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Save This Manual for Future Reference501 01 3001 0004/24/09

3 PHASE6 to 12.5 TON

AC CONDENSERS

CAS SERIESSPLIT SYSTEM

Installation, Start−Up, and Service Instructions

Split System CondensersInstallation Instructions

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TABLE OF CONTENTSPAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFE INSTALLATION REQUIREMENTS 2. . . . . . . . . . . . . INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Nomenclature 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Physical Data 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit Positioning 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Piping Connections 7. . . . . . . . . . . . . . . . . . . . Installing Accessories 10. . . . . . . . . . . . . . . . . . . . . . . . . . . Typical Thermostat Connections 12. . . . . . . . . . . . . . . . . . System Check 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start−Up 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging Charts 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Sequence 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . System Maintenance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . LED Status Codes 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning and Maintenance 21. . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start−Up Checklist 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY CONSIDERATIONSImproper installation, adjustment, alteration, service,maintenance, or use can cause explosion, fire, electricalshock, or other conditions which may cause death,personal injury, or property damage. Consult a qualifiedinstaller, service agency, or your distributor or branch forinformation or assistance. The qualified installer oragency must use factory−authorized kits or accessorieswhen modifying this product. Refer to the individualinstructions packaged with the kits or accessories wheninstalling.

Follow all safety codes. Wear safety glasses, protectiveclothing, and work gloves. Use quenching cloth forbrazing operations. Have fire extinguisher available.Read these instructions thoroughly and follow allwarnings or cautions included in literature and attachedto the unit. Consult local building codes, the currenteditions of the National Electrical Code (NEC) NFPA 70.

In Canada refer to the current editions of the CanadianElectrical Code CSA C22.1 Recognize safetyinformation. 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 thepotential for personal injury. Understand these signalwords; DANGER, WARNING, and CAUTION. Thesewords are used with the safety−alert symbol. DANGERidentifies the most serious hazards which will result insevere personal injury or death. WARNING signifieshazards which could result in personal injury or death.CAUTION is used to identify unsafe practices which mayresult in minor personal injury or product and propertydamage. NOTE is used to highlight suggestions whichwill result in enhanced installation, reliability, oroperation.

! WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal in-jury or death.

Before performing service or maintenance operationson unit, always turn off main power switch to unit and in-stall lockout tag. Unit may have more than one powerswitch.

! WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personal in-jury, death and/or equipment damage.

R−410A systems operate at higher pressures than R−22systems. When working with R−410A systems, use onlyservice equipment and replacement components specif-ically rated or approved for R−410A service.

! WARNING

PERSONAL INJURY AND ENVIRONMENTALHAZARD

Failure to follow this warning could cause personal injuryor death.

Relieve pressure and recover all refrigerant before sys-tem repair or final unit disposal.Wear safety glasses and gloves when handling refriger-ants.Keep torches and other ignition sources away from refri-gerants and oils.

! CAUTIONCUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Usecare and war appropriate protective clothing, safetyglasses and gloves when handling parts and servicingunits.

! CAUTIONCUT HAZARD

Failure to follow this caution may cause equipment dam-age.

Ensure voltage listed on unit data plate agrees with elec-trical supply provided for the unit.

Split System Condensers Installation Instructions

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MODEL NOMENCLATUREMODEL SERIES C A S 0 9 1 H A G 0 A 0 0 APosition Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14C = R-410A Condensing Unit

A = Air Conditioning (Cooling Only)H = Heat Pump Type

S = Standard ASHRAE 90.1-2010 Efficiency Efficiency

072 = 6 Tons091 = 7.5 Tons (1 circuit)121 = 10 Tons (1 circuit)151 = 12.5 Tons (1 circuit) Nominal Cooling Capacity

H = 208/230-3-60L = 460/208/230-3-60S = 575-3-50 VOLTAGE

A = Single CircuitB = Single Circuit w/ Low Ambient Control Refrigerant System Options

G = Al/Al Standard (AC only)K = Al/Al E-Coat (AC only) Outdoor Coil Options

0 = None1 = UnPowered C.O. Service Options

A = NoneC = Non-Fused Disconnect Electrical Options

0 = Elec-Mechanical Standard Base Unit Controls

0 = Future Use Future Use

A = Standard Packaging Packaging

Installation GuidelineReplacement /Retrofit – R22 to R−410A

Replacement/retrofit installations require change−out ofoutdoor unit, metering device, and filter driers. Change−outof indoor coil (evaporator) and interconnecting tubing isrecommended.Existing evaporator coil – If the existing evaporator coil maybe re−used, check with the coil manufacturer to verify thecoil construction is suitable for operation with the higherpressures of R−410A. Also determine if the existing TXVvalve is compatible with R−410A, replace if necessary. Theminimum factory test pressure rating must be 250 psig(1725 kPa). Existing coil will need to be purged withNitrogen to remove as much mineral oil as possible toeliminate cross contamination of oil.Acid test – If the existing system is being replaced becauseof a compressor electrical failure, assume acid is in system.If system is being replaced for any other reason, use anapproved acid test kit to determine acid level. If even lowlevels of acid are detected, install a 100 percent activatedalumina suction−line filter drier in addition to thereplacement liquid−line filter drier. Remove the suction linefilter drier as soon as possible, with a maximum of 72 hoursof operation. Recommendation: Install a ball valve in theliquid line at the filter drier location when installing a suctionfilter in the suction line.

Installation1. Remove the existing evaporator coil or fan coil and

install the replacement coil when appropriate.2. Drain oil from low points and traps in suction line

tubing and hot gas bypass tubing if appropriate) andevaporator if they were not replaced. Removing oilfrom evaporator coil may require purging of thetubing with dry nitrogen.

3. Unless indoor unit is equipped with a R−410Aapproved metering device, change the meteringdevice to a thermal expansion valve (TXV) designedfor R−410A.

4. Remove the existing outdoor unit. Install the newoutdoor unit according to these installationinstructions.

5. Install a new field−supplied liquid−line filter drier atthe indoor coil just upstream of the TXV or fix orificemetering device.

6. If a suction line filter drier is also to be installed,install suction line drier downstream of suction lineservice valve at condensing unit.

7. If required, install a 100% activated alumina suctionline filter drier at the outdoor unit.

8. Evacuate and charge the system according to theinstructions in this installation manual.


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9. Operate the system for 10 hours. Monitor thepressure drop across the suction line filter drier. Ifpressure drop exceeds 3 psig (21kPa), replacesuction−line and liquid−line filter driers. Be sure topurge system with dry nitrogen and evacuate whenreplacing filter driers. Continue to monitor thepressure drop across suction−line filter drier. Repeatfilter changes is necessary. Never leavesuction−line filter drier in system longer than 72 hr(actual time).

NOTE: Do not use a torch to remove filter driers, use tubingcutters. Excess heat from the torch will drive the moisturecontained within the drier back out into the system.

Figure 1 Unit Dimensions

CAS151

DISCONNECTLOCATION

CAS072

CAS091

CAS121CAS151

UNITStandard Weight Corner A Corner B Corner C Corner D Center of Gravity Unit Height

lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. X Y Z H

072 328 149 128 58 70 32 62 28 68 3119.00

(482.6)21.00

(533.4)12.71

(322.8) 42.36 (1076.0)

091 353 160 138 63 78 35 65 29 72 3322.50

(571.5)18.50

(469.9)12.71

(322.8) 42.36 (1076.0)

121 418 190 165 75 90 41 78 35 85 3919.50

(495.3)23.00

(584.2)15.11

(383.3) 50.36 (1279.2)

151 431 196 162 73 95 43 92 42 82 3723.00

(584.2)19.25

(489.0)15.11

(383.3) 50.6 (1279.2)


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Table 1A Physical Data — 60 Hz English

UNIT CAS 072 091 121 151

NOMINAL CAPACITY (tons) 6 7.5 10 12.5

OPERATING WEIGHT (lb)

Aluminum−Fin Coils (Standard) 328 353 418 431

REFRIGERANT TYPE * R−410A

Operating Charge, Typical (lb)� 8.4 10.2 13.8 18.0

Shipping Charge (lb) 4.4 4.9 6.3 7.3

COMPRESSOR Scroll

Qty... Model 1...ZP61 1...ZP83 1...ZP103 1...ZP137

Oil Charge (oz) 56 60 110 110

No. refrigerant circuits 1

Speed (rpm) 3500

CONDENSER FANS

Qty...Rpm 2...1100

Motor Hp 1/4

Diameter 22

Nominal Airflow (CFM Total) 6000

Watts (Total) 610

CONDENSER COIL (Qty) 1... Alum Tu/Alum Fin Micro−channel

Face Area (sq ft total) 17.5 20.5 25.0 31.8

Rows/Fins per inch (FPI) 1/17 1/17 1/17 1/17

Storage Capacity (lb) ** 5.5 6.0 7.4 8.7

CONTROLS

Pressurestat Settings (psig)

High Cut−out 630 � 10

Cut−in 505 � 20

Low Cut−out 54 � 3

Cut−in 117 � 5

PIPING CONNECTIONS (in. ODS)

Qty...Suction 1...1 1/8 1...1 1/8 1...1 3/8 1...1 3/8

Qty... Liquid 1... 3/8 1... 1/2 1... 1/2 1... 5/8

LEGENDODS — Outside Diameter Sweat (socket)

* Unit is factory−supplied with partial charge only.† Typical operating charge with 25 ft of interconnecting piping.** Storage capacity of condenser coil with coil 80% full of liquidR−410A at 95�F.


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Table 1B Physical Data — 60 Hz SI

UNIT CAS 072 091 121 151

NOMINAL CAPACITY (kW) 21.1 26.4 35.1 44

OPERATING WEIGHT (kg)

Aluminum−Fin Coils (Standard) 149 160 190 196

REFRIGERANT TYPE * R−410A

Operating Charge, Typical (kg)� 3.8 4.6 6.3 8.2

Shipping Charge (kg) 2.0 2.2 2.9 3.3

COMPRESSOR Scroll

Qty... Model 1...ZP61 1...ZP83 1...ZP103 1...ZP137

Oil Charge (L) 1.7 1.8 3.3 3.3

No. refrigerant circuits 1

Speed (r/s) 58

CONDENSER FANS

Qty...Rpm 2...18

Motor Hp NEMA 1/4

Diameter (mm) 560

Nominal Airflow (L/s) 2832

Watts (Total) 610

CONDENSER COIL (Qty) 1... Alum Tu/Alum Fin Micro−channel

Face Area (sq m total) 1.6 1.9 2.3 3.0

Rows/Fins per inch (Fins/m) 1...670 1...670 1...670 1...670

Storage Capacity (kg) ** 2.5 2.7 3.4 3.9

CONTROLS

Pressurestat Settings (kPa)

High Cut−out 4347 � 70

Cut−in 3482 � 138

Low Cut−out 372 � 21

Cut−in 807 � 34

PIPING CONNECTIONS (in. ODS)

Qty...Suction 1...1 1/8 1...1 1/8 1...1 3/8 1...1 3/8

Qty... Liquid 1...3/8 1... 1/2 1... 1/2 1... 5/8

LEGENDNEMA — National Electrical Manufacturers AssociationODS — Outside Diameter Sweat (socket)

* Unit is factory−supplied with partial charge only.† Typical operating charge with 7.62 m of interconnecting piping.** Storage capacity of condenser coil with coil 80% full of liquidR−410A at 35�C.

Jobsite SurveyComplete the following checks before installation.

1. Consult local building codes and the NEC (NationalElectrical Code) ANSI/NFPA 70 for specialinstallation requirements.

2. Determine unit location (from project plans) or selectunit location.

3. Check for possible overhead obstructions whichmay interfere with unit lifting or rigging.

Step 1 — Plan for Unit LocationSelect a location for the unit and its support system (pad,rails or other) that provides for the minimum clearancesrequired for safety. This includes the clearance to

combustible surfaces, unit performance and serviceaccess below, around and above unit as specified in unitdrawings. See Figure 2.

NOTE: Consider also the effect of adjacent units on airflowperformance and control box safety clearance.

Do not install the outdoor unit in an area where fresh airsupply to the outdoor coil may be restricted or whenrecirculation from the condenser fan discharge is possible.Do not locate the unit in a well or next to high walls.

Evaluate the path and required line length forinterconnecting refrigeration piping, including suction riserrequirements (outdoor unit above indoor unit), liquid line lift(outdoor unit below indoor unit) and hot gas bypass line.


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Relocate sections to minimize the length of interconnectingtubing.

! CAUTIONUNIT OPERATION HAZARD

Failure to follow this caution may result in improperoperation.

Do not bury refrigerant piping underground.Although unit is weatherproof, avoid locations that permitwater from higher level runoff and overhangs to fall onto theunit.

Figure 2 Service Clearance Dimensional Drawing

REAR:Min 18” (457 mm)required for service

Note: Observe requirements for 39” (914 mm) operating clearance on either Left or Rear coil opening.

RIGHT:Min 18” (457 mm)required for service

LEFT:Min 18” (457 mm)required for service FRONT:

42” (1067 mm)

Step 2 — Complete Pre−Installation ChecksCHECK UNIT ELECTRICAL CHARACTERISTIC —Confirm before installation of unit that voltage, amperageand circuit protection requirements listed on unit data plateagree with power supply provided.

UNCRATE UNIT — Remove unit packaging except for thetop skid assembly, which should be left in place until afterthe unit is rigged into its final location.

INSPECT SHIPMENT — File a claim with shippingcompany if the shipment is damaged or incomplete.

CONSIDER SYSTEM REQUIREMENTS� Consult local building codes and National Electrical

Code (NEC, U.S.A.) for special installationrequirements.

� Allow sufficient space for airflow clearance, wiring,refrigerant piping, and servicing unit. See Figure 1for unit dimensions and weight distribution data.

� Locate the unit so that the outdoor coil (condenser)airflow is unrestricted on all sides and above.

� The unit may be mounted on a level pad directly onthe base channels or mounted on raised pads atsupport points. See Tables 1A and 1B for unitoperating weights. See Figure 1 for weightdistribution based on recommended support points.

NOTE: If vibration isolators are required for a particularinstallation, use the data in Figure 1 to make the properselection.

Step 3 — Prepare Unit Mounting SupportSlab Mount —Provide a level concrete slab that extends a minimum of 6in. (150 mm) beyond unit cabinet. Install a gravel apron in

front of condenser coil air inlet to prevent grass and foliagefrom obstructing airflow.

Step 4 − Rig and Mount the Unit


Failure to follow this caution may result in equipmentdamage.All panels must be in place when rigging. Unit is notdesigned for handling by fork truck.

RIGGING — These units are designed for overheadrigging. Refer to the rigging label for preferred riggingmethod. Spreader bars are not required if top crating is lefton the unit. All panels must be in place when rigging. Asfurther protection for coil faces, plywood sheets may beplaced against the sides of the unit, behind cables. Runcables to a central suspension point so that the angle fromthe horizontal is not less than 45 degrees. Raise and set theunit down carefully.

If it is necessary to roll the unit into position, mount the uniton longitudinal rails, using a minimum of 3 rollers. Applyforce to the rails, not the unit. If the unit is to be skidded intoposition, place it on a large pad and drag it by the pad. Donot apply any force to the unit.

Raise from above to lift the unit from the rails or pad whenunit is in its final position.

After the unit is in position, remove all shipping materialsand top crating.

Step 5 — Complete Refrigerant PipingConnections



Do not bury refrigerant piping underground.



A refrigerant receiver is not provided with the unit. Do notinstall a receiver.

PROVIDE SAFETY RELIEF — The unit is provided with afusible joint in the suction line in accordance with applicableUL standards for pressure relief. If local codes dictate anadditional safety relief device, purchase locally and installlocally. Installation will require the recovery of the factoryshipping charge before the factory tubing can be cut andthe supplemental relief device is installed.

SIZE REFRIGERANT LINES — Consider the linear length(actual tubing length) of piping required between theoutdoor unit and indoor unit (evaporator), the amount ofliquid lift (indoor section installed above the outdoor


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section), and compressor oil return. Consider and identifyalso the arrangement of the tubing path (quantity and typeof elbows in both lines), liquid line solenoid size, filter drierand any other refrigeration specialties located in the liquidline. Refer to the indoor unit installation instructions foradditional details.

Determine equivalent line (linear length plus equivalentlength of elbows) length adjustments for path andcomponents and add to linear line lengths. See Table 2 andTable 3. Refer to the indoor unit installation instructions foradditional information

Suction line sizing – Select a tube size that produces asuction pressure drop in range of 1.5 to 3.0�F (0.8 to1.7�C). (Higher pressure drops are permissible but therewill be a loss in cooling capacity due to the higher pressuredrop.) Insulate the suction line.

Liquid line sizing – For linear line lengths up to 50−ft (15 m),select a tube size that produces a liquid pressure drop ofapproximately 2�F (1.1�C). For linear line lengths greaterthan 50−ft (15 m), select a line size that will permit the liquidstate−point subcooling entering the indoor coil’s TXV to bea minimum of 2�F (1.1�C).

Note that refrigerant suction piping should be insulated.


Failure to follow this caution may result in equipmentdamage.For applications with liquid lift greater than 20 ft (6m), use5/8 in liquid line. Maximum lift is 60 ft (18m).

Table 2 Liquid Line Data − 60 Hz

MAXIMUMALLOWABLELIQUID LIFT

ft(m)

MaximumAllowable

Pressure Drop psig (kPa)

MaximumAllowable Temp.

Loss�F( �C)

60 (18) 7 (48) 2 (1)* Inlet and outlet

NOTE: Data shown is for units operating at 45�F (7.2�C)saturated suction temperature and 95�F (35�C) enteringair temperature. For applications with liquid lift greater than20 ft (6 m), use 5/8−in. liquid line. Maximum lift is 60 ft (18m).

Table 3 Refrigerant Piping Sizes − 60 Hz units

UNIT

LINEAR LENGTH OF INTERCONNECTINGPIPING — FT (m)

0−25(0−7.5)

25−50(7.5−15)

50−75(15−23)

75−100(23−30)*

Line Size (in. OD)

L S L S L S L S

072 3/8 11/8 3/8 11/8 3/8 11/8 3/8 11/8091 3/8 11/8 1/2 11/8 1/2 11/8 1/2 13/8

121 1/2 13/8 1/2 13/8 1/2 13/8 1/2 13/8151 1/2 13/8 1/2 13/8 1/2 13/8 1/2 13/8

LEGENDL — Liquid LineS — Suction Line*Field−supplied suction accumulator required for pipe length75−100 ft (23−30 m).NOTES:

1. Pipe sizes are based on a 2�F (1�C) saturatedtemperature loss for liquid and suction lines.

2. Pipe sizes are based on the maximum linear length,shown for each column, plus a 50% allowance forfittings.

3. Charge unit with R−410A and verify that subcooledliquid exists at TXV by checking for a full liquid linesight glass or by calculating subcooling at TXV.

INSTALL FILTER DRIER(S) AND MOISTUREINDICATOR(S) — Every unit should have a filter drier anda liquid−moisture indicator (sight glass). Refer to Table 4.In some applications, depending on space andconvenience requirements, it may be desirable to install 2filter driers and sight glasses. One filter drier and sightglass may be installed at A locations in Figure 3; or, 2 filterdriers and sight glasses may be installed at B locations.

Select the filter drier for maximum unit capacity andminimum pressure drop. Complete the refrigerant pipingfrom the indoor unit to the outdoor unit before opening theliquid and suction lines at the outdoor unit.

INSTALL LIQUID LINE SOLENOID VALVE — SOLENOIDDROP — It is recommended that a solenoid valve beplaced in the main liquid line (see Figure 3) between thecondensing unit and the evaporator coil. Refer to Table 4.(A liquid line solenoid valve is required when the liquid linelength exceeds 75 ft [23 m]. This valve prevents refrigerantmigration (which causes oil dilution) to the compressorduring the off cycle, at low outdoor ambient temperatures.Wire the solenoid in parallel with the compressor contactorcoil (see Figure 3). This means of electrical control isreferred to as solenoid drop control.

INSTALL LIQUID LINE SOLENOID VALVE (Optional) —CAPACITY CONTROL — If 2−step cooling is desired,place a solenoid valve in the location shown in Figure 3.

MAKE PIPING CONNECTIONS — Piping connections atthe unit are ball valves with stub tube extensions. Do notopen the unit service valves until all interconnecting tubebrazing has been completed and properly evacuated.

The stub tube service valve connections include 1/4−inSAE service fittings with Schrader valve cores (seeFigure 4). Before making any brazed connections to theunit service valves, remove both Schrader valve caps andcores and save for re−installation. Connect a source fornitrogen to one of these service fittings during tube brazingto prevent the formation of copper oxides inside the tubesat brazed joints.

When connecting and then brazing the field tubing to theservice valves, wrap the valves in wet rags to preventoverheating.


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Table 4 Refrigerant Specialties Part Numbers

UNIT LIQUID LINESIZE (in.)

LIQUID LINESOLENOID

VALVE (LLSV)LLSV COIL SIGHT GLASS FILTER

DRIERSUCTION LINE

ACCUMULATOR

072 3/8 1178274

1178273

1178270 1178266* 1178265

0913/8 1178274 1178270 1178266* 11782651/2 1178275 1178271 1178266 1178265

121 1/2 1178276 1178271 1178267* 1178264

151 5/8 1178277 1178272 1178267* 1178264

* Bushings required.

Figure 3 Location of Sight Glass and Filter Drier

Representative drawing only.

Figure 4 Typical Piping Connection Assembly

Factory High-FlowAccess Port

Service Valvewith Stem Cap

Field ServiceAccess Port(Schradercore)

SweatConnection

Pressure−test all joints from outdoor unit connections overto the evaporator coil, using nitrogen as pressure and withsoap and−bubbles.

When pressure−testing is completed, remove the nitrogensource at the outdoor unit service valves and re−install thetwo Schrader valve cores. Torque the cores to 2−3 in−lbs(23−34 N−cm).

EVACUATION/DEHYDRATION — Evacuate anddehydrate the connected refrigeration system, to 500microns, using a two−stage vacuum pump attached to theservice ports outside the service valves, followingdescription in GTAC II, Module 4, System Dehydration.

! WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personal in-jury, death and/or equipment damage.

R−410A systems operate at higher pressures than R−22systems. When working with R−410A systems, use onlyservice equipment and replacement components specif-ically rated or approved for R−410A service.

PRELIMINARY CHARGE — Before starting the unit,charge R−410A liquid refrigerant into the high side of thesystem through the liquid service valve. The amount ofrefrigerant added must be at least 80% of the operatingcharge listed in the Physical Data table (Tables 1A and 1B,pages 4 and 5) LESS the factory charge quantity (if factoryshipping charge has not been removed). Allow high andlow side pressures to equalize. If pressures do not equalizereadily, charge R−410A vapor (using special servicemanifold with expansion device) into the suction lineservice port for the low side of system to assure charge inthe evaporator. Refer to GTAC II, Module 5, Charging,Recover, Recycling, and Reclamation for liquid chargingprocedures.


10 501 01 3001 00

Step 6 — Install AccessoriesAccessories requiring modifications to unit wiring shouldbe completed now. These accessories may include WinterStart controls, Low Ambient controls, phase monitor,Compressor LOCout. Refer to the instructions shipped withthe accessory.

Step 7 — Complete Electrical Connections

! WARNINGELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personalinjury or death.

Do not use gas piping as an electrical ground. Unitcabinet must have an uninterrupted, unbroken electricalground to minimize the possibility of personal injury if anelectrical fault should occur. This ground may consist ofelectrical wire connected to unit ground lug in controlcompartment, or conduit approved for electrical groundwhen installed in accordance with NEC (NationalElectrical Code); ANSI/ NFPA 70, latest edition (inCanada, Canadian Electrical Code CSA [CanadianStandards Association] C22.1), and local electricalcodes.

NOTE: Check all factory and field electrical connections fortightness. Field−supplied wiring shall conform with thelimitations of 63�F (33�C) rise.All units except 208/230−v units are factory wired for thevoltage shown on the nameplate. If the 208/230−v unit isto be connected to a 208−v power supply, the controltransformer located in the unit control box must be rewiredby moving the black wire with the 1/4−in. female spadeconnector from the 230−v connection and moving it to the208−v 1/4−in. male terminal on the primary side of thetransformer. Refer to unit label diagram for to line−sideinformation. Field power wires will be connected line−sidepressure lugs on the power terminal block or at factoryinstalled option non−fused disconnect.Field power wires are connected to the unit at the leads tothe factory test connection leads (pigtails) in the unit’s maincontrol box (see Figure 6) or at factory−installed optionnon−fused disconnect switch. Max wire size is #4 AWG(copper only).NOTE: TEST LEADS − Unit may be equipped with shortleads (pigtails) on the field line connection points on theoptional disconnect switch. These leads are for factoryrun−test purposes only; remove and discard beforeconnecting field power wires to unit connection points.

! WARNINGFIRE HAZARDFailure to follow this warning could result in intermittentoperation or performance satisfaction.Do not connect aluminum wire between disconnectswitch and condensing unit. Use only copper wire. (SeeFigure 5)

Figure 5 Disconnect Switch and Unit

SWITCH

ALUMINUMWIRE

COPPER

WIRE ONLY

Units Without Factory−Installed Disconnect — Wheninstalling units, provide a disconnect switch per NEC(National Electrical Code) of adequate size. Disconnectsizing data is provided on the unit informative plate. Locateon unit cabinet or within sight of the unit per national or localcodes. Do not cover unit informative plate if mounting thedisconnect on the unit cabinet.

Units with Factory−Installed Disconnect — Thefactory−installed option disconnect switch is located in aweatherproof enclosure located under the main controlbox. The manual switch handle is accessible through anopening in the access panel.

All units − All field wiring must comply with NEC and all localcodes. Size wire based on MCA (Minimum Circuit Amps)on the unit informative plate. See Figure 6 for power wiringconnections to the unit power terminal block andequipment ground.

Provide a ground−fault and short−circuit over−currentprotection device (fuse or breaker) per NEC Article 440 (orlocal codes). Refer to unit informative data plate for MOCP(Maximum Over−current Protection) device size.

Figure 6 Power Wiring Connections

Ground Lug

Splice Terminals

(field supplied)

DISCONNECT

BLK

YEL

BLU

LEGEND

Factory Power Connection Lead

Field Power Supply Conductor

All field wiring must comply with the NEC and localrequirements.


11501 01 3001 00

Affix the crankcase heater warning sticker to the unitdisconnect switch.

Convenience Outlets —

! WARNING

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result in personal in-jury or death.

Units with convenience outlet circuits may use multipledisconnects. Check convenience outlet for power statusbefore opening unit for service. Locate its disconnectswitch, if appropriate, and open it. Tag−out this switch,if necessary.

One type of convenience outlet is offered on all models:Non−powered. The outlet provide a 125−volt GFCI(ground−fault circuit−interrupter) duplex receptacle ratedat 15−A behind a hinged waterproof access cover, locatedon the end panel of the unit. See Figure 7.

Figure 7 Convenience Outlet Location

ConvenienceOutletGFCI

Control BoxAccess Panel

Non−powered type: This type requires the field installationof a general−purpose 125−volt 15−A circuit powered froma source elsewhere in the building. Observe national andlocal codes when selecting wire size, fuse or breakerrequirements and disconnect switch size and location.Route 125−v power supply conductors into the bottom ofthe utility box containing the duplex receptacle.

Using unit−mounted convenience outlets: Units with unitmounted convenience outlet circuits will often require thattwo disconnects be opened to de−energize all power to theunit. Treat all units as electrically energized until theconvenience outlet power is also checked andde−energization is confirmed. Observe National ElectricalCode Article 210, Branch Circuits, for use of convenienceoutlets.

Installing Weatherproof Cover –A weatherproof while−in−use cover for thefactory−installed convenience outlets is now required byUL standards. This cover cannot be factory−mounted dueits depth; it must be installed at unit installation. For

shipment, the convenience outlet is covered with a blankcover plate.

The weatherproof cover kit is shipped in the unit’s controlbox. The kit includes the hinged cover, a backing plate andgasket.

DISCONNECT ALL POWER TO UNIT ANDCONVENIENCE OUTLET.

Remove the blank cover plate at the convenience outlet;discard the blank cover.

Loosen the two screws at the GFCI duplex outlet, untilapproximately 1/2−in (13 mm) of screw heads areexposed. Press the gasket over the screw heads. Slip thebacking plate over the screw heads at the keyhole slots andalign with the gasket; tighten the two screws until snug (donot over−tighten).

Mount the weatherproof cover to the backing plate asshown in Figure 8. Remove two slot fillers in the bottom ofthe cover to permit service tool cords to exit the cover.Check for full closing and latching.

Figure 8 Weatherproof Cover Installation

RECEPTACLE

NOT INCLUDED

COVER WHILE-IN-USE

WEATHERPROOF

BASE PLATE FOR

GFCI

RECEPTACLE

CONVENIENCEOUTLETCOVER

All Units — Voltage to compressor terminals duringoperation must be within voltage range indicated on unitnameplate. See Table 5. On 3−phase units, voltagesbetween phases must be balanced within 2% and thecurrent within 10%. Use the formula shown in the legend forTable 5, Note 5 (see page 13) to determine the percent ofvoltage imbalance. Operation on improper line voltage orexcessive phase imbalance constitutes abuse and maycause damage to electrical components. Such operationwould invalidate any applicable warranty.

The unit requires an external temperature control device.This device can be a thermostat (field−supplied) or athermostat emulation device provided as part of athird−party Building Management System.

Thermostat — Install an accessory commercial thermostataccording to installation instructions included with theaccessory. For complete economizer function, select atwo—stage cooling thermostat. Locate the thermostataccessory on a solid wall in the conditioned space to senseaverage temperature in accordance with the thermostatinstallation instructions.


12 501 01 3001 00

If the thermostat contains a logic circuit requiring 24−vpower, use a thermostat cable or equivalent single leads ofdifferent colors with minimum of four leads. If thethermostat does not require a 24−v source (no “C”connection required), use a thermostat cable or equivalentwith minimum of three leads. Check the thermostatinstallation instructions for additional features which mightrequire additional conductors in the cable.

For wire runs up to 50 ft. (15 m), use no. 18 AWG (AmericanWire Gage) insulated wire (35�C minimum). For 50 to 75ft. (15 to 23 m), use no. 16 AWG insulated wire (35�Cminimum). For over 75 ft. (23 m), use no. 14 AWG insulatedwire (35�C minimum). All wire sizes larger than no. 18AWG cannot be directly connected to the thermostat andwill require a junction box and splice at the thermostat.

Figure 9 Typical Remote Thermostat Connections

X

C

G

W2

W1

R

Y2

Y1

X

C

G

W2

W1

R

Y2

Y1

Thermostat

Terminal

Board

Note 1: Typical multi−function marking. Follow manufacturer’sconfiguration instructions to select Y2.

Note 2: Y2 to economizer required on single−stage cooling unitswhen integrated economizer function is desired

Note 3: Connect only if thermostat requires 24−vac power source.Field Wiring

CONTROL CIRCUIT WIRING — Control voltage is 24 v.See Figure 6 and the unit’s label diagram for field−suppliedwiring details. Route control wires through the opening inunit’s end panel to the connection in the unit’s control box.

CONTROL TRANSFORMER WIRING — On multivoltageunits, check the transformer primary wiring connections.See Figure 10 or refer to the unit’s label diagram.

If the unit will be operating at 208−3−60 power, remove theblack wire (BLK) from the transformer primary connectionlabelled “230” and move it to the connection labelled “208”.See Figure 10.

Figure 10 Control Transformer Wiring


13501 01 3001 00

Table 5 Electrical Data — 60 Hz Units

UNITCAS

NOMINALVOLTAGE

VOLTAGE RANGE* COMPRESSORFAN MOTORS

(Qty 2)POWER SUPPLY

MIN MAX RLA LRA FLA (ea) LRA (ea) MCA MOCP

072208/230-3-60 187 253 19 123 1.5 3.7 25.2 45

460-3-60 414 506 9.7 62 0.8 1.9 12.9 20575-3-60 518 633 7.4 50 0.6 1.6 9.9 15

091208/230-3-60 187 253 25 164 1.5 3.7 32.7 50

460-3-60 414 506 12.2 100 0.8 1.9 16 25575-3-60 518 633 9 78 0.6 1.6 11.8 20

121208/230-3-60 187 253 30.1 225 1.5 3.7 39.1 60

460-3-60 414 506 16.7 114 0.8 1.9 21.7 30575-3-60 518 633 12.2 80 0.6 1.6 15.8 25

151208/230-3-60 187 253 48.1 245 1.5 3.7 61.6 80

460-3-60 414 506 18.6 125 0.8 1.9 24 30575-3-60 518 633 14.7 100 0.6 1.6 19 30

FLA — Full Load AmpsLRA — Locked Rotor AmpsMCA — Minimum Circuit AmpsMOCP — Maximum Overcurrent ProtectionNEC — National Electrical CodeRLA — Rated Load Amps

*Units are suitable for use on electrical systems where voltage supplied to the unit terminals is not below or above the listed limits.NOTES:1. The MCA and MOCP values are calculated in accordance with the NEC, Article 440.2. Motor RLA and LRA values are established in accordance with Underwriters’ Laboratories (UL), Standard 1995.3. The 575−v units are UL, Canada−listed only.4. Convenience outlet is available as a factory−installed option and is 115−v, 1 ph, 60 Hz.5. Unbalanced 3−Phase Supply VoltageNever operate a motor where a phase imbalance in supplyvoltage is greater than 2%. Use the following formula to determinethe percentage of voltage imbalance.

% Voltage Imbalance = 100 xmax voltage deviation from average voltage

average voltage

Example: Supply voltage is 230-3-60

AB = 224 vBC = 231 vAC = 226 v

Average Voltage =(224 + 231 + 226)

=681

3 3

= 227

Determine maximum deviation from average voltage.(AB) 227 – 224 = 3 v(BC) 231 – 227 = 4 v(AC) 227 – 226 = 1 vMaximum deviation is 4 v.Determine percent of voltage imbalance.

% Voltage Imbalance = 100 x4

227

= 1.76%

This amount of phase imbalance is satisfactory as it is below themaximum allowable 2%.IMPORTANT: If the supply voltage phase imbalance is more than 2%,contact your local electric utility company immediately.


14 501 01 3001 00

PRE−START−UP


Failure to follow this caution may result in equipmentdamage.Before beginning Pre−Start−Up or Start−Up, reviewStart−Up Checklist at the back of this book. TheChecklist assures proper start−up of a unit and providesa record of unit condition, application requirements,system information, and operation at initial start−up.

! CAUTIONUNIT DAMAGE HAZARD

Failure to follow this caution may result in equipmentdamage.Do not attempt to start the condensing unit, evenmomentarily, until the following steps have beencompleted. Compressor damage may result.

System Check1. Check all air handler(s) and other equipment

auxiliary components. Consult the manufacturer’sinstructions regarding any other equipmentconnected to the condensing unit. If the unit hasfield−installed accessories, be sure all are properlyinstalled and correctly wired. If used, the airflowswitch must be properly installed.

2. Be sure the unit is properly leak checked anddehydrated.

3. Check tightness of all electrical connections.

4. Open the liquid line and suction line service valves.

5. Be sure the unit is properly charged. See “PreliminaryCharge”, on page 9.

6. The electrical power source must agree with theunit’s nameplate rating.

7. The crankcase heater should be firmly attached tothe compressor crankcase. Be sure the crankcase iswarm (heater must be on for 24 hours before startingcompressor).

Energize the Crankcase Heater — Turn on the crankcaseheater for 24 hours before starting the unit to be sure all therefrigerant is out of the oil. To energize the crankcaseheater, proceed as follows:

1. Set the space thermostat set point above the spacetemperature so there is no demand for cooling.

2. Close the field disconnect.

NOTE: Make sure that thermostat leads are isolatedfrom the Low Voltage terminal block when energizingCrankcase Heater for 24 hours. This insures compressorwill not operate.

Preliminary Charge — Before starting the unit, chargeliquid refrigerant into the high side of the system through a

manifold gauge set then the liquid service valve. Theamount of refrigerant added must be at least 80% of theoperating charge listed in the Physical Data table (Tables1A and 1B, pages 4 and 5). Allow high and low sidepressures to equalize before starting compressor. Ifpressures do not equalize readily, charge vapor on low sideof system to assure charge in the evaporator. Refer toGTAC II, Module 5, Charging, Recover, Recycling, andReclamation for liquid charging procedures.


Failure to follow this caution may result in equipmentdamage.Prior to starting compressor, a preliminary charge ofrefrigerant must be added to avoid possible compressordamage (approximately 80% total refrigerant capacity).

START−UPThe compressor crankcase heater must be on for 24 hoursbefore start−up. After the heater has been on for 24 hours,the unit can be started.

PRELIMINARY CHECKS

1. Check that electric power supply agrees with unitnameplate data.

2. Verify that the compressor crankcase heater issecurely in place.

3. Check that the compressor crankcase heater hasbeen on at least 24 hours.

4. Recheck for leaks using the procedure outlined in thePre−Start−Up section, Leak Test and Dehydration. Ifany leaks are detected, repair as required. Evacuateand dehydrate as described in the Leak Test andDehydration section.

5. Ensure that the preliminary charge has been addedas described in the Pre−Start−Up section,Preliminary Charge.

6. All internal wiring connections must be tight, and allbarriers and covers must be in place.

NOTE: The units are factory charged with the requiredamount of oil. If recharging is required, use Emkarate RL32−3MAF for the units.

COMPRESSOR ROTATION — On 3−phase units withscroll compressors, it is important to be certain that thecompressor is rotating in the proper direction. To determinewhether or not compressor is rotating in the properdirection:

1. Connect service gages to the suction and liquidpressure fittings.

2. Energize the compressor.3. The suction pressure should drop and the liquid

pressure should rise, as is normal on any start−up.If the suction pressure does not drop and the liquidpressure does not rise to normal levels:

1. Turn off power to the unit, tag disconnect.2. Reverse any two of the unit power leads.3. Reapply power to the compressor, verify correct

pressures.


15501 01 3001 00

The suction and liquid pressure levels should now move totheir normal start−up levels.

COMPRESSOR OVERLOAD — This overload interruptspower to the compressor when either the current or internalmotor winding temperature becomes excessive, andautomatically resets when the internal temperature dropsto a safe level. This overload may require up to 60 minutes(or longer) to reset. If the internal overload is suspected ofbeing open, disconnect the electrical power to the unit andcheck the circuit through the overload with an ohmmeter orcontinuity tester.

Temperature Overload Device (TOD) is a thermal disktemperature device embedded into the ZP61 and ZP83compressor scroll plates. This device once opened willbypass hot gas into the motor windings opening the motorthermal protector. If this device opens, the compressor mayoperate with some difference in suction and liquidpressures as measured with a manifold gauge set. Thisdevice is auto−resetting and may take up to 60+ minutesto reset.

ADVANCED SCROLL TEMPERATURE PROTECTION(ASTP) — Advanced Scroll Temperature Protection(ASTP) is a form of internal discharge temperatureprotection, used in 10 and 12.5 Ton units, that unloads thescroll compressor when the internal temperature reachesapproximately 300�F. At this temperature, an internalbi−metal disk valve opens and causes the scroll elementsto separate, which stops compression. Suction anddischarge pressures balance while the motor continues torun. The longer the compressor runs unloaded, the longerit must cool before the bi−metal disk resets. See Figure 11.

Figure 11Recommended Minimum Cool−Down Time After Compressor isStopped

0

10

20

30

40

50

60

70

80

90

100

110

120

0 10 20 30 40 50 60 70 80 90

Compressor Unloaded Run Time (Minutes)

Rec

omm

ende

d C

ooli

ng T

ime

(Min

utes

)

*Times are approximate.

NOTE: Various factors, including high humidity, highambient temperature, and the presence of a sound blanketwill increase cool−down times.

To manually reset ASTP, the compressor should bestopped and allowed to cool. If the compressor is notstopped, the motor will run until the motor protector trips,which occurs up to 90 minutes later. Advanced ScrollTemperature Protection will reset automatically before themotor protector resets, which may take up to 2 hours. Alabel located above the terminal box identifies Copeland

Scroll compressor models (ZP103 and ZP137) that containthis technology. See Figure 12.

Figure 12 Advanced Scroll TemperatureProtection Label

START UNIT — The field disconnect is closed, the indoorfan circuit breaker is closed, and the space thermostat isset above ambient so that there is no demand for cooling.Only the crankcase heater will be energized.

Reset the space thermostat below ambient so that a call forcooling is applied.


Failure to follow this caution may result in equipmentdamage.Never charge liquid into the low−pressure side ofsystem. Do not overcharge. During charging or removalof refrigerant, be sure indoor−fan system is operating.Ensure both outdoor fan motors are running; bypass anylow ambient control function.

ADJUST REFRIGERANT CHARGE — The unit must becharged in Cooling mode only. Refer to Cooling ChargingCharts, Figure 13 through Figure 16. For applications withline lengths greater than 100 ft, contact the distributor. Varyrefrigerant until the conditions of the chart are met. Notethat the charging charts are different from the type normallyused. The charts are based on charging the units to thecorrect subcooling for the various operating conditions.Accurate pressure gage and temperature sensing deviceare required. Connect the pressure gage to the service porton the liquid line service valve. Mount the temperaturesensing device on the liquid line close to the liquid lineservice valve, and insulate it so that outdoor ambienttemperature does not affect the reading. Indoor airflowmust be within the unit’s normal operating range. Operatethe unit for a minimum of 15 minutes. Ensure that pressureand temperature readings have stabilized. Plot the liquidpressure and temperature on chart and add or reduce thecharge to meet the curve. Adjust the charge to conform withthe charging chart, using the liquid pressure andtemperature to read the chart.

FINAL CHECKS — Ensure that all safety controls areoperating, control panel covers are on, and the servicepanels are in place.


16 501 01 3001 00

Figure 13 6 Ton Charging Chart

072 CHARGING CHART R−410A ALL CONDENSER FANS OPERATING072

Figure 14 7.5 Ton Charging Chart

091091 CHARGING CHART R−410A ALL CONDENSER FANS OPERATING

Figure 15 10 Ton Charging Chart



17501 01 3001 00

Figure 16 12.5 Ton Charging Chart


Figure 17 Wiring Diagram

OPTIONAL


18 501 01 3001 00

OPERATING SEQUENCEBase Unit Controls

Indoor (Supply) Fan

The indoor fan contactor (IFC) is remotely located at the fancoil or fan section. If the thermostat fan operation isselected as Continuous, the IFC is energized and theindoor (supply) fan motor runs continuously. If thethermostat fan operation is selected as Automatic, the IFCwill be energized on a call for Cooling; indoor (supply) fanmotor runs. When thermostat call for Cooling is satisfied,the IFC is de−energized and indoor (supply) fan motorstops.

Cooling, Unit Without Economizer

On a thermostat call for Cooling, IFC will be energized andindoor (supply) fan motor runs. Thermostat contact TC1closes; terminal Y1 receives 24−v. 24−v received at CADMterminal Y. If anti−recycle time delay period has not expired,CADM relay will remain open, preventing compressor start.

When safety pressure switches are closed, the liquid linesolenoid valve opens. When CADM time delay expires (3minutes), the compressor contactor is energized; bothoutdoor fan motors start and compressor starts. Whenspace cooling load is satisfied, thermostat contacts TC1open, removing 24−v at terminal Y. Compressor andoutdoor fan motors stop. Liquid line solenoid valve isde−energized and valve closes. CADM begins itsthree−minute anti−recycle time delay.

If either the Low Pressure Switch or High Pressure Switchopens while thermostat contact TC1 remains closed, thecompressor contactor is de−energized (both fan motorsand compressor stop) and liquid line solenoid isde−energized (valve closes). CADM initiates a TRIP event(cooling demand sensed at CADM terminal Y but nocurrent is measured at T1, T2, T3 motor sensors); CADMrelay opens and RED LED is illuminated. TRIP conditionmaintains lockout of compressor operation until CADM ismanually reset. Reset CADM by cycling unit main power.

Complete system shutdown may be caused by loss of mainpower, open compressor internal overload, openlow−pressure or high−pressure switch, or a fault detectedby the CADM logic. Compressor operation without coolingmay indicate the compressor’s TOD or ASTP feature isactive (unit sizes 12 and 14 only); disconnect unit powerand allow compressor to cool. See Service section forfurther details.

Cooling, Unit with EconomizerRefer to fan coil unit installation instructions andeconomizer accessory installation instructions foroperating sequences when system is equipped withaccessory economizer.

HeatingRefer to fan coil unit installation instructions and accessoryheating device installation instructions for operatingsequences in heating mode.

ROUTINE SYSTEM MAINTENANCEThese items should be part of a routine maintenanceprogram, to be checked every month or two, until a specificschedule for each can be identified for this installation:Quarterly Inspection (and 30 days after initial start)

Indoor section� Condenser coil cleanliness checked.� Return air filter replacement

� Outdoor hood inlet filters cleaned� Belt tension checked

� Belt condition checked� Pulley alignment checked

� Fan shaft bearing locking collar tightness checked� Condensate drain checked

Seasonal MaintenanceThese items should be checked at the beginning of eachseason (or more often if local conditions and usagepatterns dictate):

Air Conditioning� Condenser fan motor mounting bolts tightness� Compressor mounting bolts

� Condenser fan blade positioning� Control box cleanliness and wiring condition

� Wire terminal tightness� Refrigerant charge level

� Evaporator coil cleaning� Evaporator blower motor amperage

Heating� Power wire connections

� Fuses ready� Manual−reset limit switch is closed

Economizer or Outside Air Damper� Inlet filters condition� Check damper travel (economizer)

� Check gear and dampers for debris and dirt

SERVICEComfort Alert Diagnostic ModuleThe Comfort Alert Diagnostic Module (CADM) monitorsand analyzes data from the Copeland Scroll� three−phasecompressor and the thermostat demand. The CADM alsoprovides a 3−minute anti−recycle time delay to compressorcycling. The CADM detects causes for electrical andsystem related failures without any sensors. FlashingLEDs communicate the Alert codes to guide servicetechnicians in accurately and quickly troubleshooting thesystem and determining root cause for the failure. Inputs tothe CADM include 24−vac power, thermostat Y1,


19501 01 3001 00

compressor contactor coil (common side) and compressorpower leads (from the compressor contactor)

Input Terminal Voltage

Control Power R 24V

Control Common C 24V

Cooling Y 24V

Contactor Coil P 24V

Line A T1 Line

Line B T2 Line

Line C T3 Line

Control of the compressor contactor coil is through anormally−closed (power on the module) contact betweenterminals P and C.

Communications of status and alert conditions is throughthree LEDs located on the top edge of the module housing(see Figure 18): POWER (green), ALERT (yellow), andTRIP (red). The POWER LED indicates the presence ofcontrol power to the CADM.

Figure 18 CADM Housing/LED LocationsPOWER(GRN)

ALERT(YEL)

TRIP(RED)

The ALERT LED indicates an abnormal condition exists inthe system through a flash code. The ALERT LED will blinka number of times consecutively, pause and the repeat theprocess. The number of blinks, defined in Table 6,correlates to a particular abnormal condition;troubleshooting tips are provided for each Alert code.Reset of the ALERT may be automatic or manual. If thefault condition causing the Alert is self−corrected, the Alertcode will be removed and the CADM will automaticallyreset and allow the system to restart normally. Manualreset requires that main power to the unit be recycled afterthe cause for the Alert condition has been detected andcorrected.

The TRIP LED indicates either a time−delay period iscurrently active (RED LED is blinking) or the module haslocked out the compressor (RED LED is on steady). Alockout condition will occur when the CADM detects athermostat demand at input Y but there is no power at thecompressor line terminals T1 or T2 or T3. This lockout canoccur due to a safety switch (LPS or HPS) opening andde−energizing the compressor contactor, thecompressor−motor internal overload opens, or otherinternal power interruption has occurred. Reset of the TRIPLED requires that unit main power be recycled after theloss of power to the compressor condition has beendetected and corrected.

Simultaneous Blinking of YELLOW and RED LEDsindicates control power input to the CADM is low. Checkcontrol circuit transformer and wiring.

Troubleshooting the CADM Wiring – Flashing LEDs alsoindicate wiring problems to the CADM. See Table 7 fordiscussion of additional LED flash codes andtroubleshooting instructions.


20 501 01 3001 00

Table 6 LED Status Codes

Status LED Status LED Description Status LED Troubleshooting Information

Green “POWER” Module has power Supply voltage is present at module terminals

Red “TRIP”LED On Solid

Thermostat demand signal Yis present, but thecompressor is not running.

1. Compressor protector is open2. Condensing unit power disconnect is open3. Compressor circuit breaker or fuse(s) is open4. Broken supply wires or connector is not making contact5. Compressor power wires not routed through Comfort Alert6. Compressor contactor has failed open

Red “TRIP” LEDFlashing

The anti−short cycle timer (3 minutes), in module is preventing compressor restart.

Module locks out compressor when compressor damaging ALERT code appears.Lockout ALERT codes are noted in the Status LED Description.During a compressor lock out, 24VAC power must be removed from module to manually reset.Yellow “ALERT”LED On Solid

A short circuit or over currentcondition exists on PROTterminal.

1. Compressor contactor coil shorted2. Electrical load too high for PROT circuit (max1 Amp)3. 24 V AC wired directly to PROT terminal

Yellow “ALERT”Flash Code 2

System Pressure TripDischarge pressure out oflimits or compressoroverload (if no high pressureswitch in system)LOCKOUT

1. High head pressure2. Condenser coil poor air circulation (dirty, blocked, damaged)3. Condenser fan is not running4. If low pressure switch is open:Refer to Code 3 for troubleshooting


Short CyclingCompressor is running onlybriefly LOCKOUT

1. If low pressure switch is open:a. Low refrigerant chargeb. Evaporator blower is not runningc. Evaporator coil is frozend. Faulty metering devicee. Condenser coil is dirtyf. Liquid line restriction (filter drier blocked if present)2. If high pressure switch is open, go to Flash Code 2 in-formation3. Intermittent thermostat demand signal4. System or control board defective


Locked RotorLOCKOUT

1. Low line voltage to compressor2. Excessive liquid refrigerant in compressor3. Compressor bearings are seized


Open Circuit 1. Condensing unit power disconnect is open2. Compressor circuit breaker or fuses are open3. Compressor contactor has failed open4. High pressure switch is open and requires manual reset5. Broken supply wires or connector is not making contact6. Unusually long compressor protector reset time due toextreme ambient temperature7. Compressor windings are damaged


Missing PhaseLOCKOUT

1. Compressor fuse is open on one phase2. Broken wire or connector on one phase3. Compressor motor winding is damaged4. Utility supply has dropped one phase


Reverse PhaseLOCKOUT

1. Compressor running backward due to supplyphase reversal


Welded ContactorCompressor always runs

1. Compressor contactor has failed closed2. Thermostat demand signal not connected to module


Low VoltageControl circuit < 18VAC

1. Control circuit transformer is overloaded2. Low line voltage to compressor


21501 01 3001 00

Table 7 CADM Troubleshooting

Miswired Module Indication Recommended Troubleshooting Action

Green LED is not on,module does not power up

Determine if both R and C module terminals are connected. Verify voltage in presentat module’s R and C terminals.NOTE: The CADM requires a constant nominal 24VAC power supply. The wiring tothe module’s R and C terminals must be directly from the control transformer. Themodule cannot receive its power from another device that will interrupt the 24VACpower supply. See Figure 17, Wiring Diagram.

Green LED Intermittent,module powers up onlywhen compressor runs

Determine if R and Y terminals are wired in reverse. Verify module’s R and C termin-als have a constant source. See “NOTE” above for details on R and C wiring.

TRIP LED is on but systemand compressor check OK

Verify Y terminal is wired properly per the wiring diagram (see Figure 16). Verifyvoltage at contactor coil falls below 0.5VAC when off. Verify 24VAQC is presentacross Y and C when thermostat demand signal is present. If not, R and C are re-verse wired.

TRIP LED and ALERT LEDflashing together

Verify R and C terminals are supplied with 19−28VAC.

ALERT Flash Code 3(Compressor Short Cycling)displayed incorrectly

Verify Y terminal is connected to 24VAC at contactor coil. Verify voltage at contactorcoil falls below 0.5VAC when off.

ALERT Flash Code 5 or 6(Open Circuit, MissingPhase)displayed incorrectly

Check that compressor T1 and T3 wires are through module’s current sensing holes.Verify Y terminal is connected to 24VAC at contactor coil. Verify voltage at contactorcoil falls below 0.5VAC when off.

Alert Flash Code *(Welded Contactor)displayed incorrectly

Determine if module’s Y terminal is connected. Verify Y terminal is connected to24VAC at contactor coil. Verify 24VAC is present across Y and C when thermostatdemand signal is present. If not, R and C are reverse wired. Verify voltage at contact-or coil falls below 0.5VAC when off.

Crankcase Heater — The heater prevents refrigerantmigration and compressor oil dilution during shutdownwhenever compressor is not operating. The heater is wiredto cycle with the compressor; the heater is off whencompressor is running, and on when compressor is off.

The crankcase heater will operate as long as the powercircuit is energized.

Compressor ProtectionCOMPRESSOR OVERTEMPERATURE PROTECTION(IP) — A thermostat installed on the compressor motorwinding reacts to excessively high winding temperaturesand shuts off the compressor.

CRANKCASE HEATER — The heater minimizesabsorption of liquid refrigerant by oil in the crankcaseduring brief or extended shutdown periods. The maindisconnect must be on to energize the crankcase heater.

ADVANCED SCROLL TEMPERATURE PROTECTION(ASTP) — See “Advanced Scroll Temperature Protection(ASTP)” on page 15.

Low−Pressure Switch — The low−pressure switch isstem−mounted on the suction line. Switches are all fixed,non−adjustable type.

High−Pressure Switch — The high−pressure switch isstem−mounted on the discharge line. The switch is a fixed,non−adjustable type.

Outdoor Fans — Each fan is supported by a formed−wiremount bolted to the fan deck and covered with a wire guard.Fan motors have permanently lubricated bearings.

LubricationFAN MOTORS have sealed bearings. No provisions aremade for lubrication.

COMPRESSOR has its own oil supply. Loss of oil due to aleak in the system should be the only reason for adding oilafter the system has been in operation.

Coil Cleaning and Maintenance —To clean the condenser coil, chemicals are NOT to be used;only water is approved as the cleaning solution. Only cleanpotable water is authorized for cleaning condensers. Cleanthe coil as follows:

1. Turn off unit power.

2. Remove screws holding rear corner posts and topcover in place. Pivot top cover up 12 to 18 in. (305 to457 mm) and support with a rigid support. SeeFigure 19.


22 501 01 3001 00

Figure 19 Pivot and Support Top Cover

3. Carefully remove any foreign objects or debrisattached to the coil face or trapped within themounting frame and brackets.

4. Using a high pressure water sprayer, purge any soapor industrial cleaners from hose and/or dilution tankprior to wetting the coil. Clean condenser face byspraying the coil core steadily and uniformly from topto bottom, directing the spray straight into or towardthe coil face. Do not exceed 900 psig or a 45 degreeangle; nozzle must be at least 12 in. (30 cm) from thecoil face. Allow water to drain from the coil core andcheck for refrigerant leaks prior to start up.

5. Replace top cover and rear corner posts.

! CAUTIONPERSONAL INJURY HAZARD

Failure to follow this caution may result in personal injuryor equipment damage.Chemical cleaning should NOT be used on thealuminum microchannel condenser. Damage to the coilmay occur. Only approved cleaning is recommended.

Repairing Condenser Tube Leaks −FAST parts offers service repair kit Part Number 1178434for repairing tube leaks in the coil crosstubes. This kitincludes approved braze materials (aluminum fluxcorebraze rods), a heat shield, a stainless steel brush,replacement fin segments, adhesive for replacing finsegments, and instructions specific to the aluminum coil.See EPMS for instruction sheet 99TA526379.

The repair procedure requires the use of MAPP gas andtorch (must be supplied by servicer) instead ofconventional oxyacetylene fuel and torch. While the flametemperature for MAPP is lower than that of oxyacetylene(and thus provides more flexibility when working onaluminum), the flame temperature is still higher than themelting temperature of aluminum, so user caution isrequired. Follow instructions carefully. Use the heat shield.

Replacing Condenser Coil −The service replacement coil is preformed and is equippedwith transition joints with copper stub tubes. When brazingthe connection joints to the unit tubing, use a wet clotharound the aluminum tube at the transition joint. Avoidapplying torch flame directly onto the aluminum tubing.

Field Refrigerant Access Ports −Field service access to refrigerant pressures is through theaccess ports located at the service valves (see Figure 4).These ports are 1/4−in SAE Flare couplings with Schradercheck valves and service caps. Use these ports to admitnitrogen to the field tubing during brazing, to evacuate thetubing and evaporator coil, to admit initial refrigerantcharge into the low−side of the system and when checkingand adjusting the system refrigerant charge. When serviceactivities are completed, ensure the service caps are inplace and secure; check for leaks. If the Schrader checkvalve must be removed and re−installed, tighten to 2−3in−lbs (23−34 N−cm).

Factory High−Flow Access Ports −There are two additional access ports in the system − onthe suction tube between the compressor and the suctionservice valve and on the liquid tube near the liquid servicevalve (see Figure 4). These are brass fittings with blackplastic caps. The hose connection fittings are standard1/4−in SAE Male Flare couplings.

The brass fittings are two−piece High Flow valves, with areceptacle base brazed to the tubing and an integral springclosed check valve core screwed into the base. (SeeFigure 20) This check valve is permanently assembled intothis core body and cannot be serviced separately; replacethe entire core body if necessary. Service tools areavailable from the distributor or FAST parts that allow thereplacement of the check valve core without having torecover the entire system refrigerant charge. Applycompressor refrigerant oil to the check valve core’s bottomo−ring. Install the fitting body with 96 �10 in−lbs (1085�23 N−cm) of torque; do not overtighten. O−ring must bein place under the black plastic cap. Potential refrigerantleak may occur should this o−ring become missing ordeteriorated.


23501 01 3001 00

Figure 20 CoreMax Access Port Assembly

1/2-20 UNF RH

30º

0.596

SEAT CORE

WASHER DEPRESSOR PER ARI 720+�.01/�-.035FROM FACE OF BODY

7/16-20 UNF RH

O-RING

45º

1/2" HEX

This surface provides a metal to metal seal when torqued into the seat. Appropriate handling is required to not scratch or dent the surface.

(Part No. 1173177)

FASTENER TORQUE VALUESTable 8 Torque Values

Compressor mounting bolts 65–75 in–lbs (734–847 N–cm)

Condenser fan motor mounting bolts 20 �2 in–lbs (226 �23 N–cm)

Condenser fan hub setscrew 84 �2 in–lbs (949 �136 N–cm)

High−flow service port 96 �10 in–lbs (1085 �23 N–cm)

Schrader−type service check valve 2–3 in–lbs (23–34 N–cm)

TROUBLESHOOTINGPROBLEM SOLUTION

COMPRESSOR DOES NOT RUN

Contactor Open

1. Power off. 1. Restore power.

2. Fuses blown in field power circuit. 2. After finding cause and correcting, replace with cor

rect size fuse.

3. No control power. 3. Check control transformer primary connections and

circuit breaker.

4. Thermostat circuit open. 4. Check thermostat setting.

5. Safety device lockout circuit active. 5. Reset lockout circuit.

6. Low-pressure switch open. 6. Check for refrigerant undercharge, obstruction of

indoor airflow. Make sure liquid line solenoid valve(s)

is open.

7. High-pressure switch open. 7. Check for refrigerant overcharge, obstruction of

outdoor airflow, air in system. Be sure outdoor fans

are operating correctly.

8. Compressor overtemperature switch open. 8. Check for open condition. Allow for reset. Replace

if defective.

9. Loose electrical connections. 9. Tighten all connections.

10. Compressor stuck. 10. See compressor service literature.

Contactor Closed

1. Compressor leads loose. 1. Check connections.

2. Motor windings open. 2. See compressor service literature.

3. Single phasing. 3. Check for blown fuse. Check for loose connection

at compressor terminal.


24 501 01 3001 00

TROUBLESHOOTING (cont)PROBLEM SOLUTION

COMPRESSOR STOPS ON HIGH-PRESSURE SWITCH

Outdoor Fan On

1. High-pressure switch faulty. 1. Replace switch.

2. Reversed fan rotation. 2. Confirm rotation, correct if necessary.

3. Airflow restricted. 3. Remove obstruction.

4. Air recirculating. 4. Clear airflow area.

5. Noncondensables in system. 5. Recover refrigerant and recharge as required.

6. Refrigerant overcharge. 6. Recover refrigerant as required.

7. Line voltage incorrect. 7. Consult power company.

8. Refrigerant system restrictions. 8. Check or replace filter drier, expansion valve, etc.

Outdoor Fan Off

1. Fan slips on shaft. 1. Tighten fan hub setscrews.

2. Motor not running. 2. Check power and capacitor.

3. Motor bearings stuck. 3. Replace bearings.

4. Motor overload open. 4. Check overload rating. Check for fan blade obstruc

tion.

5. Motor burned out. 5. Replace motor.

COMPRESSOR CYCLES ON LOW-PRESSURE SWITCH

Indoor-Air Fan Running

1. Liquid line solenoid valve(s) fails to open. 1. Check liquid line solenoid valve(s) for proper opera

tion. Replace if

necessary.

2. Filter drier plugged. 2. Replace filter drier.

3. Expansion valve power head defective. 3. Replace power head.

4. Low refrigerant charge. 4. Add charge. Check low-pressure switch setting.

Airflow Restricted

1. Coil iced up. 1. Check refrigerant charge.

2. Coil dirty. 2. Clean coil fins.

3. Air filters dirty. 3. Clean or replace filters.

4. Dampers closed. 4. Check damper operation and position.

Indoor-Air Fan Stopped

1. Electrical connections loose. 1. Tighten all connections.

2. Fan relay defective. 2. Replace relay.

3. Motor overload open. 3. Power supply.

4. Motor defective. 4. Replace motor.

5. Fan belt broken or slipping. 5. Replace or tighten belt.

COMPRESSOR RUNNING BUT COOLING INSUFFICIENT

Suction Pressure Low

1. Refrigerant charge low. 1. Add refrigerant.

2. Head pressure low. 2. Check refrigerant charge. Check outdoor-air fan

thermostat settings.

3. Air filters dirty. 3. Clean or replace filters.

4. Expansion valve power head defective. 4. Replace power head.

5. Indoor coil partially iced. 5. Check low-pressure setting.

6. Indoor airflow restricted. 6. Remove obstruction.

Suction Pressure High

1. Unloaders not functioning 1. Check unloader adjustments. Check unloader set

ting.

2. Heat load excessive. 2. Check for open doors or windows in vicinity of fan

coil.

UNIT OPERATES TOO LONG OR CONTINUOUSLY

1. Low refrigerant charge. 1. Add refrigerant.

2. Control contacts fused. 2. Replace control.

3. Air in system. 3. Purge and evacuate system.

4. Partially plugged expansion valve or filter drier. 4. Clean or replace.


25501 01 3001 00

TROUBLESHOOTING (cont)SYSTEM IS NOISY

1. Piping vibration. 1. Support piping as required.

2. Compressor noisy. 2. Replace compressor if bearings are worn.

COMPRESSOR LOSES OIL

1. Leak in system. 1. Repair leak.

2. Crankcase heaters not energized during shutdown. 2. Check wiring and relays. Check heater and replace

if defective.

3. Improper interconnecting piping design. 3. Check piping for oil return. Replace if necessary.

FROSTED SUCTION LINE

Expansion valve admitting excess refrigerant. Adjust expansion valve.

HOT LIQUID LINE

1. Shortage of refrigerant due to leak. 1. Repair leak and recharge.

2. Expansion valve opens too wide. 2. Adjust expansion valve.

FROSTED LIQUID LINE

1. Restricted filter drier. 1. Remove restriction or replace.

2. Liquid line solenoid valve partially closed. 2. Replace valve.

APPENDIXAIR CONDITIONER AND HEAT PUMP WITH R−410A —QUICK REFERENCE GUIDE

� R−410A refrigerant operates at 50 percent to 70percent higher pressures than R−22. Be sure thatservicing equipment and replacement componentsare designed to operate with R−410A.

� R−410A refrigerant cylinders are rose colored.

� Recovery cylinder service pressure rating must be400 psig, DOT 4BA400 or DOT BW400.

� R−410A systems should be charged with liquidrefrigerant. Use a commercial type metering devicein the manifold hose when charging into suction linewith compressor operating.

� Manifold sets should be 700 psig high side and 180psig low side with 550 psig low−side retard.

� Use hoses with 700 psig service pressure rating.

� Leak detectors should be designed to detect HFCrefrigerant.

� R−410A, as with other HFCs, is only compatible withPOE oils.

� Vacuum pumps will not remove moisture from oil.� Use only factory specified liquid−line filter driers with

rated working pressures greater than 600 psig.� Do not install a suction−line filter direr in liquid−line.

� POE oils absorb moisture rapidly. Do not expose oilto atmosphere.

� POE oils may cause damage to certain plastics androofing materials.

� Wrap all filter driers and service valves with wet clothwhen brazing.

� A factory approved, liquid−line filter drier is requiredon every unit.

� Do not use an R−22 TXV.

� If indoor unit is equipped with a TXV, it must bechanged to a R−410A TXV.

� Never open system to atmosphere while it is under avacuum.

� When system must be opened for service, recoverrefrigerant, break vacuum with dry nitrogen beforeopening system.

� Always replace filter drier after opening system forservice.

� Do not vent R−410A into the atmosphere.� Do not use capillary tube coils.

� Observe all warnings, cautions, and bold text.� All R−410A heat pumps must have indoor TXV.� Do not leave R−410A suction line driers in place for

more than 72 hours.


26 501 01 3001 00

START-UP CHECKLIST

(SPLIT SYSTEMS WITH CAS UNITS)

I. PRELIMINARY INFORMATIONOUTDOOR: MODEL NO.

SERIAL NO.

INDOOR: MODEL NO.

SERIAL NO.

ADDITIONAL ACCESSORIES

II. PRE-START-UPOUTDOOR UNIT

IS THERE ANY SHIPPING DAMAGE? (Y/N)

IF SO, WHERE:

WILL THIS DAMAGE PREVENT UNIT START-UP? (Y/N)

IF OPERATING VOLTAGE IS 208 VOLTS THE CONTROL TRANSFORMER BLACK WIRE MUST BE CHANGED.

CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT? (Y/N)

HAS THE GROUND WIRE BEEN CONNECTED? (Y/N)

HAS THE CIRCUIT PROTECTION BEEN SIZED AND INSTALLED PROPERLY? (Y/N)

ARE THE POWER WIRES TO THE UNIT SIZED AND INSTALLED PROPERLY? (Y/N)

CONTROLS

ARE THERMOSTAT(S) AND INDOOR FAN CONTROL WIRINGCONNECTIONS MADE AND CHECKED? (Y/N)

ARE ALL WIRING TERMINALS (including main power supply) TIGHT? (Y/N)

HAVE OUTDOOR UNIT CRANKCASE HEATERS BEEN ENERGIZED FOR 24 HOURS? (Y/N)

INDOOR UNIT

IF POWER SUPPLY IS 208/230−3−60 VERIFY INDOOR FAN MOTOR IS WIRED TO SAME VOLTAGE OF INCOMING POWER;FACTORY WIRED FOR 460−3−60.

HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE? (Y/N)

ARE PROPER AIR FILTERS IN PLACE? (Y/N)

HAVE FAN AND MOTOR PULLEYS BEEN CHECKED FOR PROPER ALIGNMENT? (Y/N)

DO THE FAN BELTS HAVE PROPER TENSION? (Y/N)

PIPING

CAS UNITS

HAS FOAM SHIPPING BLOCK BEEN REMOVED FROM THE TXV (Thermostatic Expansion Valve)? (Y/N)

ARE LIQUID LINE SOLENOID VALVES LOCATED AT THE INDOOR UNIT COILS AS REQUIRED? (Y/N)

HAVE LEAK CHECKS BEEN MADE AT COMPRESSORS, CONDENSERS, INDOOR COILS,TXVs (Thermostatic Expansion Valves) SOLENOID VALVES, FILTER DRIERS, AND FUSIBLE PLUGSWITH A LEAK DETECTOR? (Y/N)

LOCATE, REPAIR, AND REPORT ANY LEAKS.

HAVE ALL COMPRESSOR SERVICE VALVES BEEN FULLY OPENED (BACKSEATED) (Y/N)

ARE THE COMPRESSOR OIL SIGHT GLASSES SHOWING CORRECT LEVELS? (Y/N)


27501 01 3001 00

CHECK VOLTAGE IMBALANCE

LINE-TO-LINE VOLTS: AB V AC V BC V

(AB + AC + BC)/3 = AVERAGE VOLTAGE = V

MAXIMUM DEVIATION FROM AVERAGE VOLTAGE = V

VOLTAGE IMBALANCE = 100 X (MAX DEVIATION)/(AVERAGE VOLTAGE) = %

IF OVER 2% VOLTAGE IMBALANCE, DO NOT ATTEMPT TO START SYSTEM!CALL LOCAL POWER COMPANY FOR ASSISTANCE.

III. START-UP

CHECK INDOOR FAN MOTOR SPEED AND RECORD.

AFTER AT LEAST 10 MINUTES RUNNING TIME, RECORD THE FOLLOWING MEASUREMENTS:

COMP A1 COMP B1

OIL PRESSURE

SUCTION PRESSURE

SUCTION LINE TEMP

LIQUID PRESSURE

LIQUID LINE TEMP

ENTERING OUTDOOR UNIT AIR TEMP

LEAVING OUTDOOR UNIT AIR TEMP

INDOOR UNIT ENTERING AIR DB TEMP

INDOOR UNIT ENTERING AIR WB TEMP

INDOOR UNIT LEAVING AIR DB TEMP

INDOOR UNIT LEAVING AIR WB TEMP

COMPRESSOR AMPS (L1/L2/L3) ____/____/____ ____/____/____

NOTES:

International Comfort Products, LLCLewisburg, TN 37091 USA

cas series split system 3 phase 6 to 12.5 ton ac …€¦ · cas series split system ... units.!...

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