPPORT
NOTE: Unit must be level 2 degrees { inch rise or fall
per foot of run (10mm rise or fall per 305mm 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. Minim u m p a d 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.
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 a flat roof, locate unit minimum 6 inches
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 P.E. (Professional Engineer) certification, when
required.
!
CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in proper-
ty damage.
Inadequate unit support may cause excessive
vibration, noise, and/or stress on the refrigerant
lines, leading to refrigerant line failure.
Figure 2 Tie Down Knockouts
” (10mm) dia. Tie Down Knockouts
In Base Pan (2 places)
A
Base Pan Width
View From Top
Base
Pan
Depth
C
B
Inches (mm)
Base Pan
Width x Depth
(889 x 889)
Tie Down
Knockouts
A B C
(230)(165)
(722)
Minimum
Mounting Pad
Dimensions
(889 x 889)
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 to achieve maximum
efficiency when used 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 if a TXV conversion kit is
available.
4 421 01 6002 01
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.
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
Figure 3 Typical TXV Installation
INDOOR
EQUALIZER
COIL
TUBE
SENSING
BULB
SUCTION
TUBE
LIQUID
TUBE
TXV
SENSING BULB
(EITHER SIDE)
STRAP
SUCTION
TUBE
8 O’CLOCK 4 O’CLOCK
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.
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.
!
WARNING
PERSONAL INJURY HAZARD
Failure to follow this warning could result in per-
sonal 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.
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” wide (25mm) to
avoid cutting into the tube insulation. Keep the liquid and
suction lines separate. Refer to Figure 4.
!
CAUTION
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. Internal system components − especially refrigerant
oils − are extremely susceptible to moisture contamination. Keep ends of tubing sealed during
installation until the last possible moment.
Figure 4 Routing and Suspending Refrigerant Lines
OUTDOOR WALL INDOOR WALL
CAULK
INSULATION
THROUGH THE WALL SUSPENSION
421 01 6002 01 5
LIQUID TUBE
SUCTION TUBE
HANGER STRAP
(AROUND SUCTION
TUBE ONLY)
1” (25mm) MIN
JOIST
INSULATION
SUCTION TUBE
LIQUID TUBE
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
F. SERVICE VALVES
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in improp-
er product operation.
Do not bury more than 36” (1m) 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 underground, provide a minimum 6” (152mm) vertical
rise at the service valve.
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. Install the
filter−drier with the arrow pointing towards the indoor coil.
Refer to Figure 5.
CAUTION
Service valves are closed and tube stubs are 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.
Service valve bodies are brass and tube stubs are
copper.
Figure 6 Service Valve
SERVICE V ALVE
VALVE CORE
G. BRAZING CONNECTIONS
NOTE: Remove valve core fr om 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 com plet ed.
Figure 5
Filter−Drier
(arrow points towards indoor coil)
Liquid Line Filter−Drier
Installed at Indoor Coil
38−11−84
!
FIRE HAZARD
Failure to follow this warning could result in per-
sonal 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 before 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 Sil−Fos or Phos−copper alloy.
!
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Braze with Sil−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.
WARNING
CAUTION
6 421 01 6002 01
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
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.
!
CAUTION
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.
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:
1. 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 Triple Evacuation Sequence
EVACUATE
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.
Figure 7
5000
4500
4000
3500
3000
2500
2000
MICRONS
1500
1000
500
Deep Vacuum Gauge Response
and System Conditions
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
WAIT
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
CHARGE SYSTEM
01
421 01 6002 01 7
246
375
MINUTES
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
I. OPENING SERVICE VALVES
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 follow this warning could result in per-
sonal 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.
The 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.
WARNING
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 of 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.
Figure 9
DISCONNECT
PER NEC AND/OR
LOCAL CODES
FIELD POWER
WIRING
FIELD GROUND
WIRING
Electrical Supply (Line Voltage)
Connections
CONTACTOR
L1
L2
GROUND
11
23
LUG
Figure 10 Typical Thermostat Connections
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.
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. Also 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) w ire. If thermostat
is located more than 100 feet (30.5m) from unit as
measured along the control voltage wires, use N o. 16 AWG
color−coded wires to avoid excessive voltage drop.
THERMOSTAT
24 VAC HOT
24 VAC COM
HEAT STAGE 1
HEAT STAGE 2
COOL STAGE 1
COOL STAGE 2
INDOOR FAN
LED INDICATOR
LIGHT
R
C
W/W1
W2
Y1
Y2
G
L
VARIABLE SPEED
FURNACE /
FAN COIL
R
C
W1
W2
Y1
Y/Y2
G
TWO−STAGE
AIR CONDITIONER
R
C
Y
Y2
L
8 421 01 6002 01
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
AIRFLOW SELECTION
Two−stage compressor operation requires two different
indoor airflow settings for proper operation. This outdoor
unit is designed for use only with an indoor blower that can
be configured for separate low−stage and high−stage
airflow (CFM) levels. Refer to Product Specifications
Sheets for recommended low−stage and high−stage
indoor airflow values. Refer to indoor unit Installation
Instructions to set the indoor blower for the proper
low−stage and high−stage airflow values.
NOTE: Optimal comfort, efficiency, and reliability will only
be achieved when the indoor airflow is properly set for
both low−stage and high−stage operation.
START−UP PROCEDURE
1. Set indoor thermostat selector switch to OFF.
2. Turn ON all electrical disconnect devices.
3. Unit has a crankcase heater. Energize the heater an d
wait 24 hours before proceeding.
REFRIGERANT CHARGE
NOTE: Charge in High −Stage onl y.
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 char ging method when
outdoor ambient temperature is between 70F and 100F
(21C and 38C)
indoor temperature is between 70 and 80F (21C and
27C)
line set is less that 80 feet (24.4m).
1. Operate unit a minimum of 25 minutes in
high−stage before checking charge.
NOTE: Outdoor unit has a 2−speed fan motor.
Motor will operate in low speed when outdoor
ambient temperature is below 82° F (28C). 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. Set indoor thermostat at desired temperature. Be
sure setpoint is below indoor ambient temperature or
thermostat will not call for cooling.
5. Set indoor thermostat selector switch to COOL.
Operate unit fo r m i n i mum 25 minutes, then check the
system refrigerant charge.
4. Refer to unit rating plate for required subcooling
temperature.
5. Refer to Figure 11. 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) .
421 01 6002 01 9
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
Figure 11 Rating Plate (required) Subcooling Temperature ° F (° C)
° F (° C) ° F (° C) ° F (° C) ° F (° C) F (° C) F (° C)
Measured Liquid
Pressure (psig)
251 78 26 76 24 74 23 72 22 70 21 68 20
259 80 27 78 26 76 24 74 23 72 22 70 21
266 82 28 80 27 78 26 76 24 74 23 72 22
274 84 29 82 28 80 27 78 26 76 24 74 23
283 86 30 84 29 82 28 80 27 78 26 76 24
291 88 31 86 30 84 29 82 28 80 27 78 26
299 90 32 88 31 86 30 84 29 82 28 80 27
308 92 33 90 32 88 31 86 30 84 29 82 28
317 94 34 92 33 90 32 88 31 86 30 84 29
326 96 36 94 34 92 33 90 32 88 31 86 30
335 98 37 96 36 94 34 92 33 90 32 88 31
345 100 38 98 37 96 36 94 34 92 33 90 32
364 104 40 102 39 100 38 98 37 96 36 94 34
374 106 41 104 40 102 39 100 38 98 37 96 36
384 108 42 106 41 104 40 102 39 100 38 98 37
395 110 43 108 42 106 41 104 40 102 39 100 38
406 112 44 110 43 108 42 106 41 104 40 102 39
416 114 46 112 44 110 43 108 42 106 41 104 40
427 116 47 114 46 112 44 110 43 108 42 106 41
439 118 48 116 47 114 46 112 44 110 43 108 42
450 120 49 118 48 116 47 114 46 112 44 110 43
462 122 50 120 49 118 48 116 47 114 46 112 44
474 124 51 122 50 120 49 118 48 116 47 114 46
6 3 8 4 10 6 12 7 14 8 16 9
R−410A Required Liquid Line Temperature ° F (° C)
SEQUENCE OF OPERATION
With power supplied to indoor and outdoor units,
transformer is energized.
NOTE: For low−stage operation, the outdoor unit Comfort
Alert UltraTech is labeled Y and the indoor
unit/thermostat is labeled Y1.
On a call for l ow−stage cooling, the thermostat energizes Y1
(low−stage compressor) and G. The call for Y1 energizes
the contactor, starting the outdoor fan motor and l ow− stage
compressor. The compress or operates at par t load. The
call for G ener gizes the indoor blower motor.
On a call for high−stage cooling, the thermostat energizes
Y1, Y2 and G. The call for Y1 energizes the contactor,
starting the outdoor fan motor and compressor. Five
seconds after the compressor starts, Y2 energizes the
compressor solenoid to load up the compressor to full
capacity. The call for G energizes the indoor blower
motor.
When the thermostat is satisfied, its contacts open,
de−energizing contactor and blower. Compressor and
motor 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.
10 421 01 6002 01
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
COMPRESSOR OPERATION
The basic scroll design has been modified with the
addition of an internal unloading mechanism that opens
a by−pass port in the first compression pocket, effectively
reducing the displacement of the scroll. The opening and
closing of the by−pass port is controlled by an internal
electrically operated solenoid. The modulated scroll uses
a single step of unloading to go from full capacity to
approximately 67% capacity.
A single speed, high efficiency motor continues to run
while the scroll modulates between the two capacity
steps. Modulation is achieved by venting a portion of the
gas in the first suction pocket back to the low side of the
compressor, thereby reducing the effective displacement
of the compressor.
TROUBLESHOOTING
Models are factory equipped with the Comfort Alert
UltraTech Diagnostics device (refer to Figure 12) in the
control box. Comfort Alert UltraTech provides
compressor staging from low to high and high to low
capacity. Comfort Alert UltraTech provides
around−the−clock monitoring for common electrical
problems, compressor defects, and broad system faults.
If trouble is detected, an alert code is displayed with a
flashing LED indicator . Alert codes are listed in Figure 13.
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 UltraT ech must be powered to properly
stage compressor to high capacity . Energizing the Y (Y1)
terminal operates the compressor in low−stage. Both the
Y (Y1) and Y2 terminals must be energized for
high−stage operation.
The Comfort Alert UltraTech device operates by
monitoring the compressor power leads and the
thermostat demand signals Y (Y1) and Y2 terminals. It
draws constant 24 VAC power at the R and C terminals.
When the compressor is operating in low−stage (Y or Y1),
the 24v DC compressor solenoid coil is de−energized.
When the compressor is operating in high−stage (Y or Y1
and Y2), the 24v DC solenoid coil is energized. The 24v
DC plug that is connected to the compressor does NOT
have an internal rectifier. DO NOT INSTALL A PLUG
WITH INTERNAL RECTIFIER.
Full capacity is achieved by blocking these vents, thus
increasing the displacement to 100%. A DC solenoid in
the compressor, controlled by a rectified external 24 volt
AC signal, moves the slider ring that covers and uncovers
these vents.
The vent covers are arranged in such a manner that the
compressor operates at approximately 67% capacity
when the solenoid is not energized and 100% capacity
when the solenoid is energized. The loading and
unloading of the two step scroll is done “on the fly” without
shutting off the motor between steps.
NOTE: 67% compressor capacity translates to
approximately 80% cooling or heating capacity at the
indoor coil.
The compressor will always start unloaded and stay
unloaded for five seconds even when the second stage
of the thermostat is calling for more capacity (a starting
advantage under low voltage conditions).
Figure 12 Comfort Alertt UltraTecht Diagnostics
“Power” LED
Thermostat Demand
nd
Stage Compressor
Y2
2
R
Thermostat Demand
1st Stage Compressor
Data Port
Thermostat Signal
24 VAC HOT
24 VAC Common
DC Compressor
Solenoid
“Alert” LED
“Trip” LED
S
C
Y
L
R
C
421 01 6002 01 11
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
Two−Stage Compressor Resistance (winding resistance) at 70° F +/− 20° F
(21°C +/− 11° C)
Winding *4A624 *4A836 *4A648 *4A660
Start (S−C) 1.40 1.29 1.52 0.60
Run (R−C) 1.32 0.89 0.64 0.49
NOTE: The rectifier for the DC solenoid is contained
within the Comfort Alert UltraTech device. The plug at the
compressor solenoid is an ordinary 2−wire plug. Never
use a plug with internal rectifier with this system.
NOTE: The DC compressor solenoid plug that connects
to the Comfort Alert UltraTech is polar dependent and
should only be connected with the tabs aligned.
Unloader Test Procedure with Comfort Alertt Module
The unloader is the compressor internal mechanism,
controlled by the DC solenoid, that modulates between
high and low−stage.
If it is suspected that the unloader is not working, the
following methods may be used to verify operation.
1. Operate the system and measure compressor
amperage. Cycle the unloader on and off at ten
plus second intervals by applying and removing Y2
voltage to the module. Wait five seconds after
power is applied to Y2 before taking a reading. The
compressor amperage should go up or down at
least 25 percent.
MAINTENANCE
2. If step one does not give the expected results,
remove the solenoid plug from the compressor
and, with the unit running and the thermostat
calling for Y2 to be energized, test the voltage
output at the plug with a DC voltmeter.
The reading here should be 4 to 18 volts. If NOT,
unplug the harness from the module and check
voltage at the “DC Sol” pins of the module. The
module will not power the unloader solenoid if the
compressor is not running or fault code 1 or 9 is
active.
3. If the correct DC voltage is at the control circuit
molded plug, measure the unloader coil
resistance. The resistance should be 32 to 60
ohms depending on compressor temperature. If
the coil resistance is infinity, much lower than 32
ohms, or is grounded, the compressor must be
replaced.
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.
2. 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.
3. 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.
12 421 01 6002 01
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
l
y
Figure 13 Comfort Alertt UltraTecht Diagnostics
Status LED Status LED Description Status LED Troubleshooting Information
Green “POWER” Module has power Supply voltage is present at module terminals
Red “TRIP” Thermostat demand signa
Y is present, but the
compressor is not running
1. Compressor protector is open
• Check for high head pressure
• Check compressor supply voltage
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. Compressor contactor has failed open
Yellow “ALERT”
Flash Code 1
Long Run Time
Compressor is running
extremely long run cycles
(18 hours or more)
1. Low refrigerant charge
2. Evaporator blower is not running
• Check blower relay coil and contacts
• Check blower motor for failure or blockage
• Check evaporator blower wiring and connectors
• Check indoor blower control board
• Check thermostat wiring for open circuit
3. Evaporator coil is frozen
• Check for low suction pressure
• Check for excessively low thermostat setting
• Check evaporator airflow (coil blockages or return air filter)
• Check ductwork or registers for blockage
4. Faulty metering device
• Check TXV bulb installation (size, location, and contact)
• Check if TXV is stuck closed or defective
5. Condenser coil is dirty
6. Liquid line restriction (filter drier blocked)
7. Compressor high−stage cooling wiring
• Solenoid plug not connected / malfunction
• Comfort Alert failure
8. Thermostat is malfunctioning
• Check thermostat sub−base or wiring for short circuit
• Check thermostat installation (location, level)
Yellow “ALERT”
Flash Code 2
Yellow “ALERT”
Flash Code 3
Internal Protector Trip 1. The internal motor protector has opened
• Wait for compressor to cool down, protector will close
automatically
Short Cycling
Compressor is running onl
briefly (1−3 minutes)
1. Thermostat demand signal is intermittent
2. High head pressure
• Check high pressure switch
• Check if system is overcharged with refrigerant
• Check for non−condensable in system
3. Condenser coil poor air circulation (dirt y, blocked, dam aged)
4. Condenser fan is not running
• Check fan capacitor
• Check fan wiring and connectors
• Check fan motor for failure or blockage
5. Return air duct has substantial leakage
6. Low pressure switch open, see Flash Code 1 information
Yellow “ALERT”
Flash Code 4
Locked Rotor
1. Run capacitor has failed
2. Low line voltage (contact utility if voltage at disconnect is low,
below 187v)
• Check wiring connections
3. Excessive liquid refrigerant in compressor
4. Compressor bearings are seized
421 01 6002 01 13
− continued on next page −
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
t
Status LED Status LED Description Status LED Troubleshooting Information
Yellow “ALERT”
Flash Code 5
Open Hi gh Voltage Circu i
1. Outdoor unit power disconnect is open
2. Compressor circuit breaker or fuse(s) is open
3. Compressor contactor has failed open
• Check compressor contactor wiring and connections
• Check for compr ess or cont act or failure (burned, pitt ed, open)
• Check wiri ng and connectors between supply and compressor
• Check for low pilot voltage at compressor contactor coil
4. Open circuit in compressor supply wiring or connections
5. Unusually long compressor protector reset time due to
extreme ambient temperature
6. Compressor windings are damaged
• Check compressor motor winding resistance
Yellow “ALERT”
Flash Code 6
Open Start Circuit
Current only in run circuit
1. Run capacitor has failed
2. Open circuit in compressor start wiring or connections
• Check wiring and connectors between supply and the
compressor “S” terminal
3. Compressor start winding is damaged
• Check compressor motor winding resistance
Yellow “ALERT”
Flash Code 7
Open Run Circuit
Current only in start circuit
1. Open circuit in compressor run wiring or connections
• Check wiring and connectors between supply and the
compressor “R” terminal
2. Compressor run winding is damaged
• Check compressor motor winding resistance
Yellow “ALERT”
Flash Code 8
Yellow “ALERT”
Flash Code 9
Welded Contactor
Compressor always runs
continuous operation
Low Voltage
Control circuit < 17 VAC
1. Compressor contactor has failed closed
2. Thermostat demand signal not connected to module
1. Control circuit transformer is overloaded
2. Low line voltage (contact utility if voltage at disconnect is low)
• Check wiring connections
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 (R terminal).
Last stored ALERT Flash code is displayed for one minute after module is powered on. The code must flash a
total of one minute before it will clear.
14 421 01 6002 01
INSTALLATION INSTRUCTIONS R−410A, Two−Stage Split System Air Conditioner
R−410A QUICK REFERENCE GUIDE
• R−410A refrigerant operates at 50% − 70% higher pressures than R−22. Be sure that servicing equipment and
replacement components are designed to operate with R−410A.
• R−410A refrigerant cylinders are rose colored.
• Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.
• R−410A systems should be charged with liquid refrigerant. Use a commercial type metering device in the
manifold hose.
• Manifold sets should be 750 psig high−side and 200 psig low−side with 520 psig low−side retard.
• Use hoses with 750 psig service pressure rating.
• Leak detectors should be designed to detect HFC refrigerant.
• R−410A, as with other HFC refrigerants, is only compatible with POE oils.
• Vacuum pumps will not remove moisture from oil.
• Do not use liquid line filter−driers with rated working pressures less than 600 psig.
• Do not install a suction line filter−drier in liquid line.
• POE oils absorb moisture rapidly. Do not expose oil to atmosphere.
• POE oils may cause damage to certain plastics and roofing materials.
• Wrap all filter−driers and service valves with wet cloth when brazing.
• A liquid line filter−drier is required on every unit.
• Do not use with an R−22 TXV.
• If indoor unit is equipped with an R−22 TXV, it must be changed to an R−410A TXV.
• Never open system to atmosphere while it is under a vacuum.
• When system must be opened for service, break vacuum with dry nitrogen and replace all filter−driers.
• Do not vent R−410A into the atmosphere.
• Do not use capillary tube indoor coils.
• Observe all WARNINGS, CAUTIONS, NOTES, and bold text.
421 01 6002 01 15
International Comfort Products, LLC
Lewisburg, TN 37091 USA
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