CAS SERIES SPLIT SYSTEM 3 PHASE AC CONDENSERS - Installation, Start Up, and Service Instructions - 6 to 12.5 TON Save This Manual for Future Reference
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Installation, Start−Up, and
Service Instructions
CAS SERIES
SPLIT SYSTEM
3 PHASE
6 to 12.5 TON
AC CONDENSERS
Save This Manual for Future Reference
501 01 3001 00
04/24/09Installation Instructions Split System Condensers
TABLE OF CONTENTS ! WARNING
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PAGE
SAFE INSTALLATION REQUIREMENTS . . . . . . . . . . . . . 2 ELECTRICAL SHOCK HAZARD
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Failure to follow this warning could result in personal in-
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 jury or death.
Physical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Before performing service or maintenance operations
Unit Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 on unit, always turn off main power switch to unit and in-
Refrigerant Piping Connections . . . . . . . . . . . . . . . . . . . . 7 stall lockout tag. Unit may have more than one power
Installing Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 switch.
Typical Thermostat Connections . . . . . . . . . . . . . . . . . . 12
System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Start−Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Charging Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
! WARNING
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Operating Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 UNIT OPERATION AND SAFETY HAZARD
System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Failure to follow this warning could cause personal in-
LED Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 jury, death and/or equipment damage.
Cleaning and Maintenance . . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 R−410A systems operate at higher pressures than R−22
Start−Up Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 systems. When working with R−410A systems, use only
service equipment and replacement components specif-
SAFETY CONSIDERATIONS ically rated or approved for R−410A service.
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical
shock, or other conditions which may cause death,
! WARNING
personal injury, or property damage. Consult a qualified
PERSONAL INJURY AND ENVIRONMENTAL
installer, service agency, or your distributor or branch for
HAZARD
information or assistance. The qualified installer or
agency must use factory−authorized kits or accessories Failure to follow this warning could cause personal injury
when modifying this product. Refer to the individual or death.
instructions packaged with the kits or accessories when Relieve pressure and recover all refrigerant before sys-
installing. tem repair or final unit disposal.
Follow all safety codes. Wear safety glasses, protective Wear safety glasses and gloves when handling refriger-
clothing, and work gloves. Use quenching cloth for ants.
brazing operations. Have fire extinguisher available. Keep torches and other ignition sources away from refri-
Read these instructions thoroughly and follow all gerants and oils.
warnings or cautions included in literature and attached
to the unit. Consult local building codes, the current
editions of the National Electrical Code (NEC) NFPA 70.
! CAUTION
In Canada refer to the current editions of the Canadian CUT HAZARD
Electrical Code CSA C22.1 Recognize safety Failure to follow this caution may result in personal injury.
information. Recognize safety information. This is the
Sheet metal parts may have sharp edges or burrs. Use
safety−alert symbol ! When you see this symbol on the care and war appropriate protective clothing, safety
unit and in instructions or manuals, be alert to the glasses and gloves when handling parts and servicing
potential for personal injury. Understand these signal units.
words; DANGER, WARNING, and CAUTION. These
words are used with the safety−alert symbol. DANGER
identifies the most serious hazards which will result in
! CAUTION
severe personal injury or death. WARNING signifies CUT HAZARD
hazards which could result in personal injury or death.
Failure to follow this caution may cause equipment dam-
CAUTION is used to identify unsafe practices which may age.
result in minor personal injury or product and property
damage. NOTE is used to highlight suggestions which Ensure voltage listed on unit data plate agrees with elec-
will result in enhanced installation, reliability, or trical supply provided for the unit.
operation.
2 501 01 3001 00Split System Condensers Installation Instructions
MODEL NOMENCLATURE
MODEL SERIES C A S 0 9 1 H A G 0 A 0 0 A
Position Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14
C = R-410A Condensing Unit
A = Air Conditioning (Cooling Only)
H = Heat Pump Type
S = Standard ASHRAE 90.1-2010 Efficiency Efficiency
072 = 6 Tons
091 = 7.5 Tons (1 circuit)
121 = 10 Tons (1 circuit)
151 = 12.5 Tons (1 circuit) Nominal Cooling Capacity
H = 208/230-3-60
L = 460/208/230-3-60
S = 575-3-50 VOLTAGE
A = Single Circuit
B = 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 = None
1 = UnPowered C.O. Service Options
A = None
C = Non-Fused Disconnect Electrical Options
0 = Elec-Mechanical Standard Base Unit Controls
0 = Future Use Future Use
A = Standard Packaging Packaging
Installation Guideline Installation
Replacement /Retrofit – R22 to R−410A 1. Remove the existing evaporator coil or fan coil and
install the replacement coil when appropriate.
Replacement/retrofit installations require change−out of
outdoor unit, metering device, and filter driers. Change−out 2. Drain oil from low points and traps in suction line
of indoor coil (evaporator) and interconnecting tubing is tubing and hot gas bypass tubing if appropriate) and
recommended. evaporator if they were not replaced. Removing oil
from evaporator coil may require purging of the
Existing evaporator coil – If the existing evaporator coil may tubing with dry nitrogen.
be re−used, check with the coil manufacturer to verify the
3. Unless indoor unit is equipped with a R−410A
coil construction is suitable for operation with the higher
approved metering device, change the metering
pressures of R−410A. Also determine if the existing TXV device to a thermal expansion valve (TXV) designed
valve is compatible with R−410A, replace if necessary. The for R−410A.
minimum factory test pressure rating must be 250 psig
(1725 kPa). Existing coil will need to be purged with 4. Remove the existing outdoor unit. Install the new
Nitrogen to remove as much mineral oil as possible to outdoor unit according to these installation
instructions.
eliminate cross contamination of oil.
5. Install a new field−supplied liquid−line filter drier at
Acid test – If the existing system is being replaced because the indoor coil just upstream of the TXV or fix orifice
of a compressor electrical failure, assume acid is in system. metering device.
If system is being replaced for any other reason, use an
approved acid test kit to determine acid level. If even low 6. If a suction line filter drier is also to be installed,
levels of acid are detected, install a 100 percent activated install suction line drier downstream of suction line
service valve at condensing unit.
alumina suction−line filter drier in addition to the
replacement liquid−line filter drier. Remove the suction line 7. If required, install a 100% activated alumina suction
filter drier as soon as possible, with a maximum of 72 hours line filter drier at the outdoor unit.
of operation. Recommendation: Install a ball valve in the 8. Evacuate and charge the system according to the
liquid line at the filter drier location when installing a suction instructions in this installation manual.
filter in the suction line.
501 01 3001 00 3Installation Instructions Split System Condensers
9. Operate the system for 10 hours. Monitor the NOTE: Do not use a torch to remove filter driers, use tubing
pressure drop across the suction line filter drier. If cutters. Excess heat from the torch will drive the moisture
pressure drop exceeds 3 psig (21kPa), replace contained within the drier back out into the system.
suction−line and liquid−line filter driers. Be sure to
purge system with dry nitrogen and evacuate when
replacing filter driers. Continue to monitor the
pressure drop across suction−line filter drier. Repeat
filter changes is necessary. Never leave
suction−line filter drier in system longer than 72 hr
(actual time).
Figure 1 Unit Dimensions
CAS151
CAS072
CAS091
CAS121
CAS151
DISCONNECT
LOCATION
Standard Weight Corner A Corner B Corner C Corner D Center of Gravity Unit Height
UNIT
lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. X Y Z H
19.00 21.00 12.71
072 328 149 128 58 70 32 62 28 68 31 42.36 (1076.0)
(482.6) (533.4) (322.8)
22.50 18.50 12.71
091 353 160 138 63 78 35 65 29 72 33 42.36 (1076.0)
(571.5) (469.9) (322.8)
19.50 23.00 15.11
121 418 190 165 75 90 41 78 35 85 39 50.36 (1279.2)
(495.3) (584.2) (383.3)
23.00 19.25 15.11
151 431 196 162 73 95 43 92 42 82 37 50.6 (1279.2)
(584.2) (489.0) (383.3)
4 501 01 3001 00Split System Condensers Installation Instructions
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
LEGEND * Unit is factory−supplied with partial charge only.
ODS — Outside Diameter Sweat (socket) † Typical operating charge with 25 ft of interconnecting piping.
** Storage capacity of condenser coil with coil 80% full of liquid
R−410A at 95_F.
501 01 3001 00 5Installation Instructions Split System Condensers
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
LEGEND * Unit is factory−supplied with partial charge only.
NEMA — National Electrical Manufacturers Association † Typical operating charge with 7.62 m of interconnecting piping.
ODS — Outside Diameter Sweat (socket) ** Storage capacity of condenser coil with coil 80% full of liquid
R−410A at 35_C.
Jobsite Survey combustible surfaces, unit performance and service
access below, around and above unit as specified in unit
Complete the following checks before installation.
drawings. See Figure 2.
1. Consult local building codes and the NEC (National NOTE: Consider also the effect of adjacent units on airflow
Electrical Code) ANSI/NFPA 70 for special
installation requirements. performance and control box safety clearance.
2. Determine unit location (from project plans) or select Do not install the outdoor unit in an area where fresh air
unit location. supply to the outdoor coil may be restricted or when
recirculation from the condenser fan discharge is possible.
3. Check for possible overhead obstructions which
may interfere with unit lifting or rigging. Do not locate the unit in a well or next to high walls.
Evaluate the path and required line length for
Step 1 — Plan for Unit Location interconnecting refrigeration piping, including suction riser
Select a location for the unit and its support system (pad, requirements (outdoor unit above indoor unit), liquid line lift
rails or other) that provides for the minimum clearances (outdoor unit below indoor unit) and hot gas bypass line.
required for safety. This includes the clearance to
6 501 01 3001 00Split System Condensers Installation Instructions
Relocate sections to minimize the length of interconnecting front of condenser coil air inlet to prevent grass and foliage
tubing. from obstructing airflow.
Step 4 − Rig and Mount the Unit
! CAUTION
UNIT OPERATION HAZARD
! CAUTION
Failure to follow this caution may result in improper UNIT OPERATION HAZARD
operation. Failure to follow this caution may result in equipment
Do not bury refrigerant piping underground. damage.
Although unit is weatherproof, avoid locations that permit All panels must be in place when rigging. Unit is not
water from higher level runoff and overhangs to fall onto the designed for handling by fork truck.
unit. RIGGING — These units are designed for overhead
rigging. Refer to the rigging label for preferred rigging
Figure 2 Service Clearance Dimensional Drawing method. Spreader bars are not required if top crating is left
on the unit. All panels must be in place when rigging. As
further protection for coil faces, plywood sheets may be
RIGHT: placed against the sides of the unit, behind cables. Run
REAR:
Min 18” (457 mm)
required for service cables to a central suspension point so that the angle from
Min 18” (457 mm)
required for service the horizontal is not less than 45 degrees. Raise and set the
unit down carefully.
LEFT:
If it is necessary to roll the unit into position, mount the unit
Min 18” (457 mm)
required for service
FRONT: on longitudinal rails, using a minimum of 3 rollers. Apply
42” (1067 mm)
force to the rails, not the unit. If the unit is to be skidded into
position, place it on a large pad and drag it by the pad. Do
Note: Observe requirements for 39” (914 mm) operating clearance
not apply any force to the unit.
on either Left or Rear coil opening.
Raise from above to lift the unit from the rails or pad when
Step 2 — Complete Pre−Installation Checks unit is in its final position.
CHECK UNIT ELECTRICAL CHARACTERISTIC — After the unit is in position, remove all shipping materials
Confirm before installation of unit that voltage, amperage and top crating.
and circuit protection requirements listed on unit data plate Step 5 — Complete Refrigerant Piping
agree with power supply provided. Connections
UNCRATE UNIT — Remove unit packaging except for the
top skid assembly, which should be left in place until after
the unit is rigged into its final location.
! CAUTION
INSPECT SHIPMENT — File a claim with shipping UNIT OPERATION HAZARD
company if the shipment is damaged or incomplete. Failure to follow this caution may result in improper
CONSIDER SYSTEM REQUIREMENTS operation.
S Consult local building codes and National Electrical Do not bury refrigerant piping underground.
Code (NEC, U.S.A.) for special installation
requirements.
S Allow sufficient space for airflow clearance, wiring,
! CAUTION
refrigerant piping, and servicing unit. See Figure 1 UNIT OPERATION HAZARD
for unit dimensions and weight distribution data.
Failure to follow this caution may result in improper
S Locate the unit so that the outdoor coil (condenser)
operation.
airflow is unrestricted on all sides and above.
S The unit may be mounted on a level pad directly on A refrigerant receiver is not provided with the unit. Do not
the base channels or mounted on raised pads at install a receiver.
support points. See Tables 1A and 1B for unit PROVIDE SAFETY RELIEF — The unit is provided with a
operating weights. See Figure 1 for weight fusible joint in the suction line in accordance with applicable
distribution based on recommended support points. UL standards for pressure relief. If local codes dictate an
NOTE: If vibration isolators are required for a particular additional safety relief device, purchase locally and install
installation, use the data in Figure 1 to make the proper locally. Installation will require the recovery of the factory
selection. shipping charge before the factory tubing can be cut and
Step 3 — Prepare Unit Mounting Support the supplemental relief device is installed.
Slab Mount — SIZE REFRIGERANT LINES — Consider the linear length
(actual tubing length) of piping required between the
Provide a level concrete slab that extends a minimum of 6 outdoor unit and indoor unit (evaporator), the amount of
in. (150 mm) beyond unit cabinet. Install a gravel apron in liquid lift (indoor section installed above the outdoor
501 01 3001 00 7Installation Instructions Split System Condensers
section), and compressor oil return. Consider and identify 121 1/
2 13/8 1/
2 13/8 1/
2 13/8 1/
2 13/8
also the arrangement of the tubing path (quantity and type 1/
of elbows in both lines), liquid line solenoid size, filter drier 151 2 13/8 1/
2 13/8 1/
2 13/8 1/
2 13/8
and any other refrigeration specialties located in the liquid LEGEND
line. Refer to the indoor unit installation instructions for L — Liquid Line
additional details. S — Suction Line
Determine equivalent line (linear length plus equivalent *Field−supplied suction accumulator required for pipe length
length of elbows) length adjustments for path and 75−100 ft (23−30 m).
components and add to linear line lengths. See Table 2 and NOTES:
Table 3. Refer to the indoor unit installation instructions for 1. Pipe sizes are based on a 2_F (1_C) saturated
additional information temperature loss for liquid and suction lines.
Suction line sizing – Select a tube size that produces a 2. Pipe sizes are based on the maximum linear length,
suction pressure drop in range of 1.5 to 3.0_F (0.8 to shown for each column, plus a 50% allowance for
1.7_C). (Higher pressure drops are permissible but there fittings.
will be a loss in cooling capacity due to the higher pressure 3. Charge unit with R−410A and verify that subcooled
drop.) Insulate the suction line. liquid exists at TXV by checking for a full liquid line
Liquid line sizing – For linear line lengths up to 50−ft (15 m), sight glass or by calculating subcooling at TXV.
select a tube size that produces a liquid pressure drop of INSTALL FILTER DRIER(S) AND MOISTURE
approximately 2_F (1.1_C). For linear line lengths greater INDICATOR(S) — Every unit should have a filter drier and
than 50−ft (15 m), select a line size that will permit the liquid a liquid−moisture indicator (sight glass). Refer to Table 4.
state−point subcooling entering the indoor coil’s TXV to be In some applications, depending on space and
a minimum of 2_F (1.1_C). convenience requirements, it may be desirable to install 2
filter driers and sight glasses. One filter drier and sight
Note that refrigerant suction piping should be insulated.
glass may be installed at A locations in Figure 3; or, 2 filter
! CAUTION driers and sight glasses may be installed at B locations.
Select the filter drier for maximum unit capacity and
minimum pressure drop. Complete the refrigerant piping
UNIT OPERATION HAZARD
from the indoor unit to the outdoor unit before opening the
Failure to follow this caution may result in equipment liquid and suction lines at the outdoor unit.
damage.
INSTALL LIQUID LINE SOLENOID VALVE — SOLENOID
For applications with liquid lift greater than 20 ft (6m), use
DROP — It is recommended that a solenoid valve be
5/8 in liquid line. Maximum lift is 60 ft (18m).
placed in the main liquid line (see Figure 3) between the
Table 2 Liquid Line Data − 60 Hz condensing unit and the evaporator coil. Refer to Table 4.
(A liquid line solenoid valve is required when the liquid line
MAXIMUM Maximum Maximum length exceeds 75 ft [23 m]. This valve prevents refrigerant
ALLOWABLE Allowable Allowable Temp. migration (which causes oil dilution) to the compressor
LIQUID LIFT Pressure Drop Loss during the off cycle, at low outdoor ambient temperatures.
ft(m) psig (kPa) _F( _C) Wire the solenoid in parallel with the compressor contactor
60 (18) 7 (48) 2 (1) coil (see Figure 3). This means of electrical control is
* Inlet and outlet referred to as solenoid drop control.
NOTE: Data shown is for units operating at 45_F (7.2_C) INSTALL LIQUID LINE SOLENOID VALVE (Optional) —
saturated suction temperature and 95_F (35_C) entering CAPACITY CONTROL — If 2−step cooling is desired,
air temperature. For applications with liquid lift greater than place a solenoid valve in the location shown in Figure 3.
20 ft (6 m), use 5/8−in. liquid line. Maximum lift is 60 ft (18 MAKE PIPING CONNECTIONS — Piping connections at
m). the unit are ball valves with stub tube extensions. Do not
open the unit service valves until all interconnecting tube
Table 3 Refrigerant Piping Sizes − 60 Hz units brazing has been completed and properly evacuated.
LINEAR LENGTH OF INTERCONNECTING The stub tube service valve connections include 1/4−in
PIPING — FT (m) SAE service fittings with Schrader valve cores (see
0−25 25−50 50−75 75−100 Figure 4). Before making any brazed connections to the
UNIT (0−7.5) (7.5−15) (15−23) (23−30)* unit service valves, remove both Schrader valve caps and
cores and save for re−installation. Connect a source for
Line Size (in. OD) nitrogen to one of these service fittings during tube brazing
L S L S L S L S to prevent the formation of copper oxides inside the tubes
3/ at brazed joints.
072 8 11/8 3/
8 11/8 3/
8 11/8 3/
8 11/8
When connecting and then brazing the field tubing to the
091 3/ 11/8 1/ 11/8 1/ 11/8 1/ 13/8
8 2 2 2 service valves, wrap the valves in wet rags to prevent
overheating.
8 501 01 3001 00Split System Condensers Installation Instructions
Table 4 Refrigerant Specialties Part Numbers
LIQUID LINE
LIQUID LINE FILTER SUCTION LINE
UNIT SOLENOID LLSV COIL SIGHT GLASS
SIZE (in.) DRIER ACCUMULATOR
VALVE (LLSV)
072 3/ 1178274 1178270 1178266* 1178265
8
3/ 1178274 1178270 1178266* 1178265
8
091 1/
2 1178275 1178273 1178271 1178266 1178265
121 1/ 1178276 1178271 1178267* 1178264
2
151 5/ 1178277 1178272 1178267* 1178264
8
* Bushings required. Pressure−test all joints from outdoor unit connections over
to the evaporator coil, using nitrogen as pressure and with
Figure 3 Location of Sight Glass and Filter Drier soap and−bubbles.
When pressure−testing is completed, remove the nitrogen
source at the outdoor unit service valves and re−install the
two Schrader valve cores. Torque the cores to 2−3 in−lbs
(23−34 N−cm).
EVACUATION/DEHYDRATION — Evacuate and
dehydrate the connected refrigeration system, to 500
microns, using a two−stage vacuum pump attached to the
service ports outside the service valves, following
description in GTAC II, Module 4, System Dehydration.
! WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could cause personal in-
Representative drawing only. jury, death and/or equipment damage.
Figure 4 Typical Piping Connection Assembly R−410A systems operate at higher pressures than R−22
systems. When working with R−410A systems, use only
service 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 the
Field Service
Access Port system through the liquid service valve. The amount of
Factory
(Schrader refrigerant added must be at least 80% of the operating
High-Flow
Access Port
core) charge listed in the Physical Data table (Tables 1A and 1B,
pages 4 and 5) LESS the factory charge quantity (if factory
shipping charge has not been removed). Allow high and
Service Valve low side pressures to equalize. If pressures do not equalize
with Stem Cap Sweat readily, charge R−410A vapor (using special service
Connection
manifold with expansion device) into the suction line
service port for the low side of system to assure charge in
the evaporator. Refer to GTAC II, Module 5, Charging,
Recover, Recycling, and Reclamation for liquid charging
procedures.
501 01 3001 00 9Installation Instructions Split System Condensers
Step 6 — Install Accessories Figure 5 Disconnect Switch and Unit
Accessories requiring modifications to unit wiring should
be completed now. These accessories may include Winter
Start controls, Low Ambient controls, phase monitor,
Compressor LOCout. Refer to the instructions shipped with
the accessory.
Step 7 — Complete Electrical Connections SWITCH
COPPER
! WARNING WIRE ONLY
ELECTRICAL SHOCK HAZARD ALUMINUM
WIRE
Failure to follow this warning could result in personal
injury or death.
Units Without Factory−Installed Disconnect — When
Do not use gas piping as an electrical ground. Unit installing units, provide a disconnect switch per NEC
cabinet must have an uninterrupted, unbroken electrical (National Electrical Code) of adequate size. Disconnect
ground to minimize the possibility of personal injury if an sizing data is provided on the unit informative plate. Locate
electrical fault should occur. This ground may consist of on unit cabinet or within sight of the unit per national or local
electrical wire connected to unit ground lug in control codes. Do not cover unit informative plate if mounting the
compartment, or conduit approved for electrical ground disconnect on the unit cabinet.
when installed in accordance with NEC (National
Electrical Code); ANSI/ NFPA 70, latest edition (in Units with Factory−Installed Disconnect — The
Canada, Canadian Electrical Code CSA [Canadian factory−installed option disconnect switch is located in a
Standards Association] C22.1), and local electrical weatherproof enclosure located under the main control
codes. box. The manual switch handle is accessible through an
opening in the access panel.
NOTE: Check all factory and field electrical connections for
tightness. Field−supplied wiring shall conform with the All units − All field wiring must comply with NEC and all local
limitations of 63_F (33_C) rise. codes. Size wire based on MCA (Minimum Circuit Amps)
on the unit informative plate. See Figure 6 for power wiring
All units except 208/230−v units are factory wired for the
connections to the unit power terminal block and
voltage shown on the nameplate. If the 208/230−v unit is
equipment ground.
to be connected to a 208−v power supply, the control
transformer located in the unit control box must be rewired Provide a ground−fault and short−circuit over−current
by moving the black wire with the 1/4−in. female spade protection device (fuse or breaker) per NEC Article 440 (or
connector from the 230−v connection and moving it to the local codes). Refer to unit informative data plate for MOCP
208−v 1/4−in. male terminal on the primary side of the (Maximum Over−current Protection) device size.
transformer. Refer to unit label diagram for to line−side
information. Field power wires will be connected line−side Figure 6 Power Wiring Connections
pressure lugs on the power terminal block or at factory Splice Terminals
installed option non−fused disconnect. BLK
(field supplied)
Field power wires are connected to the unit at the leads to
the factory test connection leads (pigtails) in the unit’s main
control box (see Figure 6) or at factory−installed option
non−fused disconnect switch. Max wire size is #4 AWG YEL
(copper only).
NOTE: TEST LEADS − Unit may be equipped with short
leads (pigtails) on the field line connection points on the
optional disconnect switch. These leads are for factory BLU
run−test purposes only; remove and discard before
connecting field power wires to unit connection points.
DISCONNECT
! WARNING Ground Lug
FIRE HAZARD
Failure to follow this warning could result in intermittent
operation or performance satisfaction. LEGEND
Do not connect aluminum wire between disconnect Factory Power Connection Lead
switch and condensing unit. Use only copper wire. (See Field Power Supply Conductor
Figure 5)
All field wiring must comply with the NEC and local
requirements.
10 501 01 3001 00Split System Condensers Installation Instructions
Affix the crankcase heater warning sticker to the unit shipment, the convenience outlet is covered with a blank
disconnect switch. cover plate.
Convenience Outlets — The weatherproof cover kit is shipped in the unit’s control
box. The kit includes the hinged cover, a backing plate and
! WARNING gasket.
DISCONNECT ALL POWER TO UNIT AND
ELECTRICAL OPERATION HAZARD CONVENIENCE OUTLET.
Failure to follow this warning could result in personal in- Remove the blank cover plate at the convenience outlet;
jury or death. discard the blank cover.
Units with convenience outlet circuits may use multiple Loosen the two screws at the GFCI duplex outlet, until
disconnects. Check convenience outlet for power status approximately 1/2−in (13 mm) of screw heads are
before opening unit for service. Locate its disconnect exposed. Press the gasket over the screw heads. Slip the
switch, if appropriate, and open it. Tag−out this switch, backing plate over the screw heads at the keyhole slots and
if necessary. align with the gasket; tighten the two screws until snug (do
not over−tighten).
One type of convenience outlet is offered on all models:
Non−powered. The outlet provide a 125−volt GFCI Mount the weatherproof cover to the backing plate as
(ground−fault circuit−interrupter) duplex receptacle rated shown in Figure 8. Remove two slot fillers in the bottom of
at 15−A behind a hinged waterproof access cover, located the cover to permit service tool cords to exit the cover.
on the end panel of the unit. See Figure 7. Check for full closing and latching.
Figure 7 Convenience Outlet Location Figure 8 Weatherproof Cover Installation
COVER WHILE-IN-USE RECEPTACLE
Convenience WEATHERPROOF NOT INCLUDED
Outlet
GFCI
CONVENIENCE BASE PLATE FOR
OUTLET GFCI
Control Box COVER RECEPTACLE
Access Panel
All Units — Voltage to compressor terminals during
operation must be within voltage range indicated on unit
Non−powered type: This type requires the field installation nameplate. See Table 5. On 3−phase units, voltages
of a general−purpose 125−volt 15−A circuit powered from between phases must be balanced within 2% and the
a source elsewhere in the building. Observe national and current within 10%. Use the formula shown in the legend for
local codes when selecting wire size, fuse or breaker Table 5, Note 5 (see page 13) to determine the percent of
requirements and disconnect switch size and location. voltage imbalance. Operation on improper line voltage or
Route 125−v power supply conductors into the bottom of excessive phase imbalance constitutes abuse and may
the utility box containing the duplex receptacle. cause damage to electrical components. Such operation
Using unit−mounted convenience outlets: Units with unit would invalidate any applicable warranty.
mounted convenience outlet circuits will often require that The unit requires an external temperature control device.
two disconnects be opened to de−energize all power to the This device can be a thermostat (field−supplied) or a
unit. Treat all units as electrically energized until the thermostat emulation device provided as part of a
convenience outlet power is also checked and third−party Building Management System.
de−energization is confirmed. Observe National Electrical Thermostat — Install an accessory commercial thermostat
Code Article 210, Branch Circuits, for use of convenience according to installation instructions included with the
outlets. accessory. For complete economizer function, select a
Installing Weatherproof Cover – two—stage cooling thermostat. Locate the thermostat
A weatherproof while−in−use cover for the accessory on a solid wall in the conditioned space to sense
factory−installed convenience outlets is now required by average temperature in accordance with the thermostat
UL standards. This cover cannot be factory−mounted due installation instructions.
its depth; it must be installed at unit installation. For
501 01 3001 00 11Installation Instructions Split System Condensers
If the thermostat contains a logic circuit requiring 24−v CONTROL CIRCUIT WIRING — Control voltage is 24 v.
power, use a thermostat cable or equivalent single leads of See Figure 6 and the unit’s label diagram for field−supplied
different colors with minimum of four leads. If the wiring details. Route control wires through the opening in
thermostat does not require a 24−v source (no “C” unit’s end panel to the connection in the unit’s control box.
connection required), use a thermostat cable or equivalent CONTROL TRANSFORMER WIRING — On multivoltage
with minimum of three leads. Check the thermostat units, check the transformer primary wiring connections.
installation instructions for additional features which might See Figure 10 or refer to the unit’s label diagram.
require additional conductors in the cable.
If the unit will be operating at 208−3−60 power, remove the
For wire runs up to 50 ft. (15 m), use no. 18 AWG (American black wire (BLK) from the transformer primary connection
Wire Gage) insulated wire (35_C minimum). For 50 to 75 labelled “230” and move it to the connection labelled “208”.
ft. (15 to 23 m), use no. 16 AWG insulated wire (35_C See Figure 10.
minimum). For over 75 ft. (23 m), use no. 14 AWG insulated
wire (35_C minimum). All wire sizes larger than no. 18 Figure 10 Control Transformer Wiring
AWG cannot be directly connected to the thermostat and
will require a junction box and splice at the thermostat.
Figure 9 Typical Remote Thermostat Connections
X X
C C
G G
W W
2 2
W W
1 1
Y2 Y2
Y1 Y1
R R
Thermostat
Terminal
Board
Note 1: Typical multi−function marking. Follow manufacturer’s
configuration instructions to select Y2.
Note 2: Y2 to economizer required on single−stage cooling units
when integrated economizer function is desired
Note 3: Connect only if thermostat requires 24−vac power source.
Field Wiring
12 501 01 3001 00Split System Condensers Installation Instructions
Table 5 Electrical Data — 60 Hz Units
FAN MOTORS
UNIT NOMINAL VOLTAGE RANGE* COMPRESSOR POWER SUPPLY
(Qty 2)
CAS VOLTAGE
MIN MAX RLA LRA FLA (ea) LRA (ea) MCA MOCP
208/230-3-60 187 253 19 123 1.5 3.7 25.2 45
072 460-3-60 414 506 9.7 62 0.8 1.9 12.9 20
575-3-60 518 633 7.4 50 0.6 1.6 9.9 15
208/230-3-60 187 253 25 164 1.5 3.7 32.7 50
091 460-3-60 414 506 12.2 100 0.8 1.9 16 25
575-3-60 518 633 9 78 0.6 1.6 11.8 20
208/230-3-60 187 253 30.1 225 1.5 3.7 39.1 60
121 460-3-60 414 506 16.7 114 0.8 1.9 21.7 30
575-3-60 518 633 12.2 80 0.6 1.6 15.8 25
208/230-3-60 187 253 48.1 245 1.5 3.7 61.6 80
151 460-3-60 414 506 18.6 125 0.8 1.9 24 30
575-3-60 518 633 14.7 100 0.6 1.6 19 30
FLA — Full Load Amps
LRA — Locked Rotor Amps
MCA — Minimum Circuit Amps
MOCP — Maximum Overcurrent Protection
NEC — National Electrical Code
RLA — 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 Voltage
Never operate a motor where a phase imbalance in supply Example: Supply voltage is 230-3-60
voltage is greater than 2%. Use the following formula to determine
the percentage of voltage imbalance. AB = 224 v
BC = 231 v
max voltage deviation from average voltage AC = 226 v
% Voltage Imbalance = 100 x
average voltage (224 + 231 + 226) 681
Average Voltage = =
3 3
= 227
Determine maximum deviation from average voltage.
(AB) 227 – 224 = 3 v
(BC) 231 – 227 = 4 v
(AC) 227 – 226 = 1 v
Maximum deviation is 4 v.
Determine percent of voltage imbalance.
4
% Voltage Imbalance = 100 x
227
= 1.76%
This amount of phase imbalance is satisfactory as it is below the
maximum allowable 2%.
IMPORTANT: If the supply voltage phase imbalance is more than 2%,
contact your local electric utility company immediately.
501 01 3001 00 13Installation Instructions Split System Condensers
PRE−START−UP manifold gauge set then the liquid service valve. The
amount of refrigerant added must be at least 80% of the
! CAUTION operating charge listed in the Physical Data table (Tables
1A and 1B, pages 4 and 5). Allow high and low side
pressures to equalize before starting compressor. If
UNIT OPERATION HAZARD
pressures do not equalize readily, charge vapor on low side
Failure to follow this caution may result in equipment of system to assure charge in the evaporator. Refer to
damage. GTAC II, Module 5, Charging, Recover, Recycling, and
Before beginning Pre−Start−Up or Start−Up, review Reclamation for liquid charging procedures.
Start−Up Checklist at the back of this book. The
Checklist assures proper start−up of a unit and provides
a record of unit condition, application requirements,
! CAUTION
system information, and operation at initial start−up.
UNIT DAMAGE HAZARD
! CAUTION Failure to follow this caution may result in equipment
damage.
Prior to starting compressor, a preliminary charge of
UNIT DAMAGE HAZARD
refrigerant must be added to avoid possible compressor
Failure to follow this caution may result in equipment damage (approximately 80% total refrigerant capacity).
damage.
Do not attempt to start the condensing unit, even START−UP
momentarily, until the following steps have been The compressor crankcase heater must be on for 24 hours
completed. Compressor damage may result. before start−up. After the heater has been on for 24 hours,
the unit can be started.
System Check
PRELIMINARY CHECKS
1. Check all air handler(s) and other equipment
auxiliary components. Consult the manufacturer’s 1. Check that electric power supply agrees with unit
instructions regarding any other equipment nameplate data.
connected to the condensing unit. If the unit has 2. Verify that the compressor crankcase heater is
field−installed accessories, be sure all are properly securely in place.
installed and correctly wired. If used, the airflow 3. Check that the compressor crankcase heater has
switch must be properly installed. been on at least 24 hours.
2. Be sure the unit is properly leak checked and 4. Recheck for leaks using the procedure outlined in the
dehydrated. Pre−Start−Up section, Leak Test and Dehydration. If
any leaks are detected, repair as required. Evacuate
3. Check tightness of all electrical connections. and dehydrate as described in the Leak Test and
Dehydration section.
4. Open the liquid line and suction line service valves.
5. Ensure that the preliminary charge has been added
5. Be sure the unit is properly charged. See “Preliminary as described in the Pre−Start−Up section,
Charge”, on page 9. Preliminary Charge.
6. The electrical power source must agree with the 6. All internal wiring connections must be tight, and all
unit’s nameplate rating. barriers and covers must be in place.
NOTE: The units are factory charged with the required
7. The crankcase heater should be firmly attached to amount of oil. If recharging is required, use Emkarate RL
the compressor crankcase. Be sure the crankcase is 32−3MAF for the units.
warm (heater must be on for 24 hours before starting
compressor). COMPRESSOR ROTATION — On 3−phase units with
scroll compressors, it is important to be certain that the
Energize the Crankcase Heater — Turn on the crankcase compressor is rotating in the proper direction. To determine
heater for 24 hours before starting the unit to be sure all the whether or not compressor is rotating in the proper
refrigerant is out of the oil. To energize the crankcase direction:
heater, proceed as follows:
1. Connect service gages to the suction and liquid
1. Set the space thermostat set point above the space pressure fittings.
temperature so there is no demand for cooling. 2. Energize the compressor.
2. Close the field disconnect. 3. The suction pressure should drop and the liquid
pressure should rise, as is normal on any start−up.
NOTE: Make sure that thermostat leads are isolated If the suction pressure does not drop and the liquid
from the Low Voltage terminal block when energizing pressure does not rise to normal levels:
Crankcase Heater for 24 hours. This insures compressor
will not operate. 1. Turn off power to the unit, tag disconnect.
2. Reverse any two of the unit power leads.
Preliminary Charge — Before starting the unit, charge 3. Reapply power to the compressor, verify correct
liquid refrigerant into the high side of the system through a pressures.
14 501 01 3001 00Split System Condensers Installation Instructions
The suction and liquid pressure levels should now move to Scroll compressor models (ZP103 and ZP137) that contain
their normal start−up levels. this technology. See Figure 12.
COMPRESSOR OVERLOAD — This overload interrupts
power to the compressor when either the current or internal Advanced Scroll Temperature
Figure 12
motor winding temperature becomes excessive, and Protection Label
automatically resets when the internal temperature drops
to a safe level. This overload may require up to 60 minutes
(or longer) to reset. If the internal overload is suspected of
being open, disconnect the electrical power to the unit and
check the circuit through the overload with an ohmmeter or
continuity tester.
Temperature Overload Device (TOD) is a thermal disk
temperature device embedded into the ZP61 and ZP83
compressor scroll plates. This device once opened will
bypass hot gas into the motor windings opening the motor
thermal protector. If this device opens, the compressor may
operate with some difference in suction and liquid
pressures as measured with a manifold gauge set. This START UNIT — The field disconnect is closed, the indoor
device is auto−resetting and may take up to 60+ minutes fan circuit breaker is closed, and the space thermostat is
to reset. set above ambient so that there is no demand for cooling.
ADVANCED SCROLL TEMPERATURE PROTECTION Only the crankcase heater will be energized.
(ASTP) — Advanced Scroll Temperature Protection Reset the space thermostat below ambient so that a call for
(ASTP) is a form of internal discharge temperature cooling is applied.
protection, used in 10 and 12.5 Ton units, that unloads the
scroll compressor when the internal temperature reaches
approximately 300_F. At this temperature, an internal ! CAUTION
bi−metal disk valve opens and causes the scroll elements
to separate, which stops compression. Suction and UNIT DAMAGE HAZARD
discharge pressures balance while the motor continues to Failure to follow this caution may result in equipment
run. The longer the compressor runs unloaded, the longer damage.
it must cool before the bi−metal disk resets. See Figure 11. Never charge liquid into the low−pressure side of
system. Do not overcharge. During charging or removal
Recommended Minimum Cool− of refrigerant, be sure indoor−fan system is operating.
Figure 11 Down Time After Compressor is Ensure both outdoor fan motors are running; bypass any
Stopped low ambient control function.
ADJUST REFRIGERANT CHARGE — The unit must be
120
charged in Cooling mode only. Refer to Cooling Charging
110 Charts, Figure 13 through Figure 16. For applications with
Recommended Cool i ng Ti me
100
90
line lengths greater than 100 ft, contact the distributor. Vary
80 refrigerant until the conditions of the chart are met. Note
(Mi nutes)
70
60
that the charging charts are different from the type normally
50 used. The charts are based on charging the units to the
40
30
correct subcooling for the various operating conditions.
20 Accurate pressure gage and temperature sensing device
10
0
are required. Connect the pressure gage to the service port
0 10 20 30 40 50 60 70 80 90 on the liquid line service valve. Mount the temperature
Compressor Unloaded Run Time (Minutes) sensing device on the liquid line close to the liquid line
*Times are approximate. service valve, and insulate it so that outdoor ambient
temperature does not affect the reading. Indoor airflow
NOTE: Various factors, including high humidity, high must be within the unit’s normal operating range. Operate
ambient temperature, and the presence of a sound blanket the unit for a minimum of 15 minutes. Ensure that pressure
will increase cool−down times. and temperature readings have stabilized. Plot the liquid
To manually reset ASTP, the compressor should be pressure and temperature on chart and add or reduce the
stopped and allowed to cool. If the compressor is not charge to meet the curve. Adjust the charge to conform with
stopped, the motor will run until the motor protector trips, the charging chart, using the liquid pressure and
which occurs up to 90 minutes later. Advanced Scroll temperature to read the chart.
Temperature Protection will reset automatically before the FINAL CHECKS — Ensure that all safety controls are
motor protector resets, which may take up to 2 hours. A operating, control panel covers are on, and the service
label located above the terminal box identifies Copeland panels are in place.
501 01 3001 00 15Installation Instructions Split System Condensers
Figure 13 6 Ton Charging Chart
072 CHARGING CHART R−410A ALL CONDENSER FANS OPERATING
072
Figure 14 7.5 Ton Charging Chart
091 CHARGING CHART R−410A ALL CONDENSER FANS OPERATING
091
Figure 15 10 Ton Charging Chart
121 CHARGING CHART R−410A ALL CONDENSER FANS OPERATING
121
16 501 01 3001 00Split System Condensers Installation Instructions
Figure 16 12.5 Ton Charging Chart
151 CHARGING CHART R−410A ALL CONDENSER FANS OPERATING
151
Figure 17 Wiring Diagram
OPTIONAL
501 01 3001 00 17Installation Instructions Split System Condensers
OPERATING SEQUENCE ROUTINE SYSTEM MAINTENANCE
Base Unit Controls These items should be part of a routine maintenance
Indoor (Supply) Fan program, to be checked every month or two, until a specific
schedule for each can be identified for this installation:
The indoor fan contactor (IFC) is remotely located at the fan
Quarterly Inspection (and 30 days after initial start)
coil or fan section. If the thermostat fan operation is
selected as Continuous, the IFC is energized and the Indoor section
indoor (supply) fan motor runs continuously. If the S Condenser coil cleanliness checked.
thermostat fan operation is selected as Automatic, the IFC S Return air filter replacement
will be energized on a call for Cooling; indoor (supply) fan
motor runs. When thermostat call for Cooling is satisfied, S Outdoor hood inlet filters cleaned
the IFC is de−energized and indoor (supply) fan motor S Belt tension checked
stops. S Belt condition checked
Cooling, Unit Without Economizer S Pulley alignment checked
On a thermostat call for Cooling, IFC will be energized and S Fan shaft bearing locking collar tightness checked
indoor (supply) fan motor runs. Thermostat contact TC1 S Condensate drain checked
closes; terminal Y1 receives 24−v. 24−v received at CADM
terminal Y. If anti−recycle time delay period has not expired, Seasonal Maintenance
CADM relay will remain open, preventing compressor start. These items should be checked at the beginning of each
When safety pressure switches are closed, the liquid line season (or more often if local conditions and usage
solenoid valve opens. When CADM time delay expires (3 patterns dictate):
minutes), the compressor contactor is energized; both Air Conditioning
outdoor fan motors start and compressor starts. When S Condenser fan motor mounting bolts tightness
space cooling load is satisfied, thermostat contacts TC1
open, removing 24−v at terminal Y. Compressor and S Compressor mounting bolts
outdoor fan motors stop. Liquid line solenoid valve is S Condenser fan blade positioning
de−energized and valve closes. CADM begins its S Control box cleanliness and wiring condition
three−minute anti−recycle time delay. S Wire terminal tightness
If either the Low Pressure Switch or High Pressure Switch S Refrigerant charge level
opens while thermostat contact TC1 remains closed, the
compressor contactor is de−energized (both fan motors S Evaporator coil cleaning
and compressor stop) and liquid line solenoid is S Evaporator blower motor amperage
de−energized (valve closes). CADM initiates a TRIP event Heating
(cooling demand sensed at CADM terminal Y but no
S Power wire connections
current is measured at T1, T2, T3 motor sensors); CADM
relay opens and RED LED is illuminated. TRIP condition S Fuses ready
maintains lockout of compressor operation until CADM is S Manual−reset limit switch is closed
manually reset. Reset CADM by cycling unit main power. Economizer or Outside Air Damper
Complete system shutdown may be caused by loss of main S Inlet filters condition
power, open compressor internal overload, open
low−pressure or high−pressure switch, or a fault detected S Check damper travel (economizer)
by the CADM logic. Compressor operation without cooling S Check gear and dampers for debris and dirt
may indicate the compressor’s TOD or ASTP feature is SERVICE
active (unit sizes 12 and 14 only); disconnect unit power
and allow compressor to cool. See Service section for Comfort Alert Diagnostic Module
further details. The Comfort Alert Diagnostic Module (CADM) monitors
Cooling, Unit with Economizer and analyzes data from the Copeland Scrollt three−phase
compressor and the thermostat demand. The CADM also
Refer to fan coil unit installation instructions and provides a 3−minute anti−recycle time delay to compressor
economizer accessory installation instructions for cycling. The CADM detects causes for electrical and
operating sequences when system is equipped with system related failures without any sensors. Flashing
accessory economizer. LEDs communicate the Alert codes to guide service
Heating technicians in accurately and quickly troubleshooting the
Refer to fan coil unit installation instructions and accessory system and determining root cause for the failure. Inputs to
heating device installation instructions for operating the CADM include 24−vac power, thermostat Y1,
sequences in heating mode.
18 501 01 3001 00Split System Condensers Installation Instructions
compressor contactor coil (common side) and compressor The ALERT LED indicates an abnormal condition exists in
power leads (from the compressor contactor) the system through a flash code. The ALERT LED will blink
a number of times consecutively, pause and the repeat the
Input Terminal Voltage process. The number of blinks, defined in Table 6,
Control Power R 24V correlates to a particular abnormal condition;
troubleshooting tips are provided for each Alert code.
Control Common C 24V Reset of the ALERT may be automatic or manual. If the
Cooling Y 24V fault condition causing the Alert is self−corrected, the Alert
code will be removed and the CADM will automatically
Contactor Coil P 24V
reset and allow the system to restart normally. Manual
Line A T1 Line reset requires that main power to the unit be recycled after
Line B T2 Line the cause for the Alert condition has been detected and
corrected.
Line C T3 Line
The TRIP LED indicates either a time−delay period is
Control of the compressor contactor coil is through a currently active (RED LED is blinking) or the module has
normally−closed (power on the module) contact between locked out the compressor (RED LED is on steady). A
terminals P and C. lockout condition will occur when the CADM detects a
thermostat demand at input Y but there is no power at the
Communications of status and alert conditions is through
compressor line terminals T1 or T2 or T3. This lockout can
three LEDs located on the top edge of the module housing
occur due to a safety switch (LPS or HPS) opening and
(see Figure 18): POWER (green), ALERT (yellow), and
de−energizing the compressor contactor, the
TRIP (red). The POWER LED indicates the presence of
compressor−motor internal overload opens, or other
control power to the CADM.
internal power interruption has occurred. Reset of the TRIP
Figure 18 CADM Housing/LED Locations LED requires that unit main power be recycled after the
loss of power to the compressor condition has been
POWER
(GRN)
detected and corrected.
Simultaneous Blinking of YELLOW and RED LEDs
indicates control power input to the CADM is low. Check
control circuit transformer and wiring.
Troubleshooting the CADM Wiring – Flashing LEDs also
indicate wiring problems to the CADM. See Table 7 for
discussion of additional LED flash codes and
troubleshooting instructions.
ALERT
(YEL)
TRIP
(RED)
501 01 3001 00 19Installation Instructions Split System Condensers
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” Thermostat demand signal Y 1. Compressor protector is open
LED On Solid is present, but the 2. Condensing unit power disconnect is open
compressor is not running. 3. Compressor circuit breaker or fuse(s) is open
4. Broken supply wires or connector is not making contact
5. Compressor power wires not routed through Comfort Alert
6. Compressor contactor has failed open
Red “TRIP” LED The anti−short cycle timer (3 minutes), in module is preventing compressor restart.
Flashing
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” A short circuit or over current 1. Compressor contactor coil shorted
LED On Solid condition exists on PROT 2. Electrical load too high for PROT circuit (max1 Amp)
terminal. 3. 24 V AC wired directly to PROT terminal
Yellow “ALERT” System Pressure Trip 1. High head pressure
Flash Code 2 Discharge pressure out of 2. Condenser coil poor air circulation (dirty, blocked, damaged)
limits or compressor 3. Condenser fan is not running
overload (if no high pressure 4. If low pressure switch is open:
switch in system) Refer to Code 3 for troubleshooting
LOCKOUT
Yellow “ALERT” Short Cycling 1. If low pressure switch is open:
Flash Code 3 Compressor is running only a. Low refrigerant charge
briefly LOCKOUT b. Evaporator blower is not running
c. Evaporator coil is frozen
d. Faulty metering device
e. Condenser coil is dirty
f. Liquid line restriction (filter drier blocked if present)
2. If high pressure switch is open, go to Flash Code 2 in-
formation
3. Intermittent thermostat demand signal
4. System or control board defective
Yellow “ALERT” Locked Rotor 1. Low line voltage to compressor
Flash Code 4 LOCKOUT 2. Excessive liquid refrigerant in compressor
3. Compressor bearings are seized
Yellow “ALERT” Open Circuit 1. Condensing unit power disconnect is open
Flash Code 5 2. Compressor circuit breaker or fuses are open
3. Compressor contactor has failed open
4. High pressure switch is open and requires manual reset
5. Broken supply wires or connector is not making contact
6. Unusually long compressor protector reset time due to
extreme ambient temperature
7. Compressor windings are damaged
Yellow “ALERT” Missing Phase 1. Compressor fuse is open on one phase
Flash Code 6 LOCKOUT 2. Broken wire or connector on one phase
3. Compressor motor winding is damaged
4. Utility supply has dropped one phase
Yellow “ALERT” Reverse Phase 1. Compressor running backward due to supply
Flash Code 7 LOCKOUT phase reversal
Yellow “ALERT” Welded Contactor 1. Compressor contactor has failed closed
Flash Code 8 Compressor always runs 2. Thermostat demand signal not connected to module
Yellow “ALERT” Low Voltage 1. Control circuit transformer is overloaded
Flash Code 9 Control circuit < 18VAC 2. Low line voltage to compressor
20 501 01 3001 00You can also read
