Installation guide

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421 01 5103 05 9/22/17

INSTALLATION INSTRUCTIONS

R- 410A Split System Air Conditioner

C4A3, H4A3, T4A3,

CXA6, HXA6, TXA6

These instructions must be read and understood completely before attempting installation.

IMPORTANT: Effective January 1, 2015, all split system and packaged air conditioners must be installed pursuant to

applicable regional efficiency standards issued by the Department of Energy.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service,

maintenance, or use can cause explosion, fire, electrical

shock, or other conditions which may cause death,

personal injury, or property damage. Consult a qualified

installer, service agency, or your distributor or branch for

information or assistance. The qualified installer or

agency must use factory- authorized kits or accessories

when modifying this product. Refer to the individual

instructions packaged with the kits or accessories when

installing.

Follow all safety codes. Wear safety glasses, protective

clothing, and work gloves. Use quenching cloth for

brazing operations. Have fire extinguisher available.

Read these instructions thoroughly and follow all

warnings or cautions included in literature and attached

to the unit. Consult local building codes and current

editions of the National Electrical Code (NEC) NFPA 70.

In Canada, refer to current editions of the Canadian

electrical code CSA 22.1.

Recognize safety information. This is the safety- alert

symbol

When you see this symbol on the unit and in

instructions or manuals, be alert to the potential for

personal injury. Understand these signal words;

DANGER, W ARNING, and CAUTION. These words are

used with the safety- alert symbol. DANGER identifies

the most serious hazards which will result in severe

personal injury or death. WARNING signifies hazards

which could result in personal injury or death. CAUTION

is used to identify unsafe practices which would result in

minor personal injury or product and property damage.

NOTE is used to highlight suggestions which will result

in enhanced installation, reliability, or operation.

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury or death.

Before installing, modifying, or servicing system, main

electrical disconnect switch must be in the OFF

position. There may be more than 1 disconnect

switch. Lock out and tag switch with a suitable

warning label.

EXPLOSION HAZARD

Failure to follow this warning could

result in death, serious personal

injury, and/or property damage.

Never use air or gases containing

oxygen for leak testing or

operating refrigerant compressors.

Pressurized mixtures of air or

gases containing oxygen can lead

to an explosion.

WARNING

INSPECT NEW UNIT

After uncrating the unit, inspect it thoroughly for any

obvious or hidden damage. If damage is found, notify the

transportation company immediately and file a

concealed damage claim.

CAUTION

PROPERTY DAMAGE HAZARD

Failure to follow this caution may result in proper-

ty damage

R- 410A systems operate at higher pressures than

R- 22 systems. When working with R- 410A sys-

tems, use only service equipment and replace-

ment components specifically rated or approved

for R- 410A service.

CUT HAZARD

Failure to follow this caution may result in personal

injury.

Sheet metal parts may have sharp edges or burrs. Use

care and wear appropriate protective clothing and

gloves when handling parts.

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.

Summary of content (21 pages)

PAGE 1
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner C4A3, H4A3, T4A3, CXA6, HXA6, TXA6 These instructions must be read and understood completely before attempting installation. IMPORTANT: Effective January 1, 2015, all split system and packaged air conditioners must be installed pursuant to applicable regional efficiency standards issued by the Department of Energy.
PAGE 2
INSTALLATION INSTRUCTIONS 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).
PAGE 3
INSTALLATION INSTRUCTIONS Figure 1 R- 410A Split System Air Conditioner Figure 2 Tie Down Knockouts Typical TXV Installation View From Top a” (10mm) dia.
PAGE 4
INSTALLATION INSTRUCTIONS Figure 3 BRASS HEX NUT R- 410A Split System Air Conditioner Indoor (cooling) Piston DISTRIBUTOR Be extra careful when bending refrigeration tubing. Tubing can “kink” easily, and if this occurs, the entire length of tubing must be replaced. TEFLON SEAL ! TEFLON RING WARNING PERSONAL INJURY HAZARD Failure to relieve system pressure could result in personal injury and/or death. PISTON FLOW IN COOLING PISTON RETAINER BRASS HEX BODY STRAINER L10S017 B.
PAGE 5
INSTALLATION INSTRUCTIONS Figure 4 R- 410A Split System Air Conditioner Routing and Suspending Refrigerant Lines OUTDOOR WALL JOIST INDOOR WALL CAULK LIQUID TUBE INSULATION HANGER STRAP (AROUND SUCTION TUBE ONLY) SUCTION TUBE SUCTION TUBE 1” (25mm) MIN THROUGH THE WALL ! INSULATION LIQUID TUBE SUSPENSION CAUTION Figure 5 Liquid Line Filter- Drier Installed at Indoor Coil UNIT OPERATION HAZARD Failure to follow this caution may result in improper product operation.
PAGE 6
INSTALLATION INSTRUCTIONS Figure 6 R- 410A Split System Air Conditioner Service Valve CAUTION ! PRODUCT DAMAGE HAZARD SERVICE VALVE VALVE CORE 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. ! WARNING FIRE HAZARD Failure to remove refrigerant and oil charge before brazing could result in personal injury, death, and/or property damage.
PAGE 7
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner 4. Close nitrogen valve and allow system to stand for 1 hour. During this time, dry nitrogen will diffuse throughout the system absorbing moisture. J. GAUGE PORTS Check for leaks at the schrader ports and tighten valve cores if necessary. Install plastic caps finger tight. 5. Repeat this procedure as indicated in Figure 8. ELECTRICAL WIRING (*XA6 all sizes; *4A3 sizes 18, 36- 60 only) 6.
PAGE 8
INSTALLATION INSTRUCTIONS Figure 9 R- 410A Split System Air Conditioner Electrical Supply (Line Voltage) Connections DISCONNECT PER NEC AND/OR LOCAL CODES CONTACTOR 11 L1 FIELD POWER WIRING L2 23 or 13 FIELD GROUND WIRING Figure 10 GROUND LUG Typical Thermostat Connections THERMOSTAT FURNACE 24 VAC HOT R R 24 VAC COM C C HEAT STAGE 1 W/W1 W COOL STAGE 1 Y/Y2 Y G G INDOOR FAN THERMOSTAT FAN COIL 24 VAC HOT R R 24 VAC COM C C HEAT STAGE 1 W/W1 W2 COOL STAGE 1 Y/Y2 Y G G
PAGE 9
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner START- UP PROCEDURE 1. Set indoor thermostat selector switch to OFF. 2. Turn ON all electrical disconnect devices. 3. If unit has a crankcase heater, energize the heater and wait 24 hours before proceeding. 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.
PAGE 10
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner 12. Optimum performance will be achieved when the operating charge produces 10_F suction superheat at suction service valve with 95_F (35_C) outdoor ambient and 80_F (27_C) dry bulb (67_F / 19_C) wet bulb) indoor temperature (DOE “A” test conditions) at rated airflow.
PAGE 11
INSTALLATION INSTRUCTIONS (° C) 3 Rating Plate (required) Subcooling Temperature ° F (° C) °F (° C) °F (° C) °F (° C) F (° C) 8 4 10 6 12 7 14 8 F 16 (° C) 9 26 27 28 29 30 31 32 33 34 36 37 38 40 41 42 43 44 46 47 48 49 50 51 R- 410A Required Liquid Line Temperature ° F (° C) 76 24 74 23 72 22 70 21 78 26 76 24 74 23 72 22 80 27 78 26 76 24 74 23 82 28 80 27 78 26 76 24 84 29 82 28 80 27 78 26 86 30 84 29 82 28 80 27 88 31 86 30 84 29 82 28 90 32 88 31 86 30 84 29 92 33 90 32 88 31 86 30 94 34 92 33
PAGE 12
INSTALLATION INSTRUCTIONS SEQUENCE OF OPERATION With power supplied to indoor and outdoor units, transformer is energized. On a call for cooling, the thermostat makes circuits R- Y and R- G. Circuit R- Y energizes contactor, starting outdoor fan motor and compressor. Circuit R- G energizes indoor unit blower relay, starting indoor blower motor. When thermostat is satisfied, its contacts open, de- energizing contactor and blower relay. Compressor and motors stop.
PAGE 13
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Figure 15 Comfort Alertt Diagnostics (*XA6 all sizes - *4A3 sizes 18, 36- 60 only) 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 signal 1. Compressor protector is open Y1 is present, but the 2. Outdoor unit power disconnect is open compressor is not running 3. Compressor circuit breaker or fuse(s) is open 4.
PAGE 14
INSTALLATION INSTRUCTIONS ELECTRICAL WIRING (for *4A3, sizes 24 and 30 only) R- 410A Split System Air Conditioner Figure 17 Outdoor Coil Thermistor (OCT) Attachment OCT Thermistor must be secured tight on the liquid tube. IMPORTANT: Check factory wiring and field wire connections to ensure terminations are secured properly. Check wire routing to ensure wires are not in contact with tubing, sheet metal, etc.
PAGE 15
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Replace stem caps after system is opened to refrigerant flow. Replace caps finger- tight and tighten with wrench an additional 1/12 turn 3. Close electrical disconnects to energize system. 4. Set room thermostat at desired temperature. Be sure set point is below indoor ambient temperature. 5. Set room thermostat to COOL and fan control to ON or AUTO mode, as desired. Operate unit for 15 minutes. Check system refrigerant charge.
PAGE 16
INSTALLATION INSTRUCTIONS Communication and Status Function Lights Green Communications (COMM) Light (Communicating Control only): A green LED (COMM light) on the outdoor board indicates successful communication with the other system products. The green LED will remain OFF until communications is established. Once a valid command is received, the green LED will turn ON continuously. If no communication is received within 2 minutes, the LED will be turned OFF until the next valid communication.
PAGE 17
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner STATUS CODES Table 3 shows the status codes flashed by the amber status light. Most system problems can be diagnosed by reading the status code as flashed by the amber status light on the control board. The codes are flashed by a series of short and long flashes of the status light. The short flashes indicate the first digit in the status code, followed by long flashes indicating the second digit of the error code. The short flash is 0.
PAGE 18
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Figure 18 Resistance vs Temperature Chart THERMISTOR CURVE 90 RESISTANCE (KOHMS) 80 70 60 50 40 30 20 10 0 0 (-17.77) 20 (-6.67) 40 (4.44) 60 (15.56) 80 (26.67) 100 (37.78) 120 (48.
PAGE 19
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Observer Communicating Wall Control Four- Wire Connection Wiring Diagrams (See Thermostat Installation Instructions for specific unit combinations) Figure 20 Variable Speed Furnace/Fan Coil Wall Control Green DX+ Yellow DX- Optional Remote Room Sensor Yellow Red R Humidifier Connection Green White C Red R S2 DX- White C S1 DX+ Outdoor DX+ DX- C R HUM LEGEND COM 24V FACTORY WIRING 24V FIELD WIRING FIELD SPLICE CONNECTI
PAGE 20
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Non- Communicating Standard Thermostat 2- Wire 24V Circuit Connections Figure 22 A/C THERMOSTAT TPPICAL FURNACE OR FAN COIL AIR CONDITIONER 24VAC HOT R R R 24VAC COM C C C HEAT STAGE 1 W/W1 W HEAT STAGE 2 Y/Y2 Y INDOOR FAN G G Y FIELD INSTALLED JUMPER WIRE LEGEND 24V FACTORY WIRING 24V FIELD WIRING FIELD SPLICE CONNECTION NOTE: Wiring must conform to NEC or local codes.
PAGE 21
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner R- 410A QUICK REFERENCE GUIDE  Observe all WARNINGS, CAUTIONS, NOTES, and bold text.  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.