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INSTALLATION INSTRUCTIONS
R- -410A SPLIT CONDENSING UNITS
CAS180/181- -240/241 with RTPF
These instructions must be read and understood completely before attempting installation
DANGER, WARNING, CAUTION, and NOTE
The signal words DANGER, WARNING,
CAUTION, and NOTE are used to identify levels of
hazard seriousness. The signal word DANGER is
only used on product labels to signify an immediate
hazard. The signal words WARNING, CAUTION,
and NOTE will be used on product labels and
throughout this manual and other manual that may
apply to the product.
DANGER -- Immediate hazards which will result in
severe personal injury or death.
WARNING --Hazards or unsafe practices which
could result in severe personal injury or death.
CAUTION -- Hazards or unsafe practices which
may result in minor personal injury or product or
property damage.
NOTE -- Used to highlight suggestions which will
result in enhanced installation, reliability, or
operation.
TABLE OF CONTENTS
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Specifications are subject to change without notice.
Signal Words in Manuals
The signal word WARNING is used throughout
this manual in the following manner:
WARNING
!
The signal word CAUTION is used throughout
this manual in the following manner:
CAUTION
!
Signal Words on Product Labeling
Signal words are used in combination with
colors and/or pictures or product labels.
WARNING
2
!
3
4
PERSONAL INJURY, AND/OR PROPERTY
9
DAMAGE HAZARD
9
Failure to carefully read and follow this warning
9
could result in equipment malfunction, property
damage, personal injury and/or death.
10
10
Installation or repairs made by unqualified
persons could result in equipment malfunction,
20
property damage, personal injury and/or death.
20
The information contained in this manual is
28
intended for use by a qualified service technician
29
familiar with safety procedures and equipped
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with proper tools and test instruments.
40
Installation must conform with local building
42
codes and with the national Electrical Code
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NFPA70 current edition or Canadian Electrical
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Code part 1 CSA C.22.1.
52
501 01 3403 01
10/19
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Table of Contents
Related Manuals for International comfort products CAS180
Summary of Contents for International comfort products CAS180
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Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS R- -410A SPLIT CONDENSING UNITS CAS180/181- -240/241 with RTPF These instructions must be read and understood completely before attempting installation Safety Labeling and Signal Words DANGER, WARNING, CAUTION, and NOTE The signal words DANGER, WARNING, Signal Words in Manuals... -
Page 2: Safety Considerations
SAFETY CONSIDERATIONS WARNING Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical UNIT OPERATION AND SAFETY HAZARD shock, or other conditions which may cause death, Failure to follow this warning could cause personal injury, personal injury, or property damage. Consult a qualified death and/or equipment damage. -
Page 3: Model Nomenclature
MODEL NOMENCLATURE MODEL SERIES Position Number C = R--410A Condensing Unit A = Air Conditioning (Cooling Only) H = Heat Pump Type S = Standard ASHRAE 90.1--2010 Efficiency Efficiency 180 = 15 Tons (2 circuit) 181 = 15 Tons (1 circuit) 240 = 20 Tons (2 circuits) 241 = 20 Tons (1 circuit) Nominal Cooling Capacity... -
Page 4: Installation Guideline
Installation Guideline 2. Drain oil from low points and traps in suction line tubing and hot gas bypass tubing if appropriate) and Replacement /Retrofit – R22 to R--410A evaporator if they were not replaced. Removing oil Replacement/retrofit installations require change--out of from evaporator coil may require purging of the tubing outdoor unit, metering device, and filter driers. - Page 5 Figure 1 Unit Dimensions - - 15 Ton CAS181 CAS180 (FOR CAS180 SYSTEMS) Standard Corner Corner Corner Corner Unit Weight Height Center of Gravity lbs. lbs. lbs. lbs. lbs. UNIT CAS181 (RTPF) [965.2] [482.6] [431.8] [1279.2] CAS180 (RTPF) [965.2] [482.6] [431.8]...
- Page 6 Figure 2 Unit Dimensions - - 20 Ton CAS241 CAS240 (FOR CAS240 SYSTEMS) Standard Corner Corner Corner Corner Unit UNIT Center of Gravity Weight Height lbs. lbs. lbs. lbs. lbs. CAS241 [965.2] [584.2] [431.8] [1279.2] (RTPF) CAS240 (RTPF) [965.2] [584.2] [431.8] [1279.2] LEGEND: RTPF = Round Tube/Plate Fin coil...
- Page 7 Table 1 Physical Data — 60 Hz English UNIT CAS NOMINAL CAPACITY (tons) OPERATING WEIGHTS (lb) Round Tube/Plate Fin Coil (Cu/Al) ‡ REFRIGERANT TYPE R-410A † Operating Charge, Typical (lb) 24.6 12.0 / 12.0 38.0 19.0 / 19.0 Shipping Charge (lb) 12.2 6.0 / 6.0 28.0...
- Page 8 Table 2 Physical Data — 60 Hz SI UNIT CAS NOMINAL CAPACITY (kW) 52.7 52.7 70.3 70.3 OPERATING WEIGHT (kg) Round Tube/Plate Fin Coil (Cu/Al) ‡ REFRIGERANT TYPE R-410A † Operating Charge, Typical (kg) 11.1 5.4 / 5.4 17.2 8.6 / 8.6 Shipping Charge (kg) 2.7 / 2.7 12.7...
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Page 9: Step 1 - Plan For Unit Location
(by manifolding the evaporator connections into a single piping system). Do not bury refrigerant piping underground. The Model CAS180/240 is a dual-circuit unit design that Although unit is weatherproof, avoid locations that permit requires two sets of refrigeration piping between the water from higher level runoff and overhangs to fall onto the outdoor unit and the evaporator coil (or coils). -
Page 10: Step 4 -- Rig And Mount Unit
CAS model. See Table UNIT OPERATION HAZARD SIZE REFRIGERANT LINES — Select the recommended Failure to follow this caution may result in improper line sizes for CAS181/241 and CAS180/240 unit from the operation. appropriate tables. Do not bury refrigerant piping underground. - Page 11 Check Tables 5 (CAS181/241) and 6 (CAS180/240) for size does not provide necessary minimum flowrates for this maximum liquid lift capabilities for line sizes. Reselect the riser.
- Page 12 When a single piece evaporator coil with two separate Hot gas bypass, if used, should be introduced before the circuits is connected to a CAS180/240, the lower coil circuit evaporator. (A bypass route that also bypasses the should be connected to the CAS180/240’s Circuit 1 so that evaporator circuit may lead to oil trapping in the evaporator the evaporator’s lower coil segment is first-on/last-off (to...
- Page 13 FIRST ON/LAST OFF = 2 VERTICAL INSTALLATION single-circuit/tandem system. Connecting FAS to CAS180/240: The FAS fan coil in sizes 15, 20 and 25 ton is a face-split coil design that also has its circuits designated as 1 and 2. See Fig.5. Note that the lower coil segment changes as the arrangement of the FAS changes.
- Page 14 Dual Circuit Coil Piping Configuration For single compressor condensing units joints. Location of Sight Glass(es) and Filter Driers Figure 8 Typical Piping Connection Assembly Figure 7 Typical CAS180/240 Systems EQUALIZER LINE SENSING BULB Field Service AIRFLOW Access Port 15 DIAMS...
- Page 15 Equivalent line length 90-ft (27.4 m) outside the CAS service valves, following description in Liquid Lift: 20-ft (6.1 m) GTAC II, Module 4, System Dehydration. Select line sizes from Table 6 (CAS180/240): WARNING Liquid Suction 1- UNIT OPERATION AND SAFETY HAZARD...
- Page 16 disconnect switch operation of the convenience outlet is Provide a ground-fault and short-circuit over-current desired, connect the source leads to the load side of the protection device (fuse or breaker) per NEC Article 440 (or unit disconnect. On a unit without a unit-mounted local codes).
- Page 17 CAS unit control voltage is 24v. See Fig. 13 (CAS181/241) all power to the unit. Treat all units as electrically and Fig. 14 (CAS180/240) for typical field control energized until the convenience outlet power is also connections and the unit’s label diagram for field-supplied checked and de-energization is confirmed.
- Page 18 Select a two—stage cooling thermostat, with or without CAS180/240 supplemental heating as needed. The CAS180/240 is a dual--circuit, two-stage cooling unit. Select a two—stage cooling thermostat, with or without supplemental heating as needed. Select a thermostat cable or equivalent single leads of...
- Page 19 Table 10 – Unit Wire/Fuse or HACR Breaker Sizing Data NOMINAL COMPRESSOR NO C.O. or UNPWRD C.O. POWER VOLTAGE No. 1 No. 2 POWER SUPPLY DISCONNECT SIZE SUPPLY RANGE FUSE or UNIT HACR SIZE V- -Ph- -Hz (ea) BRKR 208/230--3--60 25.0 25.0 60.8/60.8...
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Page 20: Pre-Start-Up
PRE-START-UP CAUTION IMPORTANT: Before beginning Pre-Start-Up UNIT DAMAGE HAZARD Start-Up, review Start-Up Checklist at the back of this Failure to follow this caution may result in equipment book. The Checklist assures proper start-up of a unit damage. and provides a record of unit condition, application Prior to starting compressor, a preliminary charge of requirements, system information, and operation at refrigerant must be added to avoid possible compressor... - Page 21 Compressor Overload — Start Unit This overload interrupts power to the compressor when Set the space thermostat to a set point above space either the current or internal motor winding temperature temperature so that there is no demand for cooling. Close becomes excessive, and automatically resets when the the CAS disconnect switch.
- Page 22 Final Checks — IMPORTANT: Oil level should only be checked when the compressors are off. Ensure that all safety controls are operating, control panel covers are on, and the service panels are in place. Add oil only if necessary to bring the oil into view in the sight glass.
- Page 23 Figure 19 CAS181 Charging Chart - - Single Circuit 15 TON CHARGING CHART R--410A ALL CONDENSER FANS OPERATING 15 TONNE TABLEAU DE CHARGE R--410A TOUTES LES SOUFFLERIES DE CONDENSATION EN FONCTIONNEMENT Figure 20 CAS241 Charging Chart - - Single Circuit 20 TON CHARGING CHART R--410A ALL CONDENSER FANS OPERATING 15 TONNE TABLEAU DE CHARGE R--410A TOUTES LES SOUFFLERIES DE CONDENSATION EN FONCTIONNEMENT...
- Page 24 Figure 21 CAS180 Charging Chart - - Dual Circuit 15 TON CHARGING CHART R--410A ALL CONDENSER FANS OPERATING 15 TONNE TABLEAU DE CHARGE R--410A TOUTES LES SOUFFLERIES DE CONDENSATION EN FONCTIONNEMENT 15 TON CHARGING CHART R--410A ALL CONDENSER FANS OPERATING...
- Page 25 Figure 22 CAS240 Charging Chart - - Dual Circuit 20 TON CHARGING CHART R--410A ALL CONDENSER FANS OPERATING 20 TONNE TABLEAU DE CHARGE R--410A TOUTES LES SOUFFLERIES DE CONDENSATION EN FONCTIONNEMENT (CIRCUIT 1) 20 TON CHARGING CHART R--410A ALL CONDENSER FANS OPERATING 20 TONNE TABLEAU DE CHARGE R--410A TOUTES LES SOUFFLERIES DE CONDENSATION EN FONCTIONNEMENT (CIRCUIT 2)
- Page 26 Figure 23 Typical CAS181/241 Wiring Diagram (15 Ton 230v Tandem Unit Shown) Specifications are subject to change without notice. 501 01 3403 01...
- Page 27 Figure 24 Typical CAS180/240 Wiring Diagram (15 Ton 230v Dual Unit Shown) 501 01 3403 01 Specifications are subject to change without notice.
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Page 28: Operating Sequence
OPERATING SEQUENCE On a thermostat calling for Stage 2 Cooling, thermostat output Y2 is energized; terminal Y2 at CAS180/240 unit Base Unit Controls receives 24-v. 24-v received at CADM2 terminal Y. If anti-recycle time delay period has not expired, CADM2 —... -
Page 29: Routine System Maintenance
ROUTINE SYSTEM MAINTENANCE SERVICE These items should be part of a routine maintenance Refrigeration System program, to be checked every month or two, until a specific schedule for each can be identified for this installation: CAUTION Quarterly Inspection (and 30 days after initial start) — EQUIPMENT DAMAGE HAZARD Indoor section S Condenser coil cleanliness checked. - Page 30 Filter drier must be replaced whenever the refrigerant Factory High-Flow Access Ports — system is opened. There are two additional access ports in the system - on When removing a filter drier, use a tubing cutter to cut the the suction tube between the compressor and the suction drier from the system.
- Page 31 Comfort Alert Diagnostic Module Figure 26 CAD/M Housing/LED Locations The Comfort Alert Diagnostic Module (CADM) monitors and POWER analyzes data from the Copeland Scroll three-phase (GRN) compressor and the thermostat demand. The CADM also provides a 3-minute anti-recycle time delay to compressor cycling.
- Page 32 Table 11 – LED Status Codes Status LED Status LED Description Status LED Troubleshooting Information Green “POWER” Module has power Supply voltage is present at module terminals Compressor protector is open Red “TRIP” Thermostat demand signal Y is LED On Solid present, but the compressor is Condensing unit power disconnect is open not running.
- Page 33 Table 12 – CADM Troubleshooting Miswired Module Indication Recommended Troubleshooting Action Green LED is not on, Determine if both R and C module terminals are connected. Verify voltage in present at module’s R module does not power up and C terminals. NOTE: The CADM requires a constant nominal 24VAC power supply.
- Page 34 Figure 28 CAS180 Cabinet Condenser Fans/Motors Access Panel - Control Box & Compressors Service Valves Figure 29 CAS180 Piping Specifications are subject to change without notice. 501 01 3403 01...
- Page 35 Figure 30 CAS181 Compressor Assembly (Rear View) Equalization Oil Equalizer Line Figure 31 CAS180 Compressor Assembly (Rear View) 501 01 3403 01 Specifications are subject to change without notice.
- Page 36 Figure 32 CAS240 Cabinet Condenser Fans/Motors Access Panel - Control Box & Compressors Service Valves Figure 33 CAS240 Piping Specifications are subject to change without notice. 501 01 3403 01...
- Page 37 Figure 34 CAS241 Compressor Assembly (Rear View) Figure 35 CAS240 Compressor Assembly (Rear View) 501 01 3403 01 Specifications are subject to change without notice.
- Page 38 Coil Type Identification Coil Cleaner Application Equipment — gallon garden sprayer CAS units are available with different coil types. Cleaning methods differ for each type so identifying the coil type is S water rinse with low velocity spray nozzle important. Unit model number and appearance can identify CAUTION the coil type.
- Page 39 7.Hold garden sprayer nozzle close to finned areas and 11. Ensure surfaces are not allowed to dry before rinsing. apply cleaner with a vertical, up-and-down motion. Reapply cleaner as needed to ensure 10-minute Avoid spraying in horizontal pattern to minimize saturation is achieved.
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Page 40: Troubleshooting
TROUBLESHOOTING PROBLEM SOLUTION COMPRESSOR DOES NOT RUN Contactor Open 1. Power off. 1. Restore power. 2. Fuses blown in field power circuit. 2. After finding cause and correcting, replace with correct size fuse. 3. No control power. 3. Check control transformer primary connections and circuit breaker. 4. - Page 41 TROUBLESHOOTING (cont) PROBLEM SOLUTION COMPRESSOR CYCLES ON LOW-PRESSURE SWITCH Indoor-Air Fan Running 1. Liquid line solenoid valve(s) fails to open. 1. Check liquid line solenoid valve(s) for proper operation. Replace if necessary. 2. Filter drier plugged. 2. Replace filter drier. 3.
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Page 42: Appendix A, R--410A Quick Reference Guide
APPENDIX A S POE oils absorb moisture rapidly. Do not expose oil to Air Conditioner & Heat Pump with R- -410A — atmosphere. Quick Reference Guide S POE oils may cause damage to certain plastics and S R--410A refrigerant operates at 50 percent to 70 percent roofing materials. -
Page 43: Appendix B, Low Ambient Option
Operation — OFM3) at start or during Fan on/off control in cooling--only units (CAS181/241, low outdoor ambient CAS180/240) is provided by an outdoor fan relay (OFR). Cooling -- Slow fan speed Check speed control sensor location for outer fans (OFM1,... - Page 44 Figure 38 Motormaster Sensor Location: Figure 37 Motormaster Sensor Location: CAS241 & CAS240 CAS181 & CAS180 Motormaster Sensor - Must be positioned on Vapor Stub of Circuit 1 coil only. Motormaster Sensor - Attach to Circuit 1 coil only. 508 mm (20 in)
- Page 45 Figure 39 Wind Baffles - - Fabrication 501 01 3403 01 Specifications are subject to change without notice.
- Page 46 Figure 40 15 Ton Wind Baffle Brackets - - Fabrication Specifications are subject to change without notice. 501 01 3403 01...
- Page 47 Figure 41 Wind Baffle Installation - - 15 Ton Units 501 01 3403 01 Specifications are subject to change without notice.
- Page 48 Figure 42 Wind Baffle Installation - - 20 Ton Units Specifications are subject to change without notice. 501 01 3403 01...
- Page 49 501 01 3403 01 Specifications are subject to change without notice.
- Page 50 Copyright 2019 International Comfort Products Replaces: 501 01 3403 00 Lewisburg, TN 37091 USA 501 01 3403 01 Specifications are subject to change without notice. 10-19...
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Page 51: Start-Up Checklist
START-UP CHECKLIST I. PRELIMINARY INFORMATION OUTDOOR: MODEL NO. SERIAL NO. INDOOR: AIRHANDLER MANUFACTURER MODEL NO. SERIAL NO. ADDITIONAL ACCESSORIES II. PRE-START-UP OUTDOOR UNIT IS THERE ANY SHIPPING DAMAGE? (Y/N) IF SO, WHERE: WILL THIS DAMAGE PREVENT UNIT START-UP? (Y/N) CHECK POWER SUPPLY. DOES IT AGREE WITH UNIT? (Y/N) HAS THE GROUND WIRE BEEN CONNECTED? (Y/N) -
Page 52: Check Voltage Balance
INDOOR UNIT LEAVING-AIR DB TEMP INDOOR UNIT LEAVING-AIR WB TEMP COMPRESSOR 1 AMPS (L1/L2/L3) COMPRESSOR 2 AMPS (L1/L2/L3) NOTES: Copyright 2019 International Comfort Products Replaces: 501 01 3403 00 Lewisburg, TN 37091 USA 501 01 3403 01 Specifications are subject to change without notice.