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501 01 3007 00 1/21/15
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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2 501 01 3007 00
SAFETY CONSIDERATIONSImproper installation, adjustment,
alteration, service,maintenance, or use can cause explosion, fire,
electricalshock, or other conditions which may cause death,personal
injury, or property damage. Consult a qualifiedinstaller, service
agency, or your distributor or branch forinformation or assistance.
The qualified installer oragency must use factory−authorized kits
or accessorieswhen modifying this product. Refer to the
individualinstructions packaged with the kits or accessories
wheninstalling.
Follow all safety codes. Wear safety glasses,
protectiveclothing, and work gloves. Use quenching cloth forbrazing
operations. Have fire extinguisher available.Read these
instructions thoroughly and follow allwarnings or cautions included
in literature and attachedto the unit. Consult local building
codes, the currenteditions of the National Electrical Code (NEC)
NFPA 70.
In Canada refer to the current editions of the
CanadianElectrical Code CSA C22.1 Recognize safetyinformation.
Recognize safety information. This is the
safety−alert symbol ! ! When you see this symbol on the
unit and in instructions or manuals, be alert to thepotential
for personal injury. Understand these signalwords; DANGER, WARNING,
and CAUTION. Thesewords are used with the safety−alert symbol.
DANGERidentifies the most serious hazards which will result
insevere personal injury or death. WARNING signifieshazards which
could result in personal injury or death.CAUTION is used to
identify unsafe practices which mayresult in minor personal injury
or product and propertydamage. NOTE is used to highlight
suggestions whichwill result in enhanced installation, reliability,
oroperation.
! WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal in-jury
or death.
Before performing service or maintenance operationson unit,
always turn off main power switch to unit and in-stall lockout tag.
Unit may have more than one powerswitch.
! WARNING
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this warning could cause personal in-jury,
death and/or equipment damage.
R−410A systems operate at higher pressures than R−22systems.
When working with R−410A systems, use onlyservice equipment and
replacement components specif-ically rated or approved for R−410A
service.
! WARNING
PERSONAL INJURY AND ENVIRONMENTALHAZARD
Failure to follow this warning could cause personal injuryor
death.
Relieve pressure and recover all refrigerant before sys-tem
repair or final unit disposal.Wear safety glasses and gloves when
handling refriger-ants.Keep torches and other ignition sources away
from refri-gerants and oils.
! CAUTIONCUT HAZARD
Failure to follow this caution may result in personal
injury.
Sheet metal parts may have sharp edges or burrs. Usecare and war
appropriate protective clothing, safetyglasses and gloves when
handling parts and servicingunits.
! 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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3501 01 3007 00
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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4 501 01 3007 00
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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5501 01 3007 00
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
OPERATING WEIGHTS (lb)
Round Tube/Plate Fin Coil (Cu/Al) 176 177 222 271
REFRIGERANT TYPE‡ R-410A
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
Material (Tube/Fin) Cu / Al
Coil Type 3/8−in RTPF
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
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 FinNEMA — National Electrical
Manufacturers AssociationODS — 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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8 501 01 3007 00
Table 2A — Physical Data — CAS120−150 Units — 60 Hz English
UNIT SIZE CAS 120 150
NOMINAL CAPACITY (tons) 10 12.5
OPERATING WEIGHTS (lb)
Round Tube/Plate Fin Coil (Cu/Al) 516 654
REFRIGERANT TYPE‡ R-410A
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
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) 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 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)
‡ Unit is factory‐supplied with partial charge only.† Typical
operating charge with 25 ft of interconnecting piping.
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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
REFRIGERANT TYPE‡ R-410A
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
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 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
PIPING CONNECTIONS (in. ODS)
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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10 501 01 3007 00
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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11501 01 3007 00
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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12 501 01 3007 00
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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13501 01 3007 00
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
CAS120 Liquid Line 3/8 3/8 3/8 or 1/2 3/8 or 1/2 3/8 or 1/2Max
Lift (ft)
�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
CAS150 Liquid Line 3/8 3/8 3/8 or 1/2 3/8 or 1/2 3/8 or 1/2Max
Lift (ft)
�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.
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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.
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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.
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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.
UNIT OPERATION AND SAFETY HAZARD
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
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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
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personalinjury or
death.
Do not use gas piping as an electrical ground. Unitcabinet must
have an uninterrupted, 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.
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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)
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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.
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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.
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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
Failure to follow this caution may result in
equipmentdamage.
Do not attempt to start the condensing unit, evenmomentarily,
until the following steps have beencompleted. Compressor damage may
result.
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
Failure to follow this caution may result in
equipmentdamage.
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.
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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
Failure to follow this caution may result in
equipmentdamage.
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
Fig. 17 − CAS091 Charging Chart (RTPF)
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
Fig. 18 − CAS121 Charging Chart (RTPF)
10 TON CHARGING CHART R−410AALL CONDENSER FANS OPERATING
10 TONNE TABLEAU DE CHARGE R−410ATOUTES LES SOUFFLERIES DE
CONDENSATION EN FONCTIONNEMENT
Fig. 19 − CAS151 Charging Chart (RTPF)
12.5 TON CHARGING CHART R−410AALL CONDENSER FANS OPERATING
12.5 TONNE TABLEAU DE CHARGE R−410ATOUTES LES SOUFFLERIES DE
CONDENSATION EN FONCTIONNEMENT
-
28 501 01 3007 00
Fig. 20 − CAS120 Charging Chart (RTPF)
10 TON CHARGING CHART R−410A ALL CONDENSER FANS OPERATING
10 TONNE TABLEAU DE CHARGE R−410ATOUTES LES SOUFFLERIES DE
CONDENSATION EN FONCTIONNEMENT
10 TON CHARGING CHART R−410A ALL CONDENSER FANS OPERATING
10 TONNE TABLEAU DE CHARGE R−410ATOUTES LES SOUFFLERIES DE
CONDENSATION EN FONCTIONNEMENT
-
29501 01 3007 00
Fig. 21 − CAS150 Charging Chart (RTPF)
12.5 TON CHARGING CHART R−410A ALL CONDENSER FANS OPERATING
12.5 TONNE TABLEAU DE CHARGE R−410ATOUTES LES SOUFFLERIES DE
CONDENSATION EN FONCTIONNEMENT
12.5 TON CHARGING CHART R−410A ALL CONDENSER FANS OPERATING
12.5 TONNE TABLEAU DE CHARGE R−410ATOUTES LES SOUFFLERIES DE
CONDENSATION EN FONCTIONNEMENT
-
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.
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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
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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