Installation guide

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421 01 1702 05 10/18/16

INSTALLATION INSTRUCTIONS

R- 410A Two- Stage Split System Air Conditioner

CCA7, HCA7, TCA7

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, WARNING, and CAUTION. These

words are used with the safety- alert symbol. DANGER identifies

the most serious hazards which will result in severe personal

injury or death. WARNING signifies hazards which could result in

personal injury or death. CAUTION is used to identify unsafe

practices which would result in minor personal injury or product

and property damage. NOTE is used to highlight suggestions

which will result in enhanced installation, reliability, or operation.

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal

injury and/or death.

Before installing, modifying, or servicing system,

main electrical disconnect switch must be in the OFF

position. There may be more than 1 disconnect

switch. Lock out and tag switch with a suitable warn -

ing label.

CAUTION

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.

INSTALLATION RECOMMENDATIONS

NOTE: In some cases noise in the living area has been traced to

gas pulsations from improper installation of equipment.

1. Locate unit away from windows, patios, decks, etc. where

unit operation sound may disturb customer.

2. Ensure that vapor and liquid tube diameters are

appropriate for unit capacity.

3. Run refrigerant tubes as directly as possible by avoiding

unnecessary turns and bends.

4. Leave some slack between structure and unit to absorb

vibration.

5. When passing refrigerant tubes through the wall, seal

opening with RTV or other pliable silicon- based caulk.

(See Fig. 1.)

6. Avoid direct tubing contact with water pipes, duct work,

floor joists, wall studs, floors, and walls.

7. Do not suspend refrigerant tubing from joists and studs with

a rigid wire or strap which comes in direct contact with

tubing.(See Fig. 1.)

8. Ensure that tubing insulation is pliable and completely

surrounds vapor tube.

9. When necessary, use hanger straps which are 1 in. (25.4

mm) wide and conform to shape of tubing insulation. (See

Fig. 1.)

10. Isolate hanger straps from insulation by using metal

sleeves bent to conform to shape of insulation.

Summary of content (14 pages)

PAGE 1
INSTALLATION INSTRUCTIONS R- 410A Two- Stage Split System Air Conditioner CCA7, HCA7, TCA7 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 Figure 1 R- 410A Split System Air Conditioner Connecting Tube Installation On rooftop applications, mount on level platform or frame. Place unit above a load- bearing wall and isolate unit and tubing set from structure. Arrange supporting members to adequately support unit and minimize transmission of vibration to building. Consult local codes governing rooftop applications.
PAGE 3
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner CAUTION ! UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation. Do not leave system open to atmosphere any longer than minimum required for installation. POE oil in compressor is extremely susceptible to moisture absorption. Always keep ends of tubing sealed during installation. If ANY refrigerant tubing is buried, provide a 6 in. (152.4 mm) vertical rise at service valve.
PAGE 4
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Sweat Connection CAUTION ! UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation. Service valves must be wrapped in a heat- sinking material such as a wet cloth. Service valves are closed from factory and ready for brazing. After wrapping service valve with a wet cloth, braze sweat connections using industry accepted methods and materials. Consult local code requirements.
PAGE 5
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Route Ground and Power Wires Remove access panel to gain access to unit wiring. Extend wires from disconnect through power wiring hole provided and into unit control box. ! 65F (18C). To furnish power to heater only, set thermostat to OFF and close electrical disconnect to outdoor unit. A crankcase heater is required if refrigerant tubing is longer than 80 ft. (24.38 m). Refer to the Long Line Applications Guidelines.
PAGE 6
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Airflow Setup with Non-Communicating Furnace or Fan Coil 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.
PAGE 7
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Communication and Status Function Lights Green communications (COMM) Light (Only with Observer Communicating Wall Control) 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.
PAGE 8
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner NOTE: The model plug takes priority over factory model information input at the factory. If the model plug is removed after initial power up, the unit will operate according to the last valid model plug installed, and flash the appropriate fault code temporarily. Pressure Switch Protection The outdoor unit is equipped with high and low pressure switches.
PAGE 9
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Unloader Test Procedure Compressor Internal Relief The unloader is the compressor internal mechanism, controlled by the DC solenoid, that modulates between high and low stage. If it is suspected that the unloader is not working, the following methods may be used to verify operation. 1. Operate the system and measure compressor amperage.
PAGE 10
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Table 6 - Status Codes OPERATION FAULT AMBER LED FLASH CODE Standby – no call for unit operation None On solid, no flash Normal operation Low Stage Cool/Heat Operation None 1, pause Normal operation High Stage Cool/Heat Operation None 2, Pause Normal operation Brown out protection is Disabled None 5, pause User mode selection, see instructions for more detail Brown out protection is Active None 6, Pause User mode selectio
PAGE 11
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Figure 9 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 (48.89) TEMPERATURE °F (°C) Figure 10 421 01 1702 05 Two- Stage Control Board Specifications subject to change without notice.
PAGE 12
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 11 Variable Speed Furnace/Fan Coil Wall Control Green DX+ DX+ Yellow DX- DX- White C S1 Optional Remote Room Sensor S2 Green DX+ Yellow DX- C Red R Outdoor C R Humidifier Connection HUM LEGEND COM 24V FACTORY WIRING 24V FIELD WIRING FIELD SPLICE CONNECTION FVM Fan
PAGE 13
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner Non- Communicating Indoor Unit with Observer Communicating Wall Control Figure 14 Wall Control DX+ NAXA00101DB Green DX+ R Red R C White C DX- Yellow DX- C C R R W2 W2 Y1 Y1 G G Y/Y2 Y2 Non-Communicating Indoor Note: This installation requires the daughter board accessory, NAXA00101DB. Note: This installation does not allow for communicating feature functionality.
PAGE 14
INSTALLATION INSTRUCTIONS R- 410A Split System Air Conditioner R- 410A QUICK REFERENCE GUIDE  R- 410A refrigerant operates at 50% - 70% higher pressures than R- 22. Be sure that servicing equipment and replacement components are designed to operate with R- 410A.  R- 410A refrigerant cylinders are rose colored.  Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.  R- 410A systems should be charged with liquid refrigerant.