INSTALLATION INSTRUCTIONS

R−410A Split System Air Conditioner

N4A3, C4A3, H4A3, T4A3,
NXA6, CXA6, HXA6, TXA6
These instructions must be read and understood completely before attempting installation.

Safety Labeling and Signal Words

DANGER, WARNING, CAUTION, and
NOTE Signal Words in Manuals
The signal words DANGER, WARNING, The signal word WARNING is used throughout this
CAUTION, and NOTE are used to identify levels of manual in the following manner:
WARNING
hazard seriousness. The signal word DANGER is
only used on product labels to signify an immediate ! WARNING
hazard. The signal words WARNING, CAUTION,
and NOTE will be used on product labels and The signal word CAUTION is used throughout this
throughout this manual and other manuals that may manual in the following manner:
apply to the product.
DANGER − Immediate hazards which will result in ! CAUTION
severe personal injury or death.
WARNING − Hazards or unsafe practices which Signal Words on Product Labeling
could result in severe personal injury or death. Signal words are used in combination with colors
CAUTION − Hazards or unsafe practices which and/or pictures on product labels.
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
! WARNING
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DEATH, PERSONAL INJURY, AND/OR PROPERTY
DAMAGE HAZARD
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 − 3
Failure to carefully read and follow this warning
Unit Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 could result in equipment malfunction, property
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . 5 − 9 damage, personal injury and/or death.
Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 10 − 11 Installation or repairs made by unqualified per-
sons could result in equipment malfunction,
Start−up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 property damage, personal injury and/or death.
Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . 12 − 15 The information contained in this manual is in-
tended for use by a qualified service technician fa-
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . 16
miliar with safety procedures and equipped with
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 the proper tools and test instruments.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installation must conform with local building
codes and with the National Electrical Code
Comfort Alertt Diagnostics Codes . . . . . . . . . . . . . . 17 NFPA70 current edition or Canadian Electrical
R−410A Quick Reference Guide . . . . . . . . . . . . . . . . . 18 Code Part 1 CSA C.22.1.

421 01 5103 00 May 2010

INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

INSPECT NEW UNIT

After uncrating unit, inspect thoroughly for hidden company immediately and file a concealed damage
damage. If damage is found, notify the transportation claim.

SAFETY CONSIDERATIONS
Consult a qualified installer, service agency, or the
dealer/distributor for information and assistance. The ! WARNING
qualified installer must use factory authorized kits and
accessories when modifying this product. Refer to the ELECTRICAL SHOCK HAZARD
individual instructions packaged with the kit or accessory Failure to turn off the main (remote) electrical dis-
when installing. connect device could result in personal injury or
The weight of the product requires careful and proper death.
handling procedures when lifting or moving to avoid Before installing, modifying or servicing system,
personal injury. Use care to avoid contact with sharp or turn OFF the main (remote) electrical disconnect
pointed edges. device. There may be more than one disconnect
Follow all safety codes. Wear safety glasses, protective device. Lock out and tag switch with a suitable
clothing, and work gloves. Use a heat sinking material − warning label.
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.
! CAUTION
Improper installation, adjustment, alteration, service or PROPERTY DAMAGE HAZARD
maintenance can void the warranty.
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.

LOCATION
Check local codes for regulations concerning zoning, Locate unit away from recessed or confined areas where
noise, platforms, and other issues. recirculation of discharge air may occur (refer to
Locate unit away from fresh air intakes, vents, or CLEARANCES section of this document).
bedroom windows. Noise may carry into the openings Roof−top installation is acceptable providing the roof will
and disturb people inside. support the unit and provisions are made for water
Locate unit in a well drained area, or support unit high drainage and noise/vibration dampening.
enough so that water runoff will not enter the unit. NOTE: Roof mounted units exposed to wind may require
Locate unit away from areas where heat, lint, or exhaust wind baffles. Consult the manufacturer for additional
fumes will be discharged onto unit (as from dryer vents). information.

CLEARANCES
Nominal minimum clearances are 48 inches (1.2m) Do not install unit under roof overhangs unless gutters
above unit for discharge air and 18 inches (457mm) on are present. A minimum vertical clearance of 48 inches
each side of the coil for intake air. Clearance on any one (1.2m) is required to the overhang.
side of the coil (normally between unit and structure) may Inside corner locations on single story structures require
be reduced to 6 inches (152mm). Nominal minimum evaluation. Large overhanging soffits may cause air
clearances are based on a solid parallel object such as a recirculation in a corner area even though recommended
wall or roof overhang. minimum clearances are maintained. As a guide, locate
the unit far enough out so that half of the discharge grille
The clearance may be reduced for a single object with is out from under the soffit.
small surface area, such as the end of a wall, outside
When placing two or more units side−by−side, provide a
corner of a wall, fence section, post, etc. As a general
minimum of 18 inches (457mm) between units.
rule, the minimum clearance from the unit should equal
the width of the object. For example, a 6 inch (152mm) Provide minimum service clearance of 24 inches
fence post should be a minimum of 6 inches (152mm) (610mm) from control box corner and side service panel.
from the unit. Refer to Figure 1.

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INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

Figure 1 Clearances (various examples)

Wall Wall
6”
(152mm) 24”
(610mm)
Service
24” 18”
(610mm) (457mm)
Service 6”

Wall
18”
(152mm)
(457mm)
18”
(457mm)
18”
(457mm)

Wall Wall
6” 6”
(152mm) (152mm)

24” 18” 24” 18”

(610mm) (152mm) (610mm) (457mm)
Service Service

4” 6”
4” (152mm)
(102mm)
(102mm)
wide fence 6”
(152mm)
Post

Wall
24” 24” 24”
(610mm) (610mm) (610mm)
Service Service Service

18” 18” 18” 18”

(457mm) (457mm) (457mm) (457mm)

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INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

UNIT SUPPORT
NOTE: Unit must be level | 2 degrees {a inch rise or fall
per foot of run (10mm rise or fall per 305 mm of run) }or
compressor may not function properly.
! CAUTION
A. GROUND LEVEL INSTALLATION PROPERTY DAMAGE HAZARD
The unit must be level and supported above grade by Failure to follow this caution may result in proper-
beams, platform, or a pad. Platform or pad can be of ty damage.
open or solid construction but should be of permanent Inadequate unit support may cause excessive
materials such as concrete, bricks, blocks, steel, or vibration, noise, and/or stress on the refrigerant
pressure− treated timbers approved for ground contact. lines, leading to refrigerant line failure.
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 Tie Down Knockouts
Figure 2.
View From Top
If beams or an open platform are used for support, it is a” (10mm) dia. Tie Down Knockouts
In Base Pan (2 places)
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. Base
Pan
B. ROOF TOP INSTALLATION Depth
This type of installation is not recommended on wood C
frame structures where low noise levels are required.
Supporting structure or platform for the unit must be
level. If installation is on a flat roof, locate unit minimum 6
inches (152mm) above roof level.
Place the unit over one or more load bearing walls. If B
there are several units, mount them on platforms that are
self−supporting and span several load bearing walls. A
These suggestions are to minimize noise and vibration Base Pan Width
transmission through the structure. If the structure is a
home or apartment, avoid locating the unit over Inches (mm)
bedrooms or study. Tie Down Minimum
Base Pan Knockouts
NOTE: When unit is to be installed on a bonded Width x Depth Mounting Pad
guaranteed roof, a release must be obtained from the A B C Dimensions
building owner to free the installer from all liabilities. @# ~ @# &w $v !* @# X~ @#
(584 x 584) (197) (113) (457) (584 x 584)
C. FASTENING UNIT DOWN
If conditions or local codes require the unit be attached in @%n ~ @%n (z $v @!4 @^ X~ @^
place, remove the knockouts in the base pan and install (652 x 652) (230) (113) (540) (660 x 660)
tie down bolts through the holes (refer to Figure 2). #!8 ~ #!8 (z ^2 @$s #!2 ~ #!2
(791 x 791) (230) (165) (625) (800 x 800)
Contact local distributor for hurricane hold−down details
and the P.E. (Professional Engineer) certification, when #$, ~ #$, (z ^2 @*v #% ~ #%
required. (887 x 887) (230) (165) (722) (889 x 889)

4 421 01 5103 00
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

REFRIGERATION SYSTEM
A. COMPONENT MATCHES Installing with Indoor Piston − cooling operation.
Check to see that the proper system components are in Check piston size shipped with indoor unit to see if it
place, especially the indoor coil. matches required indoor piston size.
If it does not match, replace indoor piston with correct
R−410A outdoor units can only be used with R−410A
piston size. (Indoor pistons are shipped with some
specific indoor coils. If there is a refrigerant mis−match, outdoor models in the accessory bag and are only
consult the indoor coil manufacturer to determine if a
qualified for Piston fan coils.)
refrigerant conversion kit is available for the indoor coil.
Example fan coils with piston: FEM4P, FSM4P, FSU4P
This outdoor unit is designed for use only with indoor (12 thru 4 ton).
coils that utilize a TXV refrigerant metering device or See Figure 4.
Piston with Teflon ring metering device. If any other type
of metering device is installed on the indoor coil, consult When changing indoor piston, use a back−up wrench.
the indoor coil manufacturer to determine if a TXV Hand tighten hex nut, then tighten with wrench 1/2 turn.
conversion kit is available. Do not exceed 30 ft−lbs.The indoor piston contains a
Teflon ring (or seal) which is used to seat against the
Installing with TXV inside of distributor body, and must be installed properly
to ensure proper seating in the direction for cooling
When installing a TXV on an indoor coil, follow the operation.
instructions provided with the new TXV.
A typical TXV installation is shown in Figure 3.
Figure 4 Indoor (cooling) Piston

BRASS DISTRIBUTOR
Figure 3 Typical TXV Installation HEX NUT TEFLON SEAL

TEFLON RING

INDOOR
COIL
EQUALIZER PISTON
TUBE
FLOW IN
COOLING
SENSING SUCTION BRASS
TUBE PISTON HEX BODY
BULB RETAINER

LIQUID
TUBE STRAINER

TXV L10S017

10 O’Clock

CAUTION
2 O’Clock
SENSING BULB !
PRODUCT OPERATION HAZARD
STRAP Failure to follow this caution may result in improper product
operation.
If using a TXV in conjunction with a single−phase reciprocat-
SUCTION TUBE ing compressor, a compressor start capacitor and relay are
required. Consult outdoor unit pre−sale literature for start as-
7/8 IN. OD & SMALLER
sist kit part number.

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INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

B. REFRIGERANT LINE SETS C. ROUTING AND SUSPENDING REFRIGERANT

The refrigerant line set must be properly sized to assure LINES
maximum efficiency and proper oil circulation. Run refrigerant lines as straight and direct as possible,
Refer to Product Specifications and Long Line avoiding unnecessary bends and turns. Always insulate
Applications Guideline for line set sizing. the entire suction line. Both lines should be insulated
NOTE: Total line set length must not exceed 200 feet when routed through an attic or when routed through an
(61m). underground raceway.
A crankcase heater must be used when the refrigerant When routing refrigerant lines through a foundation or wall,
line length exceeds 80 feet (24.4m). do not allow refrigerant lines to come in direct contact with
If outdoor unit is more than 10 feet (3m) higher than the the building structure. Make openings large enough so that
indoor coil, refer to the Long Line Applications Guideline lines can be wrapped with extra insulation. Fill all gaps with
for instructions. RTV caulk. This will prevent noise transmission between
When the outdoor unit is higher than the indoor coil, the the tubing and the foundation or wall.
vertical separation must not exceed 100 feet (30m). Along floor or ceiling joists, suspend refrigerant lines so
When the outdoor unit is lower than the indoor coil, the that they do not contact the building structure, water
vertical separation must not exceed 50 feet (15.2m). pipes, or ductwork. Use insulated or suspension type
If it is necessary to add refrigerant line in the field, use hangers. Metal straps must be at least 1” (25mm) wide to
dehydrated or dry, sealed, deoxidized, copper avoid cutting into the tube insulation. Keep the liquid and
refrigeration tubing. Do not use copper water pipe. suction lines separate. Refer to Figure 5.
Do not remove rubber plugs or caps from copper tubing
until connections are ready to be made.
Be extra careful when bending refrigeration tubing.
! CAUTION
Tubing can “kink” easily, and if this occurs, the entire
UNIT OPERATION HAZARD
length of tubing must be replaced.
Failure to follow this caution may result in im-
! WARNING proper product operation.
Do not leave system open to atmosphere any lon-
PERSONAL INJURY HAZARD ger than absolutely required for installation. Inter-
nal system components − especially refrigerant
Failure to relieve system pressure could result in oils − are extremely susceptible to moisture con-
personal injury and/or death. tamination. Keep ends of tubing sealed during
Relieve pressure and recover all refrigerant be- installation until the last possible moment.
fore servicing existing equipment, and before fi-
nal unit disposal. Use all service ports and open
all flow−control devices, including solenoid
valves.

Figure 5 Routing and Suspending Refrigerant Lines

JOIST
OUTDOOR WALL INDOOR WALL
HANGER STRAP
CAULK (AROUND SUCTION
TUBE ONLY) INSULATION
LIQUID TUBE
SUCTION TUBE

SUCTION TUBE
INSULATION
1” (25mm)
MIN LIQUID TUBE
THROUGH THE WALL SUSPENSION

6 421 01 5103 00
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

refrigerant charge sealed in the unit. Leave the service

! CAUTION valves closed until all other refrigerant system work is
complete or the charge will be lost. Leave the plugs in
UNIT OPERATION HAZARD place until line set tubing is ready to be inserted.
Failure to follow this caution may result in im- Service valve bodies are brass and tube stubs are
proper product operation. copper.
Do not bury more than 36” (1m) of line set under-
ground. Refrigerant may migrate to cooler buried Figure 7 Service Valve
section during extended periods of unit shut−
down, causing refrigerant slugging and possible
compressor damage at start−up.
If ANY section of the line set is buried under- SERVICE VALVE
ground, provide a minimum 6” (152mm) vertical VALVE CORE
rise at the service valve.

D. OUTDOOR UNIT HIGHER THAN INDOOR UNIT

Proper oil return to the compressor should be maintained
with suction gas velocity. If velocities drop below 1500
fpm (feet per minute), oil return will be decreased. To
maintain suction gas velocity, do not upsize vertical
suction risers.
G. BRAZING CONNECTIONS
E. LIQUID LINE FILTER−DRIER NOTE: Remove valve core from schrader port on both
Outdoor units are shipped with an appropriate filter−drier Service Valves BEFORE brazing. This helps prevent
for installation in the liquid line. Leave the plugs in the overheating and damage to valve seals (refer to Figure 7).
tube ends until the filter−drier is installed. The optimal Replace valve core when brazing is completed.
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 6. ! WARNING
Liquid Line Filter−Drier FIRE HAZARD
Figure 6
Installed at Indoor Coil
Failure to remove refrigerant and oil charge be-
fore brazing 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 be-
fore brazing any component or lines.

Clean line set tube ends with emery cloth or steel brush.
Remove any grit or debris.
Insert line set tube ends into service valve tube stubs.
Apply heat absorbing paste or heat sink product between
service valve and joint. Wrap service valves with a heat
sinking material such as a wet cloth.
Braze joints using a Sil−Fos or Phos−copper alloy.

! CAUTION
Filter−Drier PRODUCT DAMAGE HAZARD
(arrow points towards indoor coil) 38−11−84 Failure to follow this caution may result in product dam-
age.
F. SERVICE VALVES Braze with Sil−Fos or Phos−copper alloy on cop-
Service valves are closed and tube stubs are plugged per−to−copper joints and wrap a wet cloth around
from the factory. Outdoor units are shipped with a rear of fitting to prevent damage to TXV.

421 01 5103 00 7
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

H. EVACUATING LINE SET AND INDOOR COIL Triple Evacuation Method

The unit is shipped with a factory refrigerant charge. The The triple evacuation method should only be used when
liquid line and suction line service valves have been closed system does not contain any water in liquid form and
after final testing at the factory. Do not disturb these valves vacuum pump is only capable of pulling down to 28 inches
until the line set and indoor coil have been evacuated and of mercury (711mm Hg). Refer to Figure 9 and proceed as
leak checked, or the charge in the unit may be lost. follows:
NOTE: Do not use any portion of the factory charge for
purging or leak testing. The factory charge is for filling the 1. Pull system down to 28 inches of mercury
system only after a complete evacuation and leak check (711mm Hg) and allow pump to continue
has been performed. operating for an additional 15 minutes.
2. Close manifold valves or valve at vacuum pump
! CAUTION and shut off vacuum pump.
3. Connect a nitrogen cylinder and regulator to
PRODUCT DAMAGE HAZARD system and fill with nitrogen until system pressure
is 2 psig.
Failure to follow this caution may result in product dam-
age.
4. Close nitrogen valve and allow system to stand for
1 hour. During this time, dry nitrogen will diffuse
Never use the outdoor unit compressor as a vacu- throughout the system absorbing moisture.
um pump. Doing so may damage the compressor. 5. Repeat this procedure as indicated in Figure 8.
Line set and indoor coil should be evacuated using the 6. After the final evacuate sequence, confirm there
recommended deep vacuum method of 500 microns. If are no leaks in the system. If a leak is found,
deep vacuum equipment is not available, the alternate repeat the entire process after repair is made.
triple evacuation method may be used by following the
specified procedure. Figure 9 Triple Evacuation Sequence
If vacuum must be interrupted during the evacuation
procedure, always break vacuum with dry nitrogen. EVACUATE
Deep Vacuum Method
The deep vacuum method requires a vacuum pump BREAK VACUUM WITH DRY NITROGEN
capable of pulling a vacuum to 500 microns and a
vacuum gauge capable of accurately measuring this WAIT
vacuum level. The deep vacuum method is the most
positive way of assuring a system is free of air and water.
Watch the vacuum gauge as the system is pulling down. EVACUATE
The response of the gauge is an indicator of the condition
of the system (refer to Figure 8). BREAK VACUUM WITH DRY NITROGEN
With no leaks in the system, allow the vacuum pump to
run for 30 minutes minimum at the deep vacuum level. WAIT
Deep Vacuum Gauge Response
Figure 8
and System Conditions EVACUATE

5000 CHECK FOR TIGHT, DRY SYSTEM

4500 (IF IT HOLDS DEEP VACUUM)
4000
LEAK IN
3500 CHARGE SYSTEM
SYSTEM
MICRONS

3000
2500
2000
1500 VACUUM TIGHT
TOO WET
1000
TIGHT
500 DRY SYSTEM

0 1 2 3 4 5 6 7
MINUTES

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INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

I. OPENING SERVICE VALVES NOTE: These are not back−seating valves. It is not
Outdoor units are shipped with a refrigerant charge necessary to force the stem tightly against the rolled lip.
sealed in the unit. Opening the service valves releases The service valve cap is a primary seal for the valve and
this charge into the system. must be properly tightened to prevent leaks. Make sure
NOTE: Open the Suction service valve first. If the Liquid cap is clean and apply refrigerant oil to threads and
service valve is opened first, oil from the compressor sealing surface on inside of cap.
may be drawn into the indoor coil TXV, restricting Tighten cap finger tight and then tighten additional 6 of a
refrigerant flow and affecting operation of the system. turn (1 wrench flat) to properly seat the sealing surfaces.
Remove Suction service valve cap and insert a hex
wrench into the valve stem. Hold the valve body steady J. GAUGE PORTS
with an end−wrench and back out the stem by turning the Check for leaks at the schrader ports and tighten valve
hex wrench counterclockwise. Turn the stem until it just cores if necessary. Install plastic caps finger tight.
contacts the rolled lip of the valve body.
After the refrigerant charge has bled into the system,
open the Liquid service valve.

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INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

ELECTRICAL WIRING
Wiring Connections
! WARNING Make all outdoor electrical supply (Line Voltage)
connections with raintight conduit and fittings. Most
ELECTRICAL SHOCK HAZARD codes require a disconnect switch outdoors within sight
Failure to turn off the main (remote) electrical dis- of the unit. Consult local codes for special requirements.
connect device could result in personal injury or Route electrical supply (Line Voltage) wiring through
death. knockout hole in bottom of Control Box. Connect wires to
Before installing, modifying or servicing system, Contactor and Ground Lug according to Wiring Diagram
turn OFF the main (remote) electrical disconnect on unit. Refer to Figure 10.
device. There may be more than one disconnect Route thermostat wiring through rubber grommet in
device. bottom of Control Box. Low voltage lead wires are
provided in the control box for connection to thermostat
The supply voltage must be 208/230 volts (197 volt
wires (use wire nuts). Refer to Wiring Diagram on unit
minimum to 253 volts maximum) 60 Hz single phase.
and Figure 11 for low voltage wiring examples.
Outdoor units are approved for use with copper
conductors only. Do not use aluminum wire. NOTE: Use No. 18 AWG (American Wire Gage)
Refer to unit rating plate for minimum circuit ampacity color−coded, insulated (35 ° C minimum) wire. If
and circuit protection requirements. thermostat is located more than 100 feet (31 m) from unit
as measured along the control voltage wires, use No. 16
Grounding AWG color−coded wires to avoid excessive voltage
Permanently ground unit in accordance with the National drop.
Electrical Code and local codes or ordinances. Use a
copper conductor of the correct size from the grounding NOTE: Some models are factory equipped with Comfort
lug in control box to a grounded connection in the service Alertt Diagnostics device. If Comfort Alert is used as a
panel or a properly driven and electrically grounded field installed option, then a hot bundle must be run for
ground rod. proper connection.
Figure 10 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
GROUND
LUG

10 421 01 5103 00
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

Figure 11 Typical Thermostat Connections

THERMOSTAT FURNACE AIR CONDITIONER

24 VAC HOT R R

24 VAC COM C C

HEAT STAGE 1 W/W1 W C

COOL STAGE 1 Y/Y2 Y

INDOOR FAN G G

THERMOSTAT FAN COIL AIR CONDITIONER

24 VAC HOT R R

24 VAC COM C C

HEAT STAGE 1 W/W1 W2 C

COOL STAGE 1 Y/Y2 Y

INDOOR FAN G G

THERMOSTAT FAN COIL AC with Comfort Alert

24 VAC HOT R R

24 VAC COM C C C

HEAT STAGE 1 W/W1 W2

COOL STAGE 1 Y/Y2 Y Y

INDOOR FAN G G

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INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

START−UP PROCEDURE
1. Set indoor thermostat selector switch to OFF. 4. Set indoor thermostat at desired temperature. Be
2. Turn ON all electrical disconnect devices. sure setpoint is below indoor ambient temperature
or thermostat will not call for cooling.
3. If unit has a crankcase heater, energize the heater 5. Set indoor thermostat selector switch to COOL.
and wait 24 hours before proceeding. Operate unit for minimum 15 minutes, then check
the system refrigerant charge.

REFRIGERANT CHARGE
Factory charge amount and desired subcooling are If the indoor temperature is above 80_F (27_C), and the
shown on unit rating plate. Charging method is shown on outdoor temperature is in the favorable range, adjust
information plate inside unit. system charge by weight based on line length and allow
For TXV, use subcooling method. the indoor temperature to drop to 80_F (27_C) before
For Piston, use superheat method. attempting to check system charge by subcooling
method as described above.
To properly check or adjust charge, conditions must be
favorable for subcooling or superheat charging. If the indoor temperature is below 70_F (21_C), or the
Favorable conditions exist when the outdoor outdoor temperature is not in the favorable range, adjust
temperature is between 70_F and 100_F (21_C and charge for line set length above or below 15 feet (4.6m)
38_C), and the indoor temperature is between 70_F and only. Charge level should then be appropriate for the
80_F (21_C and 27_C). Follow the procedure below. system to achieve rated capacity. The charge level could
Unit is factory charged for 15 feet (4.6m) of lineset. then be checked at another time when the both indoor
Adjust charge by adding or removing 0.6 oz/ft (17 g/mm) and outdoor temperatures are in a more favorable range.
of 3/8 liquid line above or below 15 feet (4.6 m) NOTE: If line length is beyond 80 feet (24.4m) or greater
respectively. than 20 feet (6.1m) vertical separation, See Long Line
For standard refrigerant line lengths 80 feet (24.4m) or Guideline for special charging requirements.
less, allow system to operate in cooling mode at least 15
minutes. If conditions are favorable, check system
charge by super heat method for fixed metering device
and subcooling method for TXV. If any adjustment is
necessary, adjust charge slowly and allow system to
operate for 15 minutes to stabilize before declaring a
properly charged system.

12 421 01 5103 00
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

A. UNITS WITH COOLING MODE TXV B. UNITS WITH INDOOR PISTON

Units installed with cooling mode TXV require charging Units installed with indoor pistons require charging by the
by the subcooling method. superheat method.
1. Operate unit a minimum of 15 minutes before The following procedure is valid when indoor airflow is
checking charge. within "21 percent of its rated CFM.
2. Measure liquid service valve pressure by 1. Operate unit a minimum of 15 minutes before
attaching an accurate gage to service port. checking charge.
2. Measure suction pressure by attaching an
3. Measure liquid line temperature by attaching an accurate gage to suction valve service port.
accurate thermistor type or electronic
thermometer to liquid line near outdoor coil. 3. Measure suction temperature by attaching an
accurate thermistor type or electronic
4. Refer to unit rating plate for required subcooling thermometer to suction line at service valve.
temperature. 4. Measure outdoor air dry−bulb temperature with
5. Refer to Figure 14. Find the point where required thermometer.
subcooling temperature intersects measured 5. Measure indoor air (entering indoor coil) wet−bulb
liquid service valve pressure. temperature with a sling psychrometer.
6. To obtain required subcooling temperature at a 6. Refer to Figure 12. Find outdoor temperature and
specific liquid line pressure, add refrigerant if evaporator entering air wet−bulb temperature. At
liquid line temperature is higher than indicated or this intersection, note superheat. Where a dash
reclaim refrigerant if temperature is lower. Allow a (−−) appears on the table, do not attempt to
tolerance of "3_F (|1.7_C). charge system under these conditions or
refrigerant slugging may occur. Charge must be
weighted in, adding or removing 0.6 oz/ft of 3/8
liquid line above or below 15 feet (4.6m)
respectively.
7. Refer to Figure 13. Find superheat temperature
(from #6 above) and suction pressure. At this
intersection, note suction line temperature.
8. If unit has a higher suction line temperature than
charted temperature, add refrigerant until charted
temperature is reached.
9. If unit has a lower suction line temperature than
charted temperature, reclaim refrigerant until
charted temperature is reached.
10. When adding refrigerant, charge in liquid form into
suction service port using a flow−restricting
device.
11. If outdoor air temperature or pressure at suction
valve changes, charge to new suction line
temperature indicated on chart.
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.

421 01 5103 00 13
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

Figure 12 Superheat Charging − AC Only

EVAPORATOR ENTERING AIR TEMPERATURE (_F WB)
OUTDOOR TEMP (_F)
50 52 54 56 58 60 62 64 67 68 70 72 74 76
55 9 12 14 17 20 23 26 29 32 35 37 40 42 45
60 7 10 12 15 18 21 24 27 30 33 35 38 40 43
65 — 6 10 13 16 19 21 24 27 30 33 36 38 41
70 — — 7 10 13 16 19 21 24 27 30 33 36 39
75 — — — 6 9 12 15 18 21 24 28 31 34 37
80 — — — — 5 8 12 15 18 21 25 28 31 35
85 — — — — — — 8 11 15 19 22 26 30 33
90 — — — — — — 5 9 13 16 20 24 27 31
95 — — — — — — — 6 10 14 18 22 25 29
100 — — — — — — — — 8 12 15 20 23 27
105 — — — — — — — — 5 9 13 17 22 26
110 — — — — — — — — — 6 11 15 20 25
115 — — — — — — — — — — 8 14 18 23
*Optimum performance point, 95°F (35°C) outdoor ambient and (80°F / 27°C dry bulb), (67°F / 19°C wet bulb) indoor conditions. (DOE A Test Conditions)
Where a dash (--) appears do not attempt to charge system under these conditions or refrigerant slugging may occur. Charge must be weighed in.
Note: Superheat °F is at low-side service port, Allow a tolerance of ± 3°F (± 1.7°C)
Note: Indoor dry bulb between 70°F and 80°F (21°C and 27°C)

Figure 13 Required Suction−Line Temperature

SUCTION PRESSURE AT SERVICE PORT (PSIG)
SUPERHEAT TEMP (_F)
107.8 112.2 116.8 121.2 126 130.8 138.8 140.8 145.8
0 35 37 39 41 43 45 47 49 51
2 37 39 41 43 45 47 49 51 53
4 39 41 43 45 47 49 51 53 55
6 41 43 45 47 49 51 53 55 57
8 43 45 47 49 51 53 55 57 59
10 45 47 49 51 53 55 57 59 61
12 47 49 51 53 55 57 59 61 63
14 49 51 53 55 57 59 61 63 65
16 51 53 55 57 59 61 63 65 67
18 53 55 57 59 61 63 65 67 69
20 55 57 59 61 63 65 67 69 71
22 57 59 61 63 65 67 69 71 73
24 59 61 63 65 67 69 71 73 75
26 61 63 65 67 69 71 73 75 77
28 63 65 67 69 71 73 75 77 79
30 65 67 69 71 73 75 77 79 81
32 67 69 71 73 75 77 79 81 83
34 69 71 73 75 77 79 81 83 85
36 71 73 75 77 79 81 83 85 87
38 73 75 77 79 81 83 85 87 89
40 75 77 79 81 83 85 87 89 91

14 421 01 5103 00
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

Figure 14 Rating Plate (required) Subcooling Temperature ° F (° C)

°F (° C) °F (° C) °F (° C) °F (° C) F (° C) F (° C)
Measured Liquid 6 3 8 4 10 6 12 7 14 8 16 9
Pressure (psig)
R−410A Required Liquid Line Temperature ° F (° C)
251 78 26 76 24 74 23 72 22 70 21 68 20
259 80 27 78 26 76 24 74 23 72 22 70 21
266 82 28 80 27 78 26 76 24 74 23 72 22
274 84 29 82 28 80 27 78 26 76 24 74 23
283 86 30 84 29 82 28 80 27 78 26 76 24
291 88 31 86 30 84 29 82 28 80 27 78 26
299 90 32 88 31 86 30 84 29 82 28 80 27
308 92 33 90 32 88 31 86 30 84 29 82 28
317 94 34 92 33 90 32 88 31 86 30 84 29
326 96 36 94 34 92 33 90 32 88 31 86 30
335 98 37 96 36 94 34 92 33 90 32 88 31
345 100 38 98 37 96 36 94 34 92 33 90 32
364 104 40 102 39 100 38 98 37 96 36 94 34
374 106 41 104 40 102 39 100 38 98 37 96 36
384 108 42 106 41 104 40 102 39 100 38 98 37
395 110 43 108 42 106 41 104 40 102 39 100 38
406 112 44 110 43 108 42 106 41 104 40 102 39
416 114 46 112 44 110 43 108 42 106 41 104 40
427 116 47 114 46 112 44 110 43 108 42 106 41
439 118 48 116 47 114 46 112 44 110 43 108 42
450 120 49 118 48 116 47 114 46 112 44 110 43
462 122 50 120 49 118 48 116 47 114 46 112 44
474 124 51 122 50 120 49 118 48 116 47 114 46

421 01 5103 00 15
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

SEQUENCE OF OPERATION
With power supplied to indoor and outdoor units, When thermostat is satisfied, its contacts open,
transformer is energized. de−energizing contactor and blower relay. Compressor
On a call for cooling, the thermostat makes circuits R−Y and motors stop.
and R−G. Circuit R−Y energizes contactor, starting NOTE: If indoor unit is equipped with a time−delay relay
outdoor fan motor and compressor. Circuit R−G circuit, the blower runs an additional length of time to
energizes indoor unit blower relay, starting indoor blower increase system efficiency.
motor.

TROUBLESHOOTING
Some models are factory equipped with the Comfort Comfort Alertt Diagnostics
Alertt Diagnostics device in the control box (refer to Figure 15
(some models)
Figure 15). Comfort Alert provides around−the−clock
monitoring for common electrical problems, compressor Compressor Wires
defects, and broad system faults. If trouble is detected, Pass Through Holes (3)
an alert code is displayed with a flashing LED indicator.
Alert codes are listed in Figure 16.
The device is factory wired and requires no
modification. Low voltage lead wires are provided in the
control box for connection to thermostat wires (use wire
nuts).
The Comfort Alert device operates by monitoring the
compressor power leads and the thermostat demand
signal (Y terminal).
24 VAC Common
Thermostat Demand

MAINTENANCE
Condensate Drain 2. Keep the coil free of grass clippings, leaves,
weeds, and other debris.
During the cooling season, check monthly for free flow of NOTE: Coil may occasionally require cleaning
drainage and clean if necessary. 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
Cleanliness will remove the paint from the fins and may clog
the coil.
These tips will help keep the air conditioner looking better
3. Never use a weather cover over the outdoor unit
and working more efficiently: unless it is a ventilated type or made of breathable
fabric that will allow moisture to evaporate rapidly.
1. Free flow of air is essential. Keep fences, shrubs, A cover that holds moisture in the unit will cause
trash cans, and other obstructions at least 18 more rust build−up and damage than normal
inches (457mm) from all coil inlets. exposure to weather.

16 421 01 5103 00
INSTALLATION INSTRUCTIONS R−410A Split System Air Conditioner

Figure 16 Comfort Alertt Diagnostics (some models)

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. Broken wire or connector is not making contact
5. Low pressure switch open if present in system
6. Compressor contactor has failed open
Yellow “ALERT” Long Run Time 1. Low refrigerant charge
Flash Code 1 Compressor is running 2. Evaporator blower is not running
extremely long run cycles 3. Evaporator coil is frozen
4. Faulty metering device
5. Condenser coil is dirty
6. Liquid line restriction (filter drier blocked if present in system)
7. Thermostat is malfunctioning
Yellow “ALERT” System Pressure Trip 1. High head pressure
Flash Code 2 Discharge or suction 2. Condenser coil poor air circulation (dirty, blocked, damaged)
pressure out of limits or 3. Condenser fan is not running
compressor overloaded 4. Return air duct has substantial leakage
Yellow “ALERT” Short Cycling 1. If high pressure switch open, go to Flash Code 2 information
Flash Code 3 Compressor is running 2. If low pressure switch open, go to Flash Code 1 information
only briefly 3. Thermostat demand signal is intermittent
4. Loose wiring at contactor coil
Yellow “ALERT” Locked Rotor 1. Run capacitor has failed
Flash Code 4 2. Low line voltage (contact utility if voltage at disconnect is low)
3. Excessive liquid refrigerant in compressor
4. Compressor bearings are seized
Yellow “ALERT” Open Circuit 1. Outdoor unit power disconnect is open
Flash Code 5 2. Compressor circuit breaker or fuse(s) is open
3. Compressor contactor has failed open
4. High pressure switch is open and requires manual reset
5. Open circuit in compressor supply wiring or connections
6. Unusually long compressor protector reset time due to
extreme ambient temperature
7. Compressor windings are damaged
Yellow “ALERT” Open Start Circuit 1. Run capacitor has failed
Flash Code 6 Current only in run circuit 2. Open circuit in compressor start wiring or connections
3. Compressor start winding is damaged
Yellow “ALERT” Open Run Circuit 1. Open circuit in compressor run wiring or connections
Flash Code 7 Current only in start circuit 2. Compressor run winding is damaged
Yellow “ALERT” Low Voltage 1. Control circuit transformer is overloaded
Flash Code 9 Control circuit < 17VAC 2. Low line voltage (contact utility if voltage at disconnect is low)
S Flash Code number corresponds to a number of LED flashes, followed by a pause and then repeated.
S TRIP and ALERT LEDs flashing at same time means control circuit voltage is too low for operation.

421 01 5103 00 17
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. Use a commercial type metering device in the
manifold hose.

• Manifold sets should be 750 psig high−side and 200 psig low−side with 520 psig low−side retard.

• Use hoses with 750 psig service pressure rating.

• Leak detectors should be designed to detect HFC refrigerant.

• R−410A, as with other HFC refrigerants, is only compatible with POE oils.

• Vacuum pumps will not remove moisture from oil.

• Do not use liquid line filter−driers with rated working pressures less than 600 psig.

• Do not install a suction line filter−drier in liquid line.

• POE oils absorb moisture rapidly. Do not expose oil to atmosphere.

• POE oils may cause damage to certain plastics and roofing materials.

• Wrap all filter−driers and service valves with wet cloth when brazing.

• A liquid line filter−drier is required on every unit.

• Do not use with an R−22 TXV.

• If indoor unit is equipped with an R−22 TXV, it must be changed to an R−410A TXV.

• Never open system to atmosphere while it is under a vacuum.

• When system must be opened for service, break vacuum with dry nitrogen and replace all filter−driers.

• Do not vent R−410A into the atmosphere.

• Do not use capillary tube indoor coils.

• Observe all WARNINGS, CAUTIONS, NOTES, and bold text.

International Comfort Products, LLC

18 Lewisburg, TN 37091 USA 421 01 5103 00