i;;iii_iiiii;_ii;_ii;;iii!_
These instructions
must be read and understood completely before attempting installation.
Safety Labeling and Signal Words
DANGER,
NOTE
WARNING,
CAUTION,
and
Signal Words in Manuals
The signal word WARNING is used throughout this
manual in the following manner:
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.
The signal word CAUTION is used throughout this
manual in the following manner:
DANGER - Immediate hazards which will result in
severe personal injury or death.
Signal Words on Product Labeling
WARNING - Hazards or unsafe practices which
could result in severe personal injury or death.
Signal words are used in combination with colors
and/or pictures on product labels.
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.
TABLE OF CONTENTS
Inspect New Unit ...............................
2
Safety Considerations
2
...........................
Location .......................................
Clearances
.................................
Unit Support ...................................
Refrigeration System
........................
2
2 - 3
4
4 - 8
Electrical Wiring ................................
8
Airflow Selection
9
...............................
Start-up Procedure .............................
Refrigerant Charge
.........................
9
9 - 10
Sequence of Operation .........................
10
Compressor Operation
11
Troubleshooting
Maintenance
Diagnostics
.........................
...........................
11 - 12
..................................
12
...............................
R-410A Quick Reference Guide .................
13- 14
PERSONAL INJURY, AND/OR
AGE HAZARD
PROPERTY
DAM-
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.
15
421 01 6002 01 Oct 2009
INSPECT NEW UNIT
After uncrating unit, inspect thoroughly for hidden
damage. If damage is found, notify the transportation
company
claim.
immediately
and file a concealed
damage
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 follow this warning 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 property 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.
LOCATION
Check local codes for regulations
noise, platforms, and other issues.
concerning zoning,
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).
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.
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.
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
Figure1
L
Clearances(variousexamples)
i
6"
(152mm)
24"
(610mm)
Service
(610mm)
24"
Service
(457mm)
1
18"
18"
(457mm)
18"
(457mm)
18"
(457mm)
,,
,,
(152mm)
(152mm)
18"
24"
(152mm)
(610mm)
I
Service
_.
24"
(610mm)
Service
18"
(457mm)
,,
4"
,,
(102mml
(102mm)
,,
ide fence
(152mm)
Post
24"
24"
(610mm)
(610mm)
Service
(610mm)
Service
24"
f
f
18"
18"
(457mm)
(457mm)
421 01 6002 01
18"
I
Servicel
_ (457mm)
18"
(457mm)
3
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.
Contact local distributor for hurricane hold-down details
and the P.E. (Professional Engineer) certification, when
required.
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.
Inadequate unit support may cause excessive
vibration, noise, and/or stress on the refrigerant
lines, leading to refrigerant line failure.
I
Figure 2
[
Tie Down Knockouts
%" (10mm) dia. Tie Down Knockouts
In Base Pan (2 places)
I View From Top
I
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 fiat roof, locate unit minimum 6 inches
above roof level.
Base
Pan
Depth
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.
cO
Base Pan Width
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).
REFRIGERATION
A. COMPONENT
Base Pan
Width x Depth
35 x 35
(889 x 889)
Inches (mm)
Tie Down
Knockouts
Minimum
MountingPad
Dimensions
35 x 35
(889 x 889)
SYSTEM
MATCHES
Check to see that the proper system components are in
place, especially the indoor coil.
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.
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
Figure3
L
Typical TXV Installation
PERSONAL INJURY HAZARD
Failure to follow this warning could result in personal injury and/or death.
EQUALIZER
TUBE
SENSING
BULB
Relieve pressure and recover all refrigerant before
servicing existing equipment, and before final unit
disposal. Use all service ports and open all flowcontrol devices, including solenoid valves.
SUCTION
TUBE
C. ROUTING
LINES
TXV
STRAP
B. REFRIGERANT
4 O'CLOCK
LINE SETS
The refrigerant line set must be properly sized to assure
maximum efficiency and proper oil circulation.
Refer to Product
Specifications
and Long
Applications
Guideline for line set sizing.
REFRIGERANT
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.
SENSING BULB
8 O'CLOCK
SUSPENDING
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.
LIQUID
TUBE
(EITHER _
AND
Line
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.
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 4
L
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper product operation.
Do not leave system open to atmosphere any longer 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.
Routing and Suspending
Refrigerant Lines
HANGER
STRAP
(AROUND
SUCTION
f
_,_
LIQUID TUBE
iX
TUBE
SUCTION TUBE
JOiST
--
_,
_--INSULATIONTuBE
SUCTION
h
INSULATION
1" (25mm) MIN -_=,,-I
I_
LIQUID TUBE
THROUGH
421 01 6002 01
THE
WALL
SUSPENSION
5
F. SERVICE VALVES
UNITOPERATION
HAZARD
Failure to follow this caution may result in improper product operation.
Do not bury more than 36" (lm) of line set underground. Refrigerant may migrate to cooler buried
section during extended periods of unit shutdown, 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
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
l
Service Valve
_/.--
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.
SERVICE VALVE
VALVE CORE X
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.
Figure 5
G. BRAZING CONNECTIONS
NOTE: 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.
Liquid Line Filter-Drier
Installed at Indoor Coil
FIRE HAZARD
Failure to follow this warning 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 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 SiI-Fos or Phos-copper
alloy.
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Braze with SiI-Fos or Phos-copper alloy on copper-to-copper joints and wrap a wet cloth around
rear of fitting to prevent damage to TXV.
6
421 01 6002 01
H. EVACUATING LINE SET AND INDOOR COIL
Triple Evacuation Method
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.
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:
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
.
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.
Failure to follow this caution may result in product
damage.
Never use the outdoor unit compressor as a vacuum 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
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
J
Triple Evacuation Sequence
IEVACUATE I
BREAK VACUUM WITH DRY NITROGEN
]
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.
IEVACUATE I
IBREAK VACUUM WITH DRY NITROGEN
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
Deep Vacuum Gauge Response
and System Conditions
5000
1EVACUATE 1
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
I CHARGE SYSTEM
1
4500
4000
3500
3000
2500
o
2000
1500
1000
TIGHT
DRY SYSTEM
500
I
0
I
1
I
2
I
3
I
4
I
5
I
6
I
7
MINUTES
421 01 6002 01
7
I. OPENINGSERVICE
VALVES
Outdoor units are shipped with a refrigerant charge
sealed in the unit. Opening the service valves releases
this charge into the system.
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.
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.
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.
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.
Tighten cap finger tight and then tighten additional Y6of a
turn (1 wrench flat) to properly seat the sealing surfaces.
ELECTRICAL
J. GAUGE PORTS
Check for leaks at the schrader ports and tighten valve
cores if necessary. Install plastic caps finger tight.
WIRING
Electrical Supply (Line Voltage)
Connections
Figure 9
ELECTRICAL
SHOCK HAZARD
Failure to follow this warning 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.
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
conductors only. Do not use aluminum wire.
DISCONNECT
PER NEC AND/OR
LOCAL CODES
1
WIRING
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.
o
•@
®
L2
•®
®
23
FIELD GROUND
WIRING
-®
J
Figure 10
GROUND
LUG
J Typical Thermostat
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.
11
L1
FIELD POWER
copper
Refer to unit rating plate for minimum circuit ampacity and
circuit protection requirements.
CONTACTOR
Connections
VARIABLE SPEED
FURNACE /
TWO-STAGE
FAN COIL
AIR CONDITIONER
THERMOSTAT
24 VAC HOT
D
24 VAC COM
D
HEAT STAGE 1
HEAT STAGE 2
D-
COOL STAGE 1
D
COOL STAGE 2
D-
INDOOR
D
FAN
LED INDICATOR
LIGHT
D"
NOTE: Use No. 18 AWG (American Wire Gage)
color-coded, insulated (35° C minimum) wire. If thermostat
is located more than 100 feet (30.5m) from unit as
measured along the control voltage wires, use No. 16 AWG
color-coded wires to avoid excessive voltage drop.
8
421 01 6002 01
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.
START-UP
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.
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 and
wait 24 hours before proceeding.
REFRIGERANT
4.
5.
Set indoor thermostat at desired temperature.
Be
sure setpoint is below indoor ambient temperature or
thermostat will not call for cooling.
Set indoor thermostat selector switch to COOL.
Operate unit for minimum 25 minutes, then check the
system refrigerant charge.
CHARGE
NOTE: Charge in High-Stage only.
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:
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).
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 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 (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.
421 01 6002 01
9
Figure11
Rating Plate (required) Subcooling Temperature
Measured Liquid
Pressure (psig)
OF
OF
6
F
8
10
12
°F (° C)
14
16
R-410A Required Liquid Line Temperature °F (°C)
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
100
98
96
94
92
90
364
104
102
100
98
96
94
374
106
104
102
100
98
96
384
108
106
104
102
100
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
450
120
118
116
114
112
110
462
122
120
118
116
114
112
474
124
116
114
SEQUENCE
!i!i!i!i!i!i!i!i!i!i!i!ii!i!_i!_ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!iiill
116 ii!i!i!i!i!i!i!i!i!i!i!_!i_!i!_!`;_i!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!_!_!
114
112
110
iiiiiiiiiiiiiiiiiiiiii_i_i_;_i!_i_i_i_i_i_i_i_i_i_i_i_ii_ii_ii_i_!_ii!
122 iiiiiiiiiiiiiiiiiiiiiiii'ii_iil;_ii_!i!ii!ii!ii!ii!ii!ii!ii!ii!ii!iiiii!ii!i
120
118
ii!i!i!i!i!i!i!i!i!i!i!_!i_!i!_ii_ii_ii_
iiiiiiiiiiiiiiiiiiiiiiiiiiiii_i!_ii!iiiiiiiiiiiiii
.....
OF OPERATION
With power supplied to indoor
transformer is energized.
and outdoor
units,
NOTE: For low-stage operation, the outdoor unit Comfort
Alert
UltraTech
is labeled Y and the indoor
unit/thermostat is labeled Y1.
TM
108
NOTE: If indoor unit is equipped with a time-delay relay
circuit, the blower runs an additional length of time to
increase system efficiency.
TM
On a call for low-stage cooling, the thermostat energizes Y1
(low-stage compressor) and G. The call for Y1 energizes
the contactor, starting the outdoor fan motor and low-stage
compressor. The compressor operates at part load. The
call for G energizes 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.
10
421 01 6002 01
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.
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
unloaded for five
of the thermostat
advantage under
will always start unloaded and stay
seconds even when the second stage
is calling for more capacity (a starting
low voltage conditions).
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.
TM
Figure 12 J Comfort Alert
TM
UltraTech
TM
Diagnostics
TM
LED
ThermostatDemand
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).
ThermostatDemand
1stStageCompressor
Port
The Comfort Alert UltraTech 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.
Signal
VACHOT
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.
421 01 6002 01
VACCommon
DCCompressor
Solenoid
LED
LED
_C0mp_
_
PassThrough
Holes( 3 )
11
Two-StageCompressorResistance(windingresistance)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 Alert
TM
If it is suspected that the unloader is not working, the
following methods may be used to verify operation.
,
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.
Module
The unloader is the compressor internal mechanism,
controlled by the DC solenoid, that modulates between
high and low-stage.
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.
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.
,
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.
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:
,
,
,
12
Free flow of air is essential. Keep fences, shrubs,
trash cans, and other obstructions at least 18
inches (457mm) from all coil inlets.
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.
421 01 6002 01
Figure13
StatusLED
Green"POWER"
Red "TRIP"
Comfort Alert
Status LED Description
TM
UltraTech
TM
Diagnostics
Status LED Troubleshooting
Information
Module has power
Supply voltage is present at module terminals
Thermostat demand signal
Y is present, but the
1. Compressor protector is open
• Check for high head pressure
• Check compressor supply voltage
compressor is not running
2. Outdoor unit power disconnect is open
3. Compressor circuit breaker or fuse(s) is open
, 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
TM
8. Thermostat is malfunctioning
• Check thermostat sub-base or wiring for short circuit
• Check thermostat installation (location, level)
Yellow "ALERT"
Flash Code 2
Internal Protector
Yellow "ALERT"
Flash Code 3
Short Cycling
1. Thermostat demand signal is intermittent
Compressor is running only
briefly (1-3 minutes)
2. High head pressure
• Check high pressure switch
• Check if system is overcharged with refrigerant
• Check for non-condensable in system
Trip
1. The internal motor protector has opened
. Wait for compressor to cool down, protector will close
automatically
3. Condenser coil poor air circulation (dirty, blocked, damaged)
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
- continued on next page -
421 01 6002 01
13
StatusLED
Yellow "ALERT"
Status LED Description
Open High Voltage Circuit
Flash Code 5
Status LED Troubleshooting
Information
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 compressor contactor failure (burned, pitted, open)
• Check wiring and connectors between supply and compressor
• Check for low pilot voltage at compressor contactor coil
,
, Open circuit in compressor
supply wiring or connections
5. Unusually long compressor protector reset time due to
extreme ambient temperature
Yellow "ALERT"
Flash Code 6
Open Start Circuit
Current only in run circuit
6. Compressor windings are damaged
• Check compressor motor winding resistance
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
,
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
,
Yellow "ALERT"
Flash Code 8
Welded
Yellow "ALERT"
Flash Code 9
Low Voltage
Control circuit < 17 VAC
•
•
•
•
Contactor
Compressor always runs
continuous operation
Compressor start winding is damaged
• Check compressor motor winding resistance
Compressor run winding is damaged
• Check compressor motor winding resistance
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
R-410A
QUICK REFERENCE
GUIDE
• R-410A refrigerant operates at 50% - 70% higher pressures than R-22.
replacement components are designed to operate with R-410A.
Be sure that servicing equipment and
• 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
• A liquid line filter-drier
and service valves with wet cloth when brazing.
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,
421 01 6002 01
CAUTIONS,
NOTES, and bold text.
International Comfort Products, LLC
Lewisburg, TN 37091 USA
15
i;;iii_iiiii;_ii;_ii;;iii!_
These instructions
must be read and understood completely before attempting installation.
Safety Labeling and Signal Words
DANGER,
NOTE
WARNING,
CAUTION,
and
Signal Words in Manuals
The signal word WARNING is used throughout this
manual in the following manner:
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.
The signal word CAUTION is used throughout this
manual in the following manner:
DANGER - Immediate hazards which will result in
severe personal injury or death.
Signal Words on Product Labeling
WARNING - Hazards or unsafe practices which
could result in severe personal injury or death.
Signal words are used in combination with colors
and/or pictures on product labels.
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.
TABLE OF CONTENTS
Inspect New Unit ...............................
2
Safety Considerations
2
...........................
Location .......................................
Clearances
.................................
Unit Support ...................................
Refrigeration System
........................
2
2 - 3
4
4 - 8
Electrical Wiring ................................
8
Airflow Selection
9
...............................
Start-up Procedure .............................
Refrigerant Charge
.........................
9
9 - 10
Sequence of Operation .........................
10
Compressor Operation
11
Troubleshooting
Maintenance
Diagnostics
.........................
...........................
11 - 12
..................................
12
...............................
R-410A Quick Reference Guide .................
13- 14
PERSONAL INJURY, AND/OR
AGE HAZARD
PROPERTY
DAM-
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.
15
421 01 6002 01 Oct 2009
INSPECT NEW UNIT
After uncrating unit, inspect thoroughly for hidden
damage. If damage is found, notify the transportation
company
claim.
immediately
and file a concealed
damage
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 follow this warning 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 property 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.
LOCATION
Check local codes for regulations
noise, platforms, and other issues.
concerning zoning,
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).
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.
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.
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
Figure1
L
Clearances(variousexamples)
i
6"
(152mm)
24"
(610mm)
Service
(610mm)
24"
Service
(457mm)
1
18"
18"
(457mm)
18"
(457mm)
18"
(457mm)
,,
,,
(152mm)
(152mm)
18"
24"
(152mm)
(610mm)
I
Service
_.
24"
(610mm)
Service
18"
(457mm)
,,
4"
,,
(102mml
(102mm)
,,
ide fence
(152mm)
Post
24"
24"
(610mm)
(610mm)
Service
(610mm)
Service
24"
f
f
18"
18"
(457mm)
(457mm)
421 01 6002 01
18"
I
Servicel
_ (457mm)
18"
(457mm)
3
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.
Contact local distributor for hurricane hold-down details
and the P.E. (Professional Engineer) certification, when
required.
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.
Inadequate unit support may cause excessive
vibration, noise, and/or stress on the refrigerant
lines, leading to refrigerant line failure.
I
Figure 2
[
Tie Down Knockouts
%" (10mm) dia. Tie Down Knockouts
In Base Pan (2 places)
I View From Top
I
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 fiat roof, locate unit minimum 6 inches
above roof level.
Base
Pan
Depth
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.
cO
Base Pan Width
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).
REFRIGERATION
A. COMPONENT
Base Pan
Width x Depth
35 x 35
(889 x 889)
Inches (mm)
Tie Down
Knockouts
Minimum
MountingPad
Dimensions
35 x 35
(889 x 889)
SYSTEM
MATCHES
Check to see that the proper system components are in
place, especially the indoor coil.
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.
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
Figure3
L
Typical TXV Installation
PERSONAL INJURY HAZARD
Failure to follow this warning could result in personal injury and/or death.
EQUALIZER
TUBE
SENSING
BULB
Relieve pressure and recover all refrigerant before
servicing existing equipment, and before final unit
disposal. Use all service ports and open all flowcontrol devices, including solenoid valves.
SUCTION
TUBE
C. ROUTING
LINES
TXV
STRAP
B. REFRIGERANT
4 O'CLOCK
LINE SETS
The refrigerant line set must be properly sized to assure
maximum efficiency and proper oil circulation.
Refer to Product
Specifications
and Long
Applications
Guideline for line set sizing.
REFRIGERANT
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.
SENSING BULB
8 O'CLOCK
SUSPENDING
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.
LIQUID
TUBE
(EITHER _
AND
Line
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.
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 4
L
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper product operation.
Do not leave system open to atmosphere any longer 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.
Routing and Suspending
Refrigerant Lines
HANGER
STRAP
(AROUND
SUCTION
f
_,_
LIQUID TUBE
iX
TUBE
SUCTION TUBE
JOiST
--
_,
_--INSULATIONTuBE
SUCTION
h
INSULATION
1" (25mm) MIN -_=,,-I
I_
LIQUID TUBE
THROUGH
421 01 6002 01
THE
WALL
SUSPENSION
5
F. SERVICE VALVES
UNITOPERATION
HAZARD
Failure to follow this caution may result in improper product operation.
Do not bury more than 36" (lm) of line set underground. Refrigerant may migrate to cooler buried
section during extended periods of unit shutdown, 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
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
l
Service Valve
_/.--
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.
SERVICE VALVE
VALVE CORE X
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.
Figure 5
G. BRAZING CONNECTIONS
NOTE: 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.
Liquid Line Filter-Drier
Installed at Indoor Coil
FIRE HAZARD
Failure to follow this warning 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 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 SiI-Fos or Phos-copper
alloy.
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Braze with SiI-Fos or Phos-copper alloy on copper-to-copper joints and wrap a wet cloth around
rear of fitting to prevent damage to TXV.
6
421 01 6002 01
H. EVACUATING LINE SET AND INDOOR COIL
Triple Evacuation Method
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.
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:
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
.
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.
Failure to follow this caution may result in product
damage.
Never use the outdoor unit compressor as a vacuum 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
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
J
Triple Evacuation Sequence
IEVACUATE I
BREAK VACUUM WITH DRY NITROGEN
]
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.
IEVACUATE I
IBREAK VACUUM WITH DRY NITROGEN
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
Deep Vacuum Gauge Response
and System Conditions
5000
1EVACUATE 1
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
I CHARGE SYSTEM
1
4500
4000
3500
3000
2500
o
2000
1500
1000
TIGHT
DRY SYSTEM
500
I
0
I
1
I
2
I
3
I
4
I
5
I
6
I
7
MINUTES
421 01 6002 01
7
I. OPENINGSERVICE
VALVES
Outdoor units are shipped with a refrigerant charge
sealed in the unit. Opening the service valves releases
this charge into the system.
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.
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.
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.
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.
Tighten cap finger tight and then tighten additional Y6of a
turn (1 wrench flat) to properly seat the sealing surfaces.
ELECTRICAL
J. GAUGE PORTS
Check for leaks at the schrader ports and tighten valve
cores if necessary. Install plastic caps finger tight.
WIRING
Electrical Supply (Line Voltage)
Connections
Figure 9
ELECTRICAL
SHOCK HAZARD
Failure to follow this warning 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.
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
conductors only. Do not use aluminum wire.
DISCONNECT
PER NEC AND/OR
LOCAL CODES
1
WIRING
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.
o
•@
®
L2
•®
®
23
FIELD GROUND
WIRING
-®
J
Figure 10
GROUND
LUG
J Typical Thermostat
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.
11
L1
FIELD POWER
copper
Refer to unit rating plate for minimum circuit ampacity and
circuit protection requirements.
CONTACTOR
Connections
VARIABLE SPEED
FURNACE /
TWO-STAGE
FAN COIL
AIR CONDITIONER
THERMOSTAT
24 VAC HOT
D
24 VAC COM
D
HEAT STAGE 1
HEAT STAGE 2
D-
COOL STAGE 1
D
COOL STAGE 2
D-
INDOOR
D
FAN
LED INDICATOR
LIGHT
D"
NOTE: Use No. 18 AWG (American Wire Gage)
color-coded, insulated (35° C minimum) wire. If thermostat
is located more than 100 feet (30.5m) from unit as
measured along the control voltage wires, use No. 16 AWG
color-coded wires to avoid excessive voltage drop.
8
421 01 6002 01
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.
START-UP
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.
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 and
wait 24 hours before proceeding.
REFRIGERANT
4.
5.
Set indoor thermostat at desired temperature.
Be
sure setpoint is below indoor ambient temperature or
thermostat will not call for cooling.
Set indoor thermostat selector switch to COOL.
Operate unit for minimum 25 minutes, then check the
system refrigerant charge.
CHARGE
NOTE: Charge in High-Stage only.
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:
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).
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 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 (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.
421 01 6002 01
9
Figure11
Rating Plate (required) Subcooling Temperature
Measured Liquid
Pressure (psig)
OF
OF
6
F
8
10
12
°F (° C)
14
16
R-410A Required Liquid Line Temperature °F (°C)
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
100
98
96
94
92
90
364
104
102
100
98
96
94
374
106
104
102
100
98
96
384
108
106
104
102
100
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
450
120
118
116
114
112
110
462
122
120
118
116
114
112
474
124
116
114
SEQUENCE
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116 ii!i!i!i!i!i!i!i!i!i!i!_!i_!i!_!`;_i!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!ii!_!_!
114
112
110
iiiiiiiiiiiiiiiiiiiiii_i_i_;_i!_i_i_i_i_i_i_i_i_i_i_i_ii_ii_ii_i_!_ii!
122 iiiiiiiiiiiiiiiiiiiiiiii'ii_iil;_ii_!i!ii!ii!ii!ii!ii!ii!ii!ii!ii!iiiii!ii!i
120
118
ii!i!i!i!i!i!i!i!i!i!i!_!i_!i!_ii_ii_ii_
iiiiiiiiiiiiiiiiiiiiiiiiiiiii_i!_ii!iiiiiiiiiiiiii
.....
OF OPERATION
With power supplied to indoor
transformer is energized.
and outdoor
units,
NOTE: For low-stage operation, the outdoor unit Comfort
Alert
UltraTech
is labeled Y and the indoor
unit/thermostat is labeled Y1.
TM
108
NOTE: If indoor unit is equipped with a time-delay relay
circuit, the blower runs an additional length of time to
increase system efficiency.
TM
On a call for low-stage cooling, the thermostat energizes Y1
(low-stage compressor) and G. The call for Y1 energizes
the contactor, starting the outdoor fan motor and low-stage
compressor. The compressor operates at part load. The
call for G energizes 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.
10
421 01 6002 01
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.
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
unloaded for five
of the thermostat
advantage under
will always start unloaded and stay
seconds even when the second stage
is calling for more capacity (a starting
low voltage conditions).
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.
TM
Figure 12 J Comfort Alert
TM
UltraTech
TM
Diagnostics
TM
LED
ThermostatDemand
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).
ThermostatDemand
1stStageCompressor
Port
The Comfort Alert UltraTech 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.
Signal
VACHOT
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.
421 01 6002 01
VACCommon
DCCompressor
Solenoid
LED
LED
_C0mp_
_
PassThrough
Holes( 3 )
11
Two-StageCompressorResistance(windingresistance)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 Alert
TM
If it is suspected that the unloader is not working, the
following methods may be used to verify operation.
,
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.
Module
The unloader is the compressor internal mechanism,
controlled by the DC solenoid, that modulates between
high and low-stage.
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.
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.
,
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.
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:
,
,
,
12
Free flow of air is essential. Keep fences, shrubs,
trash cans, and other obstructions at least 18
inches (457mm) from all coil inlets.
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.
421 01 6002 01
Figure13
StatusLED
Green"POWER"
Red "TRIP"
Comfort Alert
Status LED Description
TM
UltraTech
TM
Diagnostics
Status LED Troubleshooting
Information
Module has power
Supply voltage is present at module terminals
Thermostat demand signal
Y is present, but the
1. Compressor protector is open
• Check for high head pressure
• Check compressor supply voltage
compressor is not running
2. Outdoor unit power disconnect is open
3. Compressor circuit breaker or fuse(s) is open
, 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
TM
8. Thermostat is malfunctioning
• Check thermostat sub-base or wiring for short circuit
• Check thermostat installation (location, level)
Yellow "ALERT"
Flash Code 2
Internal Protector
Yellow "ALERT"
Flash Code 3
Short Cycling
1. Thermostat demand signal is intermittent
Compressor is running only
briefly (1-3 minutes)
2. High head pressure
• Check high pressure switch
• Check if system is overcharged with refrigerant
• Check for non-condensable in system
Trip
1. The internal motor protector has opened
. Wait for compressor to cool down, protector will close
automatically
3. Condenser coil poor air circulation (dirty, blocked, damaged)
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
- continued on next page -
421 01 6002 01
13
StatusLED
Yellow "ALERT"
Status LED Description
Open High Voltage Circuit
Flash Code 5
Status LED Troubleshooting
Information
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 compressor contactor failure (burned, pitted, open)
• Check wiring and connectors between supply and compressor
• Check for low pilot voltage at compressor contactor coil
,
, Open circuit in compressor
supply wiring or connections
5. Unusually long compressor protector reset time due to
extreme ambient temperature
Yellow "ALERT"
Flash Code 6
Open Start Circuit
Current only in run circuit
6. Compressor windings are damaged
• Check compressor motor winding resistance
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
,
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
,
Yellow "ALERT"
Flash Code 8
Welded
Yellow "ALERT"
Flash Code 9
Low Voltage
Control circuit < 17 VAC
•
•
•
•
Contactor
Compressor always runs
continuous operation
Compressor start winding is damaged
• Check compressor motor winding resistance
Compressor run winding is damaged
• Check compressor motor winding resistance
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
R-410A
QUICK REFERENCE
GUIDE
• R-410A refrigerant operates at 50% - 70% higher pressures than R-22.
replacement components are designed to operate with R-410A.
Be sure that servicing equipment and
• 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
• A liquid line filter-drier
and service valves with wet cloth when brazing.
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,
421 01 6002 01
CAUTIONS,
NOTES, and bold text.
International Comfort Products, LLC
Lewisburg, TN 37091 USA
15
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