R 410A Split Condensing Units with RTPF...

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INSTALLATION INSTRUCTIONSR−410A Split Condensing Units with RTPF Coils

CAS072−151

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

DANGER, WARNING, CAUTION, andNOTEThe signal words DANGER, WARNING,CAUTION, and NOTE are used to identify levels ofhazard seriousness. The signal word DANGER isonly used on product labels to signify an immediatehazard. The signal words WARNING, CAUTION,and NOTE will be used on product labels andthroughout this manual and other manuals that mayapply to the product.

DANGER − Immediate hazards which will result insevere personal injury or death.

WARNING − Hazards or unsafe practices whichcould result in severe personal injury or death.

CAUTION − Hazards or unsafe practices whichmay result in minor personal injury or product orproperty damage.

NOTE − Used to highlight suggestions which willresult in enhanced installation, reliability, oroperation.

Signal Words in Manuals

The signal word WARNING is used throughout thismanual in the following manner:

The signal word CAUTION is used throughout thismanual in the following manner:

Signal Words on Product Labeling

Signal words are used in combination with colorsand/or pictures on product labels.

WARNING

Safety Labeling and Signal Words

!

CAUTION

WARNING

!

! WARNING

ELECTRICAL SHOCK HAZARD

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

Before installing, modifying, or servicing system, mainelectrical disconnect switch must be in the OFF posi-tion. There may be more than 1 disconnect switch.Lock out and tag switch with a suitable warning label.

PERSONAL INJURY AND ENVIRONMENTALHAZARD

Failure to follow this warning could cause personalinjury or death.

Relieve pressure and recover all refrigerant beforesystem repair or final unit disposal.

Wear safety glasses and gloves when handlingrefrigerants. Keep torches and other ignitionssources away from refrigerants and oils.

! WARNING

! CAUTIONCUT HAZARD

Failure to follow this caution may result in personal in-jury

Sheet metal parts may have sharp edges or burrs. Usecare and wear appropriate protective clothing andgloves when handling parts.

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personalinjury, death and/or equipment damage.

R−410A refrigerant systems operate at higherpressures than standard R−22 systems. Do notuse R−22 service equipment or components onR−410A refrigerant equipment.

! WARNING

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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


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


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.

! CAUTIONUNIT DAMAGE 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.

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MODEL NOMENCLATUREMODEL SERIES C A S 0 9 1 H A A 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)120 = 10 Tons (2 circuits)121 = 10 Tons (1 circuit)150 = 12.5 Tons (2 circuits)151 = 12.5Tons (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 ControlD = Dual CircuitE = Dual Circuit w/Low Ambient Control Refrigerant System Options

A = Copper / AluminumC = E-Coat Copper / Aluminum 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 = Original Design Sales Code

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Installation GuidelineReplacement /Retrofit – R22 to R−410Areplacement/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.

Existing refrigeration piping – Reuse of existingrefrigerant piping involves three issues: quality (strength) ofexisting tubing, cleanliness and tube size. Inspect all tubesegments and joints for signs of damage, corrosion or poorbrazing. Flush the interconnecting piping system with dryNitrogen to eliminate as much trace of mineral oil aspossible.

Same tube sizes are capable of handling higher flowrates(expressed as tons of cooling capacity) with R−410Arefrigerant compared to R−22 at constant pressure drops.For example, a 1/2−inch OD liquid line is rated at 33%higher tons with R−410A than with R−22 (at 5�F pressuredrop). A 1 1/8−inch OD suction line is rated at 53% highertons with R−410A than with R−22 (at 2�F pressure drop).Refrigeration lines selected for R−22 use are typicallyoversized for R−410A applications. Carefully check theexisting suction line size against the table for maximumsize (see Table 7); replace vertical riser segments ifnecessary. Check existing liquid line size against sizingdata in Table 5 or 6; replace with smaller lines whenfeasible.

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.

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.

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Unit Dimensions Service Valve ConnectionsUnit Suction Liquid Qty072 1 - 1/8 [28.6] 3/8 [9.5] 1091 1 - 1/8 [28.6] 1/2 [12.7] 1121 1 - 3/8 [34.9] 1/2 [12.7] 1151 1 - 3/8 [34.9] 5/8 [15.9] 1120 1 - 1/8 [28.6] 3/8 [9.5] 2150 1 - 3/8 [34.9] 1/2 [12.7] 2

UNITCAS

STD. UNITWT. CORNER A CORNER B CORNER C CORNER D CENTER OF GRAVITY

UNITHEIGHT

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

072 389 176 141 64 96 44 62 28 91 4118

[457.2]24

[609.6]21

[533.4]42 3/8

[1076.0]

091 391 177 142 64 96 44 62 28 91 4118

[457.2]24

[609.6]21

[533.4]42 3/8

[1076.0]

121 490 222 177 80 120 54 78 35 114 5218

[457.2]24

[609.6]24

[609.6]50 3/8

[1279.2]

120 516 234 185 84 117 53 83 38 131 5919

[482.6]23

[584.2]24

[609.6]50 3/8

[1279.2]

151 598 271 195 88 142 64 110 50 151 6820

[508.0]25

[635.0]24

[609.6]50 3/8

[1279.2]

150 654 297 214 97 155 70 120 54 165 7520

[508.0]25

[635.0]24

[609.6]50 3/8

[1279.2]

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Table 1A — Physical Data —CAS072-151 Units — 60 Hz English

UNIT SIZE CAS 072 091 121 151

NOMINAL CAPACITY (tons) 6 7.5 10 12.5

OPERATING WEIGHTS (lb)

Round Tube/Plate Fin Coil (Cu/Al) 389 389 490 598

REFRIGERANT TYPE‡ R-410A

RTPF Operating Charge, Typical (lb)† 14.0 17.0 20.0 46.0

RTPF Shipping Charge (lb) 11.0 13.0 16.0 35.0

COMPRESSOR

Qty...Type 1...Scroll 1...Scroll 1...Scroll 1...Scroll

Oil Charge (oz) 56 60 110 110

CONDENSER FANS

Qty...Rpm 2...1100

Motor Hp 1/4

Diameter 22

Nominal Airflow (Cfm Total) 6000

Watts (Total) 610

RTPF CONDENSER COIL

Material (Tube/Fin) Cu / Al

Coil Type 3/8−in RTPF

Rows/Fins per inch (FPI) 2 / 17 3 / 17

Face Area (sq ft total) 17.5 17.5 25.0 31.8

CONTROLS

Pressurestat Settings (psig)

High Cutout 630 10

Cut-in 505 20

Low Cutout 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...5/8LEGEND

RTPF — Round Tube/Plate FinODS — Outside Diameter Sweat (socket)

‡ Unit is factory‐supplied with partial charge only.† Typical operating charge with 25 ft of interconnecting piping.

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Table 1B — Physical Data — CAS072-151 Units — 60 Hz SI

UNIT SIZE CAS 072 091 121 151

NOMINAL CAPACITY (kW) 21.1 26.4 35.1 44


Round Tube/Plate Fin Coil (Cu/Al) 176 177 222 271


RTPF Operating Charge, Typical (kg)† 6.4 7.7 9.1 20.9

RTPF Shipping Charge (kg) 5.0 5.9 7.3 15.9

COMPRESSOR

Qty...Type 1...Scroll 1...Scroll 1...Scroll 1...Scroll

Oil Charge (oz) 1.7 1.8 3.3 3.3

CONDENSER FANS

Qty...r/s 2...18

Motor Hp NEMA 1/4

Diameter (mm) 560

Nominal Airflow (L/s) 2832

Watts (Total) 610

RTPF CONDENSER COIL



Rows/Fins per Meter (Fins/m) 2 / 670 3 / 670

Face Area (sq m total) 1.6 1.9 2.3 3.0

CONTROLS

Pressurestat Settings (kPa)

High Cutout 4347 70

Cut-in 3482 138

Low Cutout 372 21

Cut-in 807 34


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...5/8LEGEND

RTPF — Round Tube/Plate FinNEMA — National Electrical Manufacturers AssociationODS — Outside Diameter Sweat (socket)


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Table 2A — Physical Data — CAS120−150 Units — 60 Hz English

UNIT SIZE CAS 120 150

NOMINAL CAPACITY (tons) 10 12.5


Round Tube/Plate Fin Coil (Cu/Al) 516 654


RTPF Operating Charge A/B, Typical (lb)† 11.0 / 11.0 23.0/23.0

RTPF Shipping Charge A/B (lb) 8.0 / 8.0 17.0/17.0

COMPRESSOR

Qty...Type 2...Scroll 2...Scroll

Oil Charge A/B (oz) 42 60

CONDENSER FANS

Qty...Rpm 2...1100

Motor Hp 1/4

Diameter 22


Watts (Total) 610

RTPF CONDENSER COIL



Rows/Fins per inch (FPI) 2 / 17 3 / 17

Face Area (sq ft total) 25.0 31.8

CONTROLS

Pressurestat Settings (psig)

High Cutout 630 10

Cut-in 505 20

Low Cutout 54 3

Cut-in 117 5


Qty...Suction A/B 1...1 1/8 / 1...1 1/8 1...1 3/8 / 1...1 3/8

Qty...Liquid A/B 1...3/8 / 1...3/8 1...1/2 / 1...1/2LEGEND

RTPF — Round Tube/Plate FinODS — Outside Diameter Sweat (socket)


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Table 2B — Physical Data — CAS120−150 Units — 60 Hz SI

UNIT SIZE CAS 120 150

NOMINAL CAPACITY (kW) 35.1 44

OPERATING WEIGHTS (kg)

Round Tube/Plate Fin Coil (Cu/Al Tube) 234 297


RTPF Operating Charge A/B, Typical (kg)† 5.0 / 5.0 10.4 / 10.4

RTPF Shipping Charge A/B (kg) 3.6 / 3.6 7.7 / 7.7

COMPRESSOR

Qty...Type 2...Scroll 2...Scroll

Oil Charge A/B (L) 1.2 1.7

CONDENSER FANS

Qty...r/s 2...1100

Motor Hp NEMA 1/4

Diameter (mm) 560


Watts (Total) 610

RTPF CONDENSER COIL



Rows/Fins per Meter (Fins/m) 2 / 670 3 / 670

Face Area (sq m total) 2.3 3.0

CONTROLS

Pressurestat Settings (kPa)

High Cutout 4347 70

Cut-in 3482 138

Low Cutout 372 21

Cut-in 807 34


Qty...Suction A/B 1...1 1/8 / 1...1 1/8 1...1 3/8 / 1...1 3/8

Qty...Liquid A/B 1...3/8 / 1...3/8 1...1/2 / 1...1/2LEGEND

RTPF — Round Tube/Plate FinNEMA — 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.

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Matching CAS Model To Evaporator Coil

The CAS072, 091, 121, 151 models have a single-circuitunit design, requiring one set of refrigeration piping. Thismodel can be connected to an evaporator coil with onecircuit or with two circuits (by manifolding the evaporatorconnections into a single piping system).

The CAS120, 150 is a dual-circuit unit design thatrequires two sets of refrigeration piping between theoutdoor unit and the evaporator coil (or coils). Thismodel can only be connected to an evaporator coil thathas two refrigeration circuits (or to two separateevaporator coils). The CAS120, 150 CANNOT beconnected to a single-circuit evaporator coil and itCANNOT be field-converted to a single-circuit design.

Table 3 – Evaporator Coil Connections

Evaporator Coil has Connect to Model Notes

Single CircuitCAS072, 091, 121,151

Two Circuits

CAS072, 091, 121,151

Manifold evaporatorcircuits into single piping system

Or

CAS120, 150Use two separate piping systems

Before unpacking this new CAS model, compare theevaporator coil design to the CAS model.

.INSTALLATION

Jobsite Survey

Complete 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 which mayinterfere with unit lifting or rigging.

Step 1 — Plan for Unit Location

Select 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 tocombustible surfaces, unit performance and serviceaccess below, around and above unit as specified in unitdrawings. See Fig.1.

NOTE: Local codes may require different clearancesthan specified in Fig. 1. It is the responsibility of installersto be knowledgeable in local codes and to modify therecommended clearances to satisfy local codes.NOTE: Consider also the effect of adjacent units onairflow performance 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 highwalls.

Evaluate the path and required line length forinterconnecting refrigeration piping, including suctionriser requirements (outdoor unit above indoor unit), liquidline lift (outdoor unit below indoor unit) and hot gasbypass line. Relocate sections to minimize the length ofinterconnecting tubing.

DO NOT BURY REFRIGERATION LINES.

Although unit is weatherproof, avoid locations that permitwater from higher level runoff and overhangs to fall ontothe unit.

Fig. 1 − Service Clearance Dimensional Drawing

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

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

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

LEFT:Min 18” (457 mm)requried for service FRONT:42” (1067 mm)

Step 2 — Complete Pre-Installation Checks

Check Unit Electrical Characteristics: Confirm beforeinstallation of unit that voltage, amperage and circuitprotection requirements listed on unit data plate agree withpower supply provided.

Un−crate Unit: Remove unit packaging except for thetop skid assembly, which should be left in place untilafter the unit is rigged into its final location.

Inspect Shipment: File a claim with shipping company ifthe shipment is damaged or incomplete.

Consider System Requirements:

� Consult local building codes and National Electrical Code(NEC, U.S.A.) for special installation requirements.

� Allow sufficient space for airflow clearance, wiring,refrigerant piping, and servicing unit. See unitdimensions and weight distribution data on page 5.

� 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 on thebase channels or mounted on raised pads at supportpoints. See Tables 1A through 2B for unit operatingweights. See Fig. 1 for weight distribution based onrecommended support points.

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

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Step 3 — Prepare Unit Mounting Support

Slab Mount —

Provide a level concrete slab that extends a minimum of6 in. (150 mm) beyond unit cabinet. Install a gravel apronin front of condenser coil air inlet to prevent grass andfoliage from obstructing airflow.

Step 4 — Rig and Mount the Unit

UNIT DAMAGE HAZARD

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.

CAUTION!

Rigging: These units are designed for overhead rigging.Refer to the rigging label for preferred rigging method.Spreader bars are not required if top crating is left on theunit. All panels must be in place when rigging. As furtherprotection for coil faces, plywood sheets may be placedagainst the sides of the unit, behind cables. Run cablesto a central suspension point so that the angle from thehorizontal is not less than 45 degrees. Raise and set theunit down carefully.

If it is necessary to roll the unit into position, mount theunit on longitudinal rails, using a minimum of 3 rollers.Apply force to the rails, not the unit. If the unit is to beskidded into position, place it on a large pad and drag itby the pad. Do not apply any force to the unit.

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

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

Step 5 — Complete Refrigerant PipingConnections

IMPORTANT: Do not bury refrigerant pipingunderground.

IMPORTANT: A refrigerant receiver is notprovided with the unit. Do not install a receiver.

Provide Safety Relief —

If local codes dictate an additional safety relief device,purchase locally and install locally. Installation willrequire the recovery of the factory shipping chargebefore the factory tubing can be cut and thesupplemental relief device is installed.

Models CAS120, 150 have two separate refrigerationsystems. If required, each circuit will require afield-supplied/installed supplemental relief device.

Table 4 – Equivalent Lengths for Common Fittings(ft)

NominalTubeOD

Elbows

90 Std 90 Lrad 90 Street 45 Std 45 Street

3/8 1.3 0.8 2.2 0.6 11/2 1.4 0.9 2.3 0.7 1.15/8 1.6 1 2.5 0.8 1.33/4 1.8 1.2 2.9 0.9 1.57/

8 2 1.4 3.2 0.9 1.6

11/8 2.6 1.7 4.1 1.3 2.1

13/8 3.3 2.3 5.6 1.7 3

15/8 4 2.6 6.3 2.1 3.4

21/8 5 3.3 8.2 2.6 4.5

NominalTubeOD

Tees

BranchFlow

Straight-Thru

No Reduct Reduce 25% Reduce 50%

3/8 2.6 0.8 1.1 1.31/2 2.7 0.9 1.2 1.45/8 3 1 1.4 1.63/4 3.5 1.2 1.7 1.87/

8 4 1.4 1.9 2

11/8 5 1.7 2.3 2.6

13/8 7 2.3 3.1 3.3

15/8 8 2.6 3.7 4

21/8 10 3.3 4.7 5

Check CAS Model with Evaporator Coil Connections

Confirm before installation of unit that the evaporator coilconnections are consistent with this CAS model. SeeTable 3.

Determine Refrigerant Line Sizes —

Select the recommended line sizes for CAS072, 091,121, 151 and CAS120, 150 unit from the appropriatetables.

Determine the linear length of interconnecting pipingrequired between the outdoor unit and indoor unit(evaporator). Consider and identify also the arrangementof the tubing path (quantity and type of elbows in bothlines), liquid line solenoid size, filter drier and any otherrefrigeration specialties located in the liquid line. Refer tothe indoor unit installation instructions for additionaldetails on refrigeration specialties devices.

Determine equivalent line length adjustments for pathand components and add to linear line lengths. SeeTable 4, Equivalent Lengths for Common Fittings, forusual fitting types. Also identify adjustments forrefrigeration specialties. Refer to the indoor unitinstallation instructions for additional information.

NOTE: Equivalent line lengths will vary based on tubediameter. Calculate equivalent line length for each pipeby adding equivalent length adjustments to linear lengthsfor each pipe.

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Enter the appropriate table to select the recommendedline sizes.

Model:Line Sizes

TableQuantity of Line

Sets

CAS072, 091, 121, 151 5 1

CAS120, 150 6 2

Liquid Lift —

A liquid lift condition exists when the outdoor unit islocated below the indoor (evaporator) unit and liquidflows vertically up in a portion of the liquid line. Thevertical column of liquid reduces the available state pointsubcooling at the evaporator coil’s thermal expansionvalve. This effect reduces the length of liquid lift (feet ofelevation) that a liquid line size can accommodate.Longer linear tube lengths will also reduce the amount ofliquid lift possible.

Check Tables 5 (CAS072, 091, 121, 151) and 6(CAS120, 150) for maximum liquid lift capabilities for line

sizes. Reselect the liquid line tube size if necessary. Ifmaximum available tube size cannot provide therequired lift distance on this installation, relocate theoutdoor unit to reduce the equivalent line length or the liftrequirement.

Suction Riser —

A suction riser condition exists when the outdoor unit islocated above the indoor (evaporator) unit and suctionvapor must flow vertically up to return to the compressor.Oil return is a concern when the suction tube size is toolarge to produce the minimum refrigerant velocity toensure oil return at minimum load conditions.

Check Table 7 for maximum suction tube size for CASunits at minimum load conditions. Consider suctionspeed riser (reduced tube size for vertical segment only)or double suction riser arrangement if the recommendedsuction tube size does not provide necessary minimumflowrates for this riser.

Table 5 – CAS072-151 Piping Recommendations (Single-Circuit Unit)R-410A

Linear Length Ft 0-25 25-50 50-75 75-100 100-125

m 0-8 8-15 15-23 23-30 30-38

EquivalentLength

Ft 0-38 38-75 75-113 113-150 150-188

m 0-12 12-23 23-34 34-46 46-57

Model

CAS072 Liquid Line 3/8 3/8 or 1/2 1/2 1/2 or 5/8 1/2 or 5/8Max Lift (ft)

RTPF 25 50 or 50 75 100 or 100 125 or 125

Suction Line 7/8 or 1‐1/8

7/8 or 1‐1/8 1‐

1/8 1‐1/8 1‐

1/8

Suction PD (�F) 1.0 or 0.3 2.1 or 0.6 0.9 1.2 1.5

Charge (lbs)

�RTPF 14.0 15.2 or 16.7 18.6 20.6 or 24.4 22.5 or 28.2

CAS091 Liquid Line 1/2 1/2 1/2 1/2 1/2Max Lift (ft)

�RTPF 25 50 75 100 93

Suction Line 7/8 or 1‐1/8 1‐

1/8 1‐1/8 1‐

1/8 1‐1/8

Suction PD (�F) 1.8 or 0.5 1.0 1.4 1.9 2.4

Charge (lbs)

�RTPF 18.6 19.7 21.7 23.8 25.5

CAS121 Liquid Line 1/2 1/2 1/2 or 5/8 1/2 or 5/8 1/2 or 5/8Max Lift (ft)

�RTPF 25 50 57 or 75 61 or 100 47 or 99

Suction Line 1‐1/8 1‐1/8 1‐

1/8 1‐1/8 or 1‐

3/8 1‐1/8 or 1‐

3/8

Suction PD (�F)(Cap Red)

0.7 1.4 2.1 2.8 or 1.0(‐1.4%)

3.5 or 1.2(‐2.6%)

Charge (lbs)

�RTPF 19.8 21.8 23.5 or 26.2 26.2 or 29.9 DNU or 33.0

CAS151 Liquid Line 1/2 1/2 or 5/8 1/2 or 5/8 1/2 or 3/4 1/2 or 3/4Max Lift (ft)

�RTPF 25 50 or NR 75 or NR 100 or NR 125 or NR

Suction Line 1‐1/8 1‐1/8 1‐

3/8 1‐3/8 1‐

3/8

Suction PD (�F) 1.2 2.4 1.3 1.7 2.2

Charge (lbs)

�RTPF 46.0 47.9 or NR 50.4 or NR 56.3 or NR 59.3 or NR

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Legend:

Linear Length Linear tubing length, feet

Equivalent Length Equivalent tubing length, including effects of refrigeration specialties devices

Liquid Line Tubing size, inches OD.

Max Lift Maximum liquid lift (indoor unit ABOVE outdoor unit only), at maximum permitted liquid line pressure drop� Linear Length Less than 75 ft (23 m): Minimum 2.0°F subcooling entering TXV� Linear Length Greater than 75 ft (23m): Minimum 0.5°F subcooling entering TXV

Suction Line Tube size, inches OD

Suction PD (�F) Suction Line Pressure Drop, saturated temperature, �F

(Cap Red) Capacity Reduction caused by suction line PD greater than 2�F

Charge Charge Quantity, lbs. Calculated for both liquid line sizes (where applicable), but only with larger suction line size (where applicable)

DNU Do Not Use (pressure drop exceeds available subcooling in this model)

NR Not Recommended (use smaller liquid tube size)

NOTE: For applications with equivalent length greater than 188 ft (57 m) and/or linear length greater than 125 ft (38 m), contact your local Carrier representative.

Table 6 – CAS120−150 Piping Recommendations (Two-Circuit Unit)NOTE: CAS120−150 requires TWO sets of refrigeration pipingR-410A

Linear Length Ft 0-25 25-50 50-75 75-100 100-125

m 0-8 8-15 15-23 23-30 30-38

EquivalentLength

Ft 0-38 38-75 75-113 113-150 150-188

m 0-12 12-23 23-34 34-46 46-57

Model


�RTPF 25 50 75 or NR 83 or 100 62 or 125

Suction Line 7/87/8 1‐

1/8 1‐1/8 1‐

1/8

Suction PD (�F) 1.1 2.1 0.9 1.2 1.5

Charge (lbs) (ea circuit)

�RTPF 13.3 14.3 15.8 or NR 16.9 or 20.0 18.1 or 22.0


�RTPF 25 50 75 or NR 54 or 100 45 or 125

Suction Line 7/87/8 1‐

1/8 1‐1/8 1‐/8

Suction PD (�F) 1.1 2.2 1.0 1.3 1.6

Charge (lbs) (ea circuit)

�RTPF 23.0 24.0 27.8 or NR 26.6 or 29.7 27.8 or 31.7

Legend:

Linear Length Linear tubing length, feet

EquivalentLength

Equivalent tubing length, including effects of refrigeration specialties devices

Liquid Line Tubing size, inches OD.

Max Lift Maximum liquid lift (indoor unit ABOVE outdoor unit only), at maximum permitted liquid line pressure drop� Linear Length Less than 75 ft (23 m): Minimum 2.0°F subcooling entering TXV� Linear Length Greater than 75 ft (23m): Minimum 0.5°F subcooling entering TXV

Suction Line Tube size, inches OD

Suction PD (�F) Suction Line Pressure Drop, saturated temperature, �F

(Cap Red) Capacity Reduction caused by suction line PD greater than 2�F

Charge Charge Quantity, lbs. Calculated for both liquid line sizes (where applicable), but only with larger suction line size (where applicable)

DNU Do Not Use (pressure drop exceeds available subcooling in this model)

NR Not Recommended (use smaller liquid tube size)

NOTE: For applications with equivalent length greater than 188 ft (57 m) and/or linear length greater than 125 ft (38 m), contact your local Carrier representative.

Table 7 – CAS Maximum Suction Pipe Size

Model CAS Maximum Tube Size

072 13/8091 15/8121 15/8151 21/8120 13/8150 15/8

Vertical Separation (outdoor unit above indoor unit)

Vertical elevation difference of 200 ft (60 m) is permittedwhen the outdoor unit (CAS) is located above the indoorunit.

Insulate Suction Lines —

Apply closed-cell tubular insulation to all suction linesbetween evaporator coil connection and CAS unit’ssuction service valve.

14 501 01 3007 00

Hot Gas Bypass — (Not available on these models)

Hot gas bypass, if used, should be introduced before theevaporator. (A bypass route that also bypasses theevaporator circuit may lead to oil trapping in theevaporator circuit during low load conditions and then tooil slugging as evaporator load increases.) Model CASunits do not include a hot gas stub connection; a teemust be field-supplied and installed in the compressordischarge line. Run a 1/2-in OD line between outdoor unitand evaporator coil inlet. Install an Auxiliary SideConnector at the evaporator between TXV anddistributor (follow instructions for the side connectorpart). Insulate the hot gas line.

CAS120, 150: Generally only one hot gas bypasssystem will be applied on a two-circuit unit. Connect thehot gas bypass system to Circuit 1 (first-on/last-off,connected to the evaporator coil’s bottom circuit).

CAS120, 150 Piping Connections —

The CAS120, 150 units two circuits are designatedCircuit 1 and Circuit 2. Circuit 1 is controlled by thethermostat’s Y1 (or TC1) contact and will be the firstcircuit on and last circuit off. Circuit 2 is controlled by thethermostat’s Y2 (or TC2) contact and this circuit isalways the “lag” circuit.

See Fig. 2 for location of Circuit 1 and Circuit 2 servicevalves and field piping connections. Circuit 1 is on theleft-hand side of the service valve compartment; Circuit 2is on the right.

When a single piece evaporator coil with two separatecircuits is connected to a CAS120, 150, the lower coilcircuit should be connected to the CAS120, 150 unitsCircuit 1 so that the evaporator’s lower coil segment isfirst-on/last-off (to avoid re-evaporation of condensate ondry lower coil segments).

Fig. 2 − CAS120, 150 Service Valve Locations

Circuit 1Connections

Circuit 2 Connections

CKT2 CKT

1

Plan the Circuit 1 and Circuit 2 tubing segmentscarefully, mark each segment and check constantly aspiping systems are assembled to avoid piping errors.

CAS120, 150 units cannot be field-piped as asingle-circuit/tandem system.

Connecting FAS to CAS120, 150: The FAS fan coil insizes 10, 12.5, and 15 ton is a face-split coil design thatalso has its circuits designated as 1 and 2. See Fig. 3.Note that the lower coil segment changes as thearrangement of the FAS changes. In a verticalarrangement, the FAS’s lower coil segment is segment 2;this segment should be connected to the CAS120, 150’sCircuit 1. In a horizontal arrangement, the FAS’s lowersegment is now segment 1; this segment should beconnected to the CAS120, 150’s Circuit 1.

Note that refrigerant suction piping should be insulated.

FASArrangement

CoolingStage

FAS CoilSegment

Connect toCAS120, 150

VerticalY1Y2

21

Circuit 1Circuit 2

HorizontalY1Y2

12

Circuit 1Circuit 2

Install Filter Drier(s) and Moisture Indicator(s) —

Every unit MUST have a filter drier in the liquid line.CAS120, 150 models require two filter driers (one ineach liquid line). Locate the filter drier(s) at the indoorunit, close to the evaporator coil’s thermal expansionvalve (TXV) inlets.

CAS units include one (CAS072, 091, 121, 151) or two(CAS120, 150) R−410A-duty filter drier(s), shipped incartons attached to the unit basepan. Remove the filterdrier(s) and prepare to install in the liquid line(s) at theevaporator coil. Do not remove connection fitting plugs untilready to connect and braze the filter drier into the liquidline position.

15501 01 3007 00

Fig. 3 − Typical Evaporator Coil Connections (FAS)

FIRST ON/LAST OFF = 2VERTICAL INSTALLATION

FIRST ON/LAST OFF = 1HORIZONTAL INSTALLATION

1

2

2

1

Table 8 – R−410A-duty Filter Drier(s)

Model-Size QtyLiquid

Line ODDesiccant

VolumePart

Number Ref

CAS072 1 3/8-in 8 cu. in. 1179492

CAS091 1 1/2-in 16 cu. in. 1179538

CAS121 1 1/2-in 16 cu. in. 1179538

CAS151 1 5/8‐in 16 cu. in. 1183798

CAS120 2 3/8-in 8 cu. in. 1179492

CAS150 2 1/2‐in 16 cu. in. 1179538

Installation of liquid line moisture indicating sightglass ineach circuit is recommended. Locate the sightglass(es)between the outlet of the filter drier and the TXV inlet.

Refer to Table 9 for recommendations on refrigerationspecialties.

Table 9 – Refrigerant Specialties Part Numbers

LIQUID LINESIZE (in.)

LIQUID LINESOLENOID

VALVE (LLSV)

LLSVCOIL

SIGHTGLASS

FILTERDRIER

3/8 1179871 1179874 1179879 providedwith unit

see Table8

1/2 1179872 1179874 1179878

5/8 1179873 1179874 1179877

CAS120, 150 units require TWO sets of parts.

Fig. 4 − Location of Sight Glass(es) and Filter DriersTypical CAS072, 091, 121, 151 Systems

INDOORCOIL CKT 2

AIRFLOW

INDOORCOIL CKT 1

AIRFLOW

15 DIAMSMIN 10

DIAMS8 DIAMS

MIN

TXVSENSINGBULB

EQUALIZER LINE

SIGHT GLASSA LOCATION

SIGHT GLASSESB LOCATION

TXVCKT 2

FILTER DRIERA LOCATION

FILTER DRIERS B LOCATION

FLOWTXVSENSINGBULB

TXVCKT 1

8 DIAMSMIN

15 DIAMSMIN 10

DIAMS

Single Circuit Coil Piping ConfigurationFor single compressor condensing units

Dual Circuit Coil Piping ConfigurationFor single compressor condensing units

15 DIAMSMIN 10

DIAMS8 DIAMS

MIN

INDOORCOIL CKT

AIRFLOW

TXVSENSINGBULB

EQUALIZER LINE

SIGHT GLASSA LOCATION

TXV

FILTER DRIERA LOCATION

LIQUID LINESOLENOIDVALVE

FLOW

LIQUID LINESOLENOIDVALVE

Fig. 5 − Location of Sight Glasses and Filter DriersTypical CAS120, 150 Systems

AIRFLOW

SUCTIONCIRCUIT 2

SUCTIONCIRCUIT 1

AIRFLOW

15 DIAMSMIN 10

DIAMS8 DIAMS

MIN

TXVSENSINGBULB

EQUALIZER LINE

SIGHT GLASSES

TXVCKT 2

FILTER DRIERS

LIQUID LINESOLENOID VALVECIRCUIT 2

FLOW

LIQUID LINESOLENOID VALVECIRCUIT 1

FLOW

TXVSENSINGBULB

TXVCKT 1

8 DIAMSMIN

15 DIAMSMIN 10

DIAMS

Dual Circuit Coil Piping ConfigurationFor two circuit condensing units

In some applications, depending on space andconvenience requirements, it may be desirable to install2 filter driers and sight glasses in a single circuitapplication. One filter drier and sight glass may beinstalled at A locations (see Fig. 4) or 2 filter driers andsight glasses may be installed at B locations (see Figs. 4and 5).

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

16 501 01 3007 00

Install Liquid Line Solenoid Valve —

It is recommended that a solenoid valve be placed in themain liquid line (see Figs. 4 & 5) between thecondensing unit and the evaporator coil. Locate thesolenoid valve at the outlet end of the liquid line, near theevaporator coil connections, with flow direction arrowpointed at the evaporator coil. Refer to Table 9. (A liquidline solenoid valve is required when the liquid line lengthexceeds 75 ft [23 m].) This valve prevents refrigerantmigration (which causes oil dilution) to the compressorduring the off cycle, at low outdoor ambienttemperatures.

Solenoid drop control wiring: control the power to theliquid line solenoid through a Solenoid Valve Relay (SVR)in all units. Use part number 1178205 (field−supplied,installed). CAS072, 091, 121, 151 units requires one SVR;CAS120, 150 units requires two relays.

CAS120, 150 units also requires a separate control powertransformer for the liquid solenoid valve loads. Selecttransformer part number according to unit power supply.

Unit Power Transformer Part #

208/230 1178027

460 1178077

575 1177852

Mount the SVR (and transformer TRAN3 when used) inunit control box. Connect per wiring schematic label onunit.

Capacity Control Liquid Line Solenoid Valve:Evaporator capacity staging control via direct thermostatcontrol of a liquid solenoid valve on the evaporator’ssecond stage circuit is not possible with CAS models. Ifthis installation is a retrofit for a unit that includedautomatic pressure−operated unloading, check theexisting thermostat and liquid solenoid valve wiring forpossible direct thermostat control of a solenoid valve;re−wire per Figs. 11 or 12 and 22 − 23.

Make Piping Connections —

Piping connections at the CAS072, 091, 121, 151 unitsare ball valves with stub tube extensions. Do not openthe unit service valves until all interconnecting tubebrazing has been completed.

The stub tube connections include 1/4-in SAE servicefittings with Schrader valve cores (see Fig. 6). Beforemaking any brazed connections to the unit servicevalves, remove both Schrader valve caps and cores andsave for re-installation. Connect a source for nitrogen toone of these service fittings during tube brazing toprevent the formation of copper oxides inside the tubesat brazed joints.

Fig. 6 − Typical Piping Connection Assembly

Factory High-FlowAccess Port

Service Valvewith Stem Cap

Field ServiceAccess Port(Schrader core)

SweatConnection

C150028

When connecting the field tubing to the CAS servicevalves, wrap the valves in wet rags to preventoverheating

Pressure-test all joints from outdoor unit connectionsover to the evaporator coil, using nitrogen as pressureand with soap-and-bubbles.

When pressure-testing is completed, remove thenitrogen source at the outdoor unit service valves andre-install the two Schrader valve cores. Torque the coresto 2-3 in-lbs (23-34 N-cm).

Evacuation/Dehydration —

Evacuate and dehydrate the connected refrigerationsystem(s) (excluding the CAS unit) to 500 microns usinga two-stage vacuum pump attached to the service portsoutside the CAS service valves, following description inGTAC II, Module 4, System Dehydration.


Failure to follow this warning could cause personalinjury, death and/or equipment damage.

R−410A refrigerant systems operate at higherpressure than standard R−22 systems. Do not useR−22 service equipment or components on R−410Arefrigerant equipment.

! WARNING

This unit is designed for use with R−410A refrigerant. Donot use any other refrigerant in this system.

R−410A refrigerant is provided in pink (rose) coloredcylinders. These cylinders are available with and withoutdip tubes; cylinders with dip tubes will have a labelindicating this feature. For a cylinder with a dip tube,place the cylinder in the upright position (access valve atthe top) when removing liquid refrigerant for charging.For a cylinder without a dip tube, invert the cylinder(access valve on the bottom) when removing liquidrefrigerant.

Because R−410A refrigerant is a blend, it is stronglyrecommended that refrigerant always be removed from

17501 01 3007 00

the cylinder as a liquid. Admit liquid refrigerant into thesystem in the discharge line. If adding refrigerant into thesuction line, use a commercial metering/expansiondevice at the gauge manifold; remove liquid from thecylinder, pass it through the metering device at thegauge set and then pass it into the suction line as avapor. Do not remove R−410A refrigerant from thecylinder as a vapor.

Preliminary Charge —

Before starting the unit, charge R-410A liquid refrigerantinto the high side of each CAS circuit through the liquidservice valve(s). The amount of refrigerant added mustbe at least 80% of the operating charge listed in Tables 5or 6 for LINEAR line length LESS the factory chargequantity (if factory shipping charge has not beenremoved). See example below.

Allow high and low side pressures to equalize. Ifpressures do not equalize readily, charge R-410A vapor(using special service manifold with expansion device)into the suction line service port for the low side ofsystem to assure charge in the evaporator. Refer toGTAC II, Module 5, Charging, Recover, Recycling, andReclamation for liquid charging procedures.

Example:

CAS121

60-ft (18.3 m) linear line length

Equivalent line length 90-ft (27.4 m)

Liquid Lift: 20-ft (6.1 m)

Select line sizes from Table 5:

Liquid 1/2 in

Suction 1 1/8 in.

Charge 23.5 lbs (at 75−ft linear length)

80% of Operating Charge:

0.80 x 23.5 = 18.8 lbs

Factory Shipping Charge: 16 lbs

Field-Charge quantity: 18.8 − 16.0 = 2.8 lbs

For linear line lengths longer than 125 ft (38 m), contactyour local representative for system charge value.

Step 6 — Install Accessories

Accessories requiring modifications to unit wiring shouldbe completed now. These accessories may includeWinter Start controls and Low Ambient controls. Refer tothe instructions shipped with the accessory.

Step 7 — Complete Electrical Connections


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, unbrokenelectrical ground to minimize the possibility of personalinjury if an electrical fault should occur. This groundmay consist of electrical wire connected to unit groundlug in control compartment, or conduit approved forelectrical ground when installed in accordance withNEC (National Electrical Code); ANSI/NFPA 70, latestedition (in Canada, Canadian Electrical Code CSA[Canadian Standards Association] C22.1), and localelectrical codes.

! WARNING

NOTE: Check all factory and field electrical connectionsfor tightness. Field-supplied wiring shall conform with thelimitations of 63F (33C) rise.

Field Power Supply —

Field power wires are connected to the unit at line-sidepressure lugs on compressor contactor C and TB1 (seewiring diagram label for control box componentarrangement) or at factory-installed option non-fuseddisconnect switch. Max wire size is #4 AWG (copperonly).

NOTE: TEST LEADS - Unit may be equipped with shortleads (pigtails) on the field line connection points oncontactor C or optional disconnect switch. These leadsare for factory run-test purposes only; remove anddiscard before connecting field power wires to unitconnection points. Make field power connections directlyto line connection pressure lugs only.

FIRE HAZARD

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

Do not connect aluminum wire between disconnectswitch and condensing unit. Use only copper wire.(See Fig. 7.)

! WARNING

18 501 01 3007 00

Fig. 7 − Disconnect Switch and Unit

COPPER

WIRE ONLY

ELECTRICDISCONNECT

SWITCH

ALUMINUMWIRE

Units Without Factory-Installed Disconnect —

When installing units, provide a disconnect switch perNEC (National Electrical Code) of adequate size.Disconnect sizing data is provided on the unit informativeplate. Locate on unit cabinet or within sight of the unitper national or local codes. Do not cover unit informativeplate if mounting the disconnect on the unit cabinet.

Units with Factory-Installed Disconnect —

The factory-installed option disconnect switch is locatedin a weatherproof enclosure located under the maincontrol box. The manual switch handle is accessiblethrough an opening in the access panel.

All Units —

All field wiring must comply with NEC and all local codes.Size wire based on MCA (Minimum Circuit Amps) on theunit informative plate. See Fig. 8 for power wiringconnections to the unit contactor and terminal block andequipment ground.

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

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 must be rewired by moving the black wirewith the ��-in. female spade connector from the 230-vconnection and moving it to the 208-v ��-in. maleterminal on the primary side of the transformer. Refer tounit label diagram for line-side information.

Fig. 8 − Power Wiring Connections

11 13

L1 L2 L3

C TB1

208/230-3-60460-3-60575-3-60

Units Without Disconnect Option

Units With Disconnect Option

2

4

6

1

3

5

L1

L2

L3

OptionalDisconnect

Switch

Disconnect factory test leads; discard.

FactoryWiring

Disconnectper

NEC

Affix the crankcase heater warning sticker to the unitdisconnect switch.

Convenience Outlets —

ELECTRICAL OPERATION HAZARD

Failure to follow this warning could result inpersonal injury or death.

Units with convenience outlet circuits may usemultiple disconnects. Check convenience outletfor power status before opening unit for service.Locate its disconnect switch, if appropriate, andopen it. Tag-out this switch, if necessary.

! WARNING

Non−powered convenience outlets are offered on CASmodels that provide a 125-volt GFCI (ground-faultcircuit-interrupter) duplex receptacle rated at 15-Abehind a hinged waterproof access cover, located on theend panel of the unit. See Fig. 9.

19501 01 3007 00

Fig. 9 − Convenience Outlet Location

Control BoxAccess Panel

ConvenienceOutletGFCI

Non-powered type: This type requires the fieldinstallation of a general-purpose 125-volt 15-A circuitpowered from a source elsewhere in the building.Observe national and local codes when selecting wiresize, fuse or breaker requirements and disconnect switchsize and location. Route 125-v power supply conductorsinto the bottom of the utility box containing the duplexreceptacle.

ELECTRICAL OPERATION HAZARD

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

Using unit-mounted convenience outlets: Units withunit-mounted convenience outlet circuits will oftenrequire that two disconnects be opened tode-energize all power to the unit. Treat all units aselectrically energized until the convenience outletpower is also checked and de-energization isconfirmed. Observe National Electrical Code Article210, Branch Circuits, for use of convenience outlets.

! WARNING

Installing Weatherproof Cover: A weatherproof while inuse cover for the factory installed convenience outlets isnow required by UL standards. This cover cannot befactory mounted due its depth; it must be installed at unitinstallation. For shipment, the convenience outlet iscovered with a blank cover plate.

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

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) under screw heads areexposed. Press the gasket over the screw heads. Slipthe backing plate over the screw heads at the keyholeslots and align with the gasket; tighten the two screwsuntil snug (do not overtighten).

Mount the weatherproof cover to the backing plate asshown in Fig. 10. Remove two slot fillers in the bottom ofthe cover to permit service tool cords to exit the cover.Check for full closing and latching.

Fig. 10 − Weatherproof Cover Installation

All Units —

Voltage to compressor terminals during operation mustbe within voltage range indicated on unit nameplate. SeeTables 10 and 11. On 3-phase units, voltages betweenphases must be balanced within 2% and the currentwithin 10%. Use the formula shown in the legend forTables 10 and 11, Note 5 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.

Field Control Wiring —

CAS unit control voltage is 24 v. See Fig. 22 − 23 fortypical field control connections and the unit’s labeldiagram for field-supplied wiring details. Route controlwires to the CAS unit through the opening in unit’s end

20 501 01 3007 00

panel to the connections terminal board in the unit’scontrol box.

Remainder of the system controls connection will varyaccording to the specific construction details of theindoor section (air handler or packaged fan coil). Fig. 11(CAS072, 091, 121, 151) and Fig. 12 (CAS120, 150)depict typical connections to a FAS fan coil unit. Plan forfield connections carefully and install control wiringcorrectly per the project plan. Additional components andsupplemental transformer accessory may be required.

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

Thermostat —

Install an approved accessory thermostat according toinstallation instructions included with the accessory.Locate the thermostat accessory on a solid wall in theconditioned space to sense average temperature inaccordance with the thermostat installation instructions.

The CAS072, 091, 121, 151 unit is a single−stage coolingunit. If no economizer function is required, select asingle−stage cooling thermostat. If an integratedeconomizer function is required, select a two−stage coolingthermostat.

The CAS120, 150 is a dual−circuit, two-stage coolingunit. Select a two—stage cooling thermostat.

Select a thermostat cable or equivalent single leads ofdifferent colors with minimum of four leads for CAS072,091, 121, 151 or five leads for CAS120, 150 unit. Checkthe thermostat installation instructions for additionalfeatures which might require additional conductors in thecable.

For wire runs up to 50 ft. (15 m), use no. 18 AWG(American Wire Gage) insulated wire (35C minimum).For 50 to 75 ft. (15 to 23 m), use no. 16 AWG insulatedwire (35C minimum). For over 75 ft. (23 m), use no. 14AWG insulated wire (35C minimum). All wire sizeslarger than no. 18 AWG cannot be directly connected tothe thermostat and will require a junction box and spliceat the thermostat.

Fig. 11 − Typical Remote Thermostat Connections— CAS072, 091, 121, 151

Note 1: �Connect only if thermostat requires 24-vac power source.

Note 2: �Connect W1 and W2 if supplemental heaters are installed

�� Field Wiring

(Note 1)

(Note 2)

(Note 2)

FAS CAS

Fig. 12 − Typical Remote Thermostat Connections— CAS120, 150

Note 1: �Typical multi-function marking. Follow manufacturer's configuration

�� instructions to select Y2.

Note 2: �Connect only if thermostat requires 24-vac power source.

Note 3: ��Connect W1 and W2 if supplemental heaters are installed

�� Field Wiring

(Note 1)

(Note 2)

(Note 3)

(Note 3)

21501 01 3007 00

If the unit will be operating at 208-3-60 power, removethe black wire (BLK) from the transformer primaryconnection labelled “230” and move it to the connectionlabelled “208”. See Fig. 13.

Fig. 13 − Control Transformer Wiring

External Devices —

The CAS control transformers provide 24−v NEC Class 2power sources to energize external control devices. Thesedevices will include the indoor fan motor contactor (orcontrol relay). These devices may also include liquid linesolenoid valve (two on CAS120, 150 models), economizercontrol relay, supplemental electric heater contactors orcontrol relays and other devices selected by systemdesigner.

Control transformer TRAN1 provides control power throughterminal R to C on the CTB’s field connection terminal stripfor supply fan motor interlock. This source may also beused to energize economizer control relay and electricheater contactors or relays. Maximum available power is20 va. Check concurrent loadings by external controldevices. If the maximum concurrent loading exceeds 20va, purchase and install the accessory Transformer−Relaypackage (available for 208/230 and 460−v units).

CAS120, 150 ONLY: Control transformer TRAN3 providescontrol power through terminals A1 (9) and A2 (10) to C forliquid line solenoids. Maximum available power is 75 va.These outputs are switched ON/OFF by the SolenoidValve Relays.

22 501 01 3007 00

Table 10 – Electrical Data — CAS072−151 60 Hz Units

WITHOUT POWERED CONVENIENCE OUTLET

UNITCAS

V-Ph-Hz

VOLTAGERANGE�

COMPRESSOR 1 OFM (ea)POWERSUPPLY

DISCONNECT SIZE

MIN MAX RLA LRA QTY FLA MCA

Fuse orHACRBrkr

FLA LRA

072Units produced

on or after02/09/2015

208/230-3-60 187 253 19.6 136 2 1.5 28/28 45/45 26/26 142/142

460-3-60 414 506 8.2 66 2 0.8 12 20 11 70

575-3-60 518 633 6.6 55 2 0.7 10 15 9 59

072Units producedon or prior to02/08/2015

208/230-3-60 187 253 19.0 123 2 1.5 26.8/26.8 45/45 25/25 129/129

460-3-60 414 506 9.7 62 2 0.8 13.7 20 13 66

575-3-60 518 633 7.4 50 2 0.7 10.4 15 10 54

091

208/230-3-60 187 253 25.0 164 2 1.5 35/35 50/50 32/32 170/170

460-3-60 414 506 12.2 100 2 0.8 17 25 16 104

575-3-60 518 633 9.0 78 2 0.7 13 20 12 82

121

208/230-3-60 187 253 30.1 225 2 1.5 41/41 60/60 38/38 231/231

460-3-60 414 506 16.7 114 2 0.8 23 30 21 118

575-3-60 518 633 12.2 80 2 0.7 17 25 16 84

151

208/230-3-60 187 253 48.1 245 2 1.5 64/64 80/80 59/59 251/251

460-3-60 414 506 18.6 125 2 0.8 25 30 23 129

575-3-60 518 633 14.7 100 2 0.7 20 30 19 104

NOTE: See “Legend and Notes for Tables 10 & 11” on page 22.

Table 11 – Electrical Data — CAS120−150 60 Hz Units

WITHOUT POWERED CONVENIENCE OUTLET

UNITCAS

V-Ph-Hz

VOLTAGERANGE�

COMPRESSOR1

COMPRESSOR2

OFM (ea)POWERSUPPLY

DISCONNECTSIZE

MIN MAX RLA LRA RLA LRA QTY FLA MCAFuse orHACRBrkr

LRA RLA

120

208/230-3-60 187 253 15.9 110 15.9 110 2 1.5 39/39 50/50 40/40226/22

6

460-3-60 414 506 7.7 52 77 52 2 0.8 19 25 20 108

575-3-60 518 633 5.7 39 5.7 39 2 0.7 15 20 15 82

150

208/230-3-60 187 253 22.4 149 22.4 149 2 1.5 54/54 60/60 55/55304/30

4

460-3-60 414 506 10.6 75 10.6 75 2 0.8 26 30 26 154

575-3-60 518 633 7.7 54 7.7 54 2 0.7 19 25 19 112

NOTE: See “Legend and Notes for Tables 10 & 11” on page 22.

23501 01 3007 00

Legend and Notes for Table 10 and 11LEGEND:FLA − Full Load AmpsLRA − Locked Rotor AmpsMCA − Minimum Circuit Amps

ProtectionMOCP − Maximum Overcurrent

ProtectionNEC − National Electrical CodeRLA − Rated Load Amps

� Units are suitable for use on electrical systems where voltagesupplied to the unit terminals is not below or above the listedlimits.

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 accordancewith Underwriters' Laboratories (UL). Standard 1995.

3. The 575-v units are UL, Canada-listed only.

4. Unbalanced 3‐Phase Supply VoltageNever operate a motor where a phase imbalance in supplyvoltage is greater than 2%. Use the following formula to determine the percentage of voltage imbalance.

Example: Supply voltage is 230-3-60

% Voltage Imbalance = 100 xmax voltage deviation from average voltage

average voltage

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.

24 501 01 3007 00

PRE-START-UPIMPORTANT: Before beginning Pre-Start-Up orStart-Up, review Start-Up Checklist at the back of thisbook. The Checklist assures proper start-up of a unitand provides a record of unit condition, applicationrequirements, system information, and operation atinitial start-up.

UNIT DAMAGE HAZARD


Do not attempt to start the condensing unit, evenmomentarily, until the following steps have beencompleted. Compressor damage may result.

CAUTION!

System Check1.The electrical power source must agree with the unit’s

nameplate rating.2.Check all air handler(s) and other equipment auxiliary

components. Consult the manufacturer’s instructionsregarding any other equipment connected to thecondensing unit. If the unit has field-installedaccessories, be sure all are properly installed andcorrectly wired. If used, the airflow switch must beproperly installed.

3.Check tightness of all electrical connections.4.Be sure liquid line and low side of the system are

properly leak checked and dehydrated.5.Be sure the unit is properly charged. See “Preliminary

Charge”, below.6.Open the liquid line and suction line service valves.7.The crankcase heater must be firmly attached to the

compressor crankcase. Be sure the crankcase iswarm (heater must be on for 24 hours before startingcompressor).

Turn On Crankcase Heater —

Turn on the crankcase heater for 24 hours before startingthe unit to be sure all the refrigerant is out of the oil. Toenergize the crankcase heater, 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.

Preliminary Charge —

Before starting the unit, charge liquid refrigerant into thehigh side of the system through the liquid service valve.The amount of refrigerant added must be at least 80% ofthe operating charge listed in the Physical Data table(Tables 1A through 2B). Allow high and low side pressuresto equalize before starting compressor. If pressures do notequalize readily, charge vapor on low side of system toassure charge in the evaporator. Refer to GTAC II, Module5, Charging, Recover, Recycling, and Reclamation forliquid charging procedures.

UNIT DAMAGE HAZARD


Prior to starting compressor, a preliminary charge ofrefrigerant must be added to avoid possiblecompressor damage.

CAUTION!

START-UPCAS Units: The compressor crankcase heater must beon for 24 hours before start-up. After the heater hasbeen on for 24 hours, the unit can be started. If no timeelapsed since the preliminary charge step wascompleted, it is unnecessary to wait the 24-hour period.

Preliminary Checks1.Check that electric power supply agrees with unit

nameplate data.2.Verify that the compressor crankcase heater is

securely in place.3.Check that the compressor crankcase heater has

been on at least 24 hours.4.Recheck for leaks using the procedure outlined in the

Pre-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 added asdescribed in the Pre-Start-Up section, PreliminaryCharge.

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

NOTE: The CAS units are factory charged with therequired amount of oil. If recharging in required, useEmkarate RL 32-3MAF for the CAS units.

Compressor Rotation —

On 3−phase units with scroll compressors, it is important tobe certain that the compressor is rotating in the properdirection. CAS units are equipped with a Comfort AlertDiagnostic Module (CADM). Alert Code 7 indicates reversepower phasing.

To correct phase order:

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.

To verify the 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.

25501 01 3007 00

Compressor Overload —

This overload interrupts power to the compressor wheneither the current or internal motor winding temperaturebecomes excessive, and automatically resets when theinternal temperature drops to a safe level. This overloadmay require up to 60 minutes (or longer) to reset. If theinternal overload is suspected of being open, disconnectthe electrical power to the unit and check the circuitthrough the overload with an ohmmeter or continuitytester.

Advanced Scroll Temperature Protection (ASTP) —

A label located above the terminal box identifies CopelandScroll compressor models that contain this technology. SeeFig. 14. Advanced Scroll Temperature Protection (ASTP) isa form of internal discharge temperature protection, thatunloads the scroll compressor when the internaltemperature reaches approximately 149�C (300�F). At thistemperature, an internal bi−metal disk valve opens andcauses the scroll elements to separate, which stopscompression. Suction and discharge pressures balancewhile the motor continues to run. The longer thecompressor runs unloaded, the longer it must cool beforethe bi−metal disk resets. See Fig. 15.

Fig. 14 − Advanced Scroll Temperature ProtectionLabel

Fig. 15 − Recommended Minimum Cool-Down TimeAfter Compressor is Stopped

0

10

20

30

40

50

60

70

80

90

100

11�0

120

0��10�� 20�� 30�40�� 60�� 70�� 80�� 9050

Compressor Unloaded Run Time (Minutes)*

Recom

mended C

oolin

g T

ime

*

(Min

ute

s)

*Times are approximate.NOTE: Various factors, including high humidity, high ambient temperature,and the presence of a sound blanket will 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 beforethe motor protector resets, which may take up to 2hours.

Start Unit

Set the space thermostat to a set point above spacetemperature so that there is no demand for cooling.Close the CAS disconnect switch. Only the crankcaseheater will be energized.

Reset the space thermostat below ambient so that a callfor cooling is ensured.

UNIT DAMAGE HAZARD


Never charge liquid into the low-pressure side ofsystem. Do not overcharge. During charging orremoval of refrigerant, be sure indoor-fan system isoperating. Ensure both outdoor fan motors arerunning; bypass any Motormaster function.

CAUTION!

Adjust Refrigerant Charge —

Refer to Cooling Charging Charts, Fig. 16 through Fig. 21.For applications with line lengths greater than 125 ft (38m), contact your service representative. Vary refrigerantuntil the conditions of the chart are met. Note that thecharging charts are different from the type normally used.The charts are based on charging the units to the correctsubcooling for the various operating conditions. Accuratepressure gage and temperature sensing device arerequired. Connect the pressure gage to the service port onthe 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 conformwith the charging chart, using the liquid pressure andtemperature to read the chart.

Using plotted operating point:

If plotted operating condition is − Adjust charge by −

BELOW the curve REDUCE charge

ABOVE the curve ADD charge

Final Checks —

Ensure that all safety controls are operating, controlpanel covers are on, and the service panels are in place.

26 501 01 3007 00

Fig. 16 − CAS072 Charging Chart (RTPF)

6 TON CHARGING CHART R−410AALL CONDENSER FANS OPERATING

6 TONNE TABLEAU DE CHARGE R−410ATOUTES LES SOUFFLERIES DE CONDENSATION EN FONCTIONNEMENT


7.5 TON CHARGING CHART R−410AALL CONDENSER FANS OPERATING

7.5 TONNE TABLEAU DE CHARGE R−410ATOUTES LES SOUFFLERIES DE CONDENSATION EN FONCTIONNEMENT

27501 01 3007 00


10 TON CHARGING CHART R−410AALL CONDENSER FANS OPERATING



12.5 TON CHARGING CHART R−410AALL CONDENSER FANS OPERATING


28 501 01 3007 00


10 TON CHARGING CHART R−410A ALL CONDENSER FANS OPERATING


10 TON CHARGING CHART R−410A ALL CONDENSER FANS OPERATING


29501 01 3007 00


12.5 TON CHARGING CHART R−410A ALL CONDENSER FANS OPERATING


12.5 TON CHARGING CHART R−410A ALL CONDENSER FANS OPERATING


30 501 01 3007 00

Fig. 22 − Typical CAS072, 091, 121, 151 WIRING DIAGRAM

C10925

31501 01 3007 00

Fig. 23 − Typical CAS120, 150 WIRING DIAGRAM

C10926

32 501 01 3007 00

OPERATING SEQUENCE

Base Unit Controls

Indoor (Supply) Fan —

The indoor fan contactor (IFC) is remotely located at thefan coil 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 —

CAS072, 091, 121, 151 (Single Circuit)

On a thermostat call for Cooling, IFC will be energizedand indoor (supply) fan motor runs. Thermostat outputY1 is energized; terminal Y1 at CAS072, 091, 121, 151units receives 24-v. 24-v received at CADM1 terminal Y.If anti-recycle time delay period has not expired, CADM1relay will remain open, de-energizing Solenoid ValveRelay (SVR) and preventing compressor start. Whensafety pressure switches are closed and CADM1 timedelay expires, CADM1 relay closes, SVR andcompressor contactor C are energized; liquid linesolenoid valve LLSV opens, all outdoor fan motors startand Compressor starts.

As space cooling load is satisfied, thermostat output Y1is de−energized, removing 24-v at CAS072, 091, 121,151 terminal Y1. On Y1 opening, Compressor stops, alloutdoor fan motors stop and SVR relay is de-energized.Liquid line solenoid valve is de-energized and valvecloses. CADM1 begins its three-minute anti-recycle timedelay.

CAS120, 150 (Two Circuit)

On a thermostat call for Cooling, IFC will be energizedand indoor (supply) fan motor runs. Thermostat outputY1 is energized; terminal Y1 at CAS120, 150 unitreceives 24-v. 24-v received at CADM1 terminal Y. Ifanti-recycle time delay period has not expired, CADM1relay will remain open, de-energizing Solenoid ValveRelay 1 (SVR1) and preventing compressor start. Whensafety pressure switches are closed and CADM1 timedelay expires, CADM1 relay closes, SVR1 andcompressor contactor C1 are energized; liquid linesolenoid valve LLSV1 opens, all outdoor fan motors startand Circuit 1 compressor starts.

On a thermostat calling for Stage 2 Cooling, thermostatoutput Y2 is energized; terminal Y2 at CAS120, 150 unitreceives 24-v. 24-v received at CADM2 terminal Y. Ifanti-recycle time delay period has not expired, CADM2relay will remain open, de-energizing Solenoid ValveRelay 2 (SVR2) and preventing compressor start. Whensafety pressure switches are closed and CADM2 timedelay expires, CADM2 relay closes, SVR2 andcompressor contactor C2 are energized; liquid line

solenoid valve LLSV2 opens and Circuit 2 compressorstarts.

As space cooling load is satisfied, thermostat outputs Y2and Y1 are de−energized, removing 24-v at CAS120,150 terminals Y2 and Y1. Circuit 2 compressor stops onY2 opening; SVR2 is de-energized and LLSV2 closes.CADM2 begins its three-minute anti-recycle time delay.On Y1 opening, Circuit 1 compressor stops, all outdoorfan motors stop and SVR1 relay is de-energized. Liquidline solenoid valve LLSV1 is de-energized and valvecloses. CADM1 begins its three-minute anti-recycle timedelay.

All Units

If either the Low Pressure Switch or High PressureSwitch opens while thermostat output Y1 or Y2 remainenergized, the compressor contactor is de-energized,the compressor stops and liquid line solenoid isde-energized (valve closes). CADM initiates a TRIPevent (cooling demand sensed at CADM terminal Y butno current is measured at T1, T2, T3 motor sensors);CADM relay opens and RED LED is illuminated. TRIPcondition maintains lockout of compressor operation untilCADM is manually reset. Reset CADM by cycling unitmain power.

Complete system shutdown may be caused by loss ofmain power, open compressor internal overload, openlow-pressure or high-pressure switch, or a fault detectedby the CADM logic. Compressor operation withoutcooling may indicate the compressor’s ASTP feature isactive; disconnect unit power and allow compressor tocool. See Service section for further details.

Cooling, Unit With Economizer —

Refer to fan coil unit installation instructions andeconomizer accessory installation instructions foroperating sequences when system is equipped withaccessory economizer.

Heating —

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

33501 01 3007 00

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 Maintenance —

These 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

SERVICERefrigeration System

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in damage toequipment.

This system uses R−410A refrigerant which hashigher pressures than R-22 and other refrigerants.No other refrigerant may be used in this system.Gage set, hoses, and recovery system must bedesigned to handle R−410A. If you are unsureconsult the equipment manufacturer.

CAUTION!

Compressor Oil —

EQUIPMENT DAMAGE HAZARD

Failure to follow this caution may result in damage toequipment.

The compressor in a R−410A system uses apolyolester (POE) oil. This oil is extremelyhygroscopic, meaning it absorbs water readily. POEoils can absorb 15 times as much water as other oilsdesigned for HCFC and CFC refrigerants. Take allnecessary precautions to avoid exposure of the oil tothe atmosphere.

CAUTION!

Servicing Systems on Roofs With Synthetic Materials

POE (polyolester) compressor lubricants are known tocause long term damage to some synthetic roofingmaterials. Exposure, even if immediately cleaned up, maycause embrittlement (leading to cracking) to occur in oneyear or more. When performing any service which may riskexposure of compressor oil to the roof, take appropriateprecautions to protect roofing. Procedures which risk oilleakage include but are not limited to compressorreplacement, repairing refrigerants leaks, replacingrefrigerant components such as filter drier, pressure switch,metering device, coil, accumulator, or reversing valve.

Synthetic Roof Precautionary Procedure:

1.Cover extended roof working area with animpermeable polyethylene (plastic) drop cloth or tarp.Cover an approximate 10 x 10 ft (3.3 x 3.3 m) area.

2.Cover area in front of the unit service panel with aterry cloth shop towel to absorb lubricant spills andprevent run-offs, and protect drop cloth from tearscaused by tools or components.

3.Place terry cloth shop towel inside unit immediatelyunder component(s) to be serviced and preventlubricant run-offs through the louvered openings in thebase pan.

4.Perform required service.5.Remove and dispose of any oil contaminated material

per local codes.

34 501 01 3007 00

Liquid Line Filter Drier —

The factory-provided filter drier is specifically designed tooperate with R−410A. Replace the filter drier withfactory-authorized components only with a filter drier withdesiccant made from 100% molecular sieve gradeXH-11. Filter drier must be replaced whenever therefrigerant system is opened.

When removing a filter drier, use a tubing cutter to cutthe drier from the system. Do not unsweat a filter drierfrom the system. Heat from unsweating will releasemoisture and contaminants from drier into system.

Field Refrigerant Access Ports —

Field service access to refrigerant pressures is throughthe access ports located at the service valves (see Figs28 and 30). These ports are -in SAE Flare couplingswith Schrader check valves and service caps. Use theseports to admit nitrogen to the field tubing during brazing,to evacuate the tubing and evaporator coil, to admitinitial refrigerant charge into the low-side of the systemand when checking and adjusting the system refrigerantcharge. When service activities are completed, ensurethe service caps are in place and secure; check forleaks. If the Schrader check valve must be removed andre-installed, tighten to 2-3 in-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 thesuction service valve and on the liquid tube near theliquid service valve (see Figs 28 and 30). These arebrass fittings with black plastic caps. The hoseconnection fittings are standard -in SAE Male Flarecouplings.

The brass fittings are two-piece High Flow valves, with areceptacle base brazed to the tubing and an integralspring-closed check valve core screwed into the base.(See Fig. 24) This check valve is permanentlyassembled into this core body and cannot be servicedseparately; replace the entire core body if necessary.Service tools are available from FAST that allow thereplacement of the check valve core without having torecover the entire system refrigerant charge. Applycompressor refrigerant oil to the check valve core’sbottom o-ring. Install the fitting body with 96 -10 in-lbs(1085 23 N-cm) of torque; do not overtighten.

Fig. 24 − CoreMax Access Port Assembly

1/2-20 UNF RH

30

0.596

SEAT CORE

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

7/16-20 UNF RH

O-RING

45

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)

⅝ Hex .47

35501 01 3007 00

Comfort Alert Diagnostic Module

The 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. Each compressor has a separate CADM module.

The CADM detects causes for electrical and systemrelated failures without any sensors. Flashing LEDscommunicate the Alert codes to guide servicetechnicians in accurately and quickly troubleshooting thesystem and determining root cause for the failure.

Inputs to the CADM include 24-vac power, thermostat Y1or Y2, compressor contactor coil (common side) andcompressor power leads (from the compressorcontactor).

Input Terminal Voltage

ControlPower R 24-V

ControlCommon C 24-V

Cooling Y 24-V

ContactorCoil P 24-V

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 modulehousing (see Fig. 25): POWER (green), ALERT (yellow),and TRIP (red).

The POWER LED indicates the presence of controlpower to the CADM.

The ALERT LED indicates an abnormal condition existsin the system through a flash code. The ALERT LED willblink a number of times consecutively, pause and therepeat the process. The number of blinks, defined inTable 12, 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, theAlert code will be removed and the CADM willautomatically reset and allow the system to restartnormally. Manual reset requires that main power to theCAS unit be recycled after the cause for the Alertcondition has been detected and corrected.

Fig. 25 − CADM Housing/LED LocationsPOWER(GRN)

ALERT(YEL)

TRIP(RED)

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 atthe compressor line terminals T1 or T2 or T3. Thislockout can occur due to a safety switch (LPS or HPS)opening and de-energizing the compressor contactor,the compressor-motor internal overload opens, or otherinternal power interruption has occurred. Reset of theTRIP LED requires that unit main power be recycledafter the loss of power to the compressor condition hasbeen detected 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 13 fordiscussion of additional LED flash codes andtroubleshooting instructions.

36 501 01 3007 00

Table 12 – 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 signalY is present, but the com-pressor is not running.

1. Compressor protector is open

2. Condensing unit power disconnect is open

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” 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 cur-rent condition exists onPROT terminal.

1. Compressor contactor coil shorted

2. Electrical load too high for PROT circuit (maximum 1 Amp)

3. 24 V AC wired directly to PROT terminal

Yellow “ALERT”Flash Code 2

System Pressure Trip Discharge pressure out oflimits or compressor over-load (if no high pressureswitch in system) LOCKOUT

1. High head pressure

2. Condenser coil poor air circulation (dirty, blocked, damaged)

3. Condenser fan is not running

4. If low pressure switch is open: Refer to Code 3 for troubleshooting

Yellow “ALERT”Flash Code 3

Short Cycling Compressor is running onlybriefly (four consecutivecycles of less than threeminutes each)LOCKOUT

1. If low pressure switch is open:

a. Low refrigerant charge

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

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