Page 1: Table Of Contents
INSTALLATION INSTRUCTIONS R- -410A Split Condensing Units with RTPF Coils CAS090*G/H NOTE: Read the entire instruction manual before starting the installation TABLE OF CONTENTS SAFETY CONSIDERATIONS ....ROUTINE SYSTEM MAINTENANCE .
Page 2: Safety Considerations
SAFETY CONSIDERATIONS WARNING Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical ELECTRICAL SHOCK HAZARD shock or other conditions which may cause personal Failure to follow this warning could cause personal injury or property damage. Consult a qualified installer, injury or death.
Page 3: Rated Indoor Airflow (Cfm)
Rated Indoor Airflow (cfm) Model Number Full Load Airflow (cfm) CAS090*G/H --- FAS091 3000 The table to the right lists the rated indoor airflow used for the AHRI efficiency rating for the units covered in this document. MODEL SERIES Position Number C = R-410A Condensing Unit A = Air Conditioning (Cooling Only) Type...
Page 4 C14314 STD. UNIT WT. CORNER A CORNER B CORNER C CORNER D CENTER OF GRAVITY UNIT HEIGHT UNIT lbs. lbs. lbs. lbs. lbs. CAS090*G/H [457] [610] [533] [1076] Fig. 2 - - CAS090*G/H Unit Dimensions 501 01 3600 01 Specifications are subject to change without notice.
Page 5 Table 1 – Physical Data Table 2 – Physical Data CAS090*G/H — 60 Hz English CAS090*G/H — 60 Hz SI NOMINAL CAPACITY (tons) NOMINAL CAPACITY (kW) 26.4 OPERATING WEIGHTS (lb) OPERATING WEIGHTS (lb) Round Tube/Plate Fin Coil (Cu/Al) Round Tube/Plate Fin Coil (Cu/Al) ‡...
Page 6: Matching Cas090*G/H Model To Evaporator Coil
Matching CAS090*G/H Model to Evaporator bypass line. Relocate sections to minimize the length of interconnecting tubing. Coil The Model CAS090*G/H is a single-circuit, two- - stage DO NOT BURY REFRIGERATION LINES. unit design, requiring one set of refrigeration piping. Although unit is weatherproof, avoid locations that permit INSTALLATION water from higher level runoff and overhangs to fall onto the unit.
Page 7: Step 5 - - Determine Refrigerant Line Sizes
Step 5 — Determine Refrigerant Line Sizes Spreader bars are required. Use the wooden top skid, when rigging, to prevent rigging straps from damaging the Select the recommended line sizes for the CAS090 unit unit. All panels must be in place when rigging. As further from the Table 3.
Page 8: Step 6 - Complete Refrigerant Piping Connections
Table 4 – Equivalent Lengths for Common Fittings (ft) riser (reduced tube size for vertical segment only) (see Fig. 4) or double suction riser arrangement (see Fig. 5) if Elbows the planned suction tube size does not provide necessary Nominal Tube OD 90...
Page 9 Table 6 – Refrigerant Specialties Part Numbers LIQUID LINE LIQUID LINE LLSV SIGHT FILTER SIZE (in.) SOLENOID VALVE (LLSV) COIL GLASS DRIER EF680035 EF680037 KM680004 KH43LS085 EF680036 EF680037 KM680005 KH43LS087 Check CAS090*G/H Model with Evaporator Coil Evaporator Capacity Control Liquid Line Solenoid Valve: Many older unit designs included automatic Connections —...
Page 10: Step 7 - Install Accessories
Preliminary Charge — Before starting the unit, charge R-410A liquid refrigerant into the high side of each CAS090 circuit through the liquid service valve(s). The amount of refrigerant added Field Service Access Port must be at least 80% of the operating charge listed in Factory (Schrader core) Table 3 for LINEAR line length LESS the factory charge...
Page 11: Step 8 - Complete Electrical Connections
Step 8 — Complete Electrical Connections Units with Factory-Installed Non- - Fused Disconnect — WARNING The factory- - installed option non- - fused disconnect (NFD) switch is located in a weatherproof enclosure located under the main control box. The manual switch handle and ELECTRICAL SHOCK HAZARD shaft are shipped in the disconnect enclosure.
Page 12 4. Make sure the NFD shipped from the factory is at OFF Provide a ground-fault and short-circuit over-current position (the arrow on the black handle knob is at OFF). protection device (fuse or breaker) per NEC Article 440 (or local codes). Refer to unit informative data plate for 5.
Page 13 backing plate over the screw heads at the keyhole slots Convenience and align with the gasket; tighten the two screws until Outlet GFCI snug (do not overtighten). Mount the weatherproof cover to the backing plate as Pwd-CO shown in Fig. 13. Remove two slot fillers in the bottom of Fuse Switch the cover to permit service tool cords to exit the cover.
Page 14 Thermostat — For wire runs up to 50 ft. (15 m), use no. 18 AWG (American Wire Gage) insulated wire (35C minimum). Install an approved accessory thermostat according to For 50 to 75 ft. (15 to 23 m), use no. 16 AWG insulated installation instructions included with the accessory.
Page 15 Table 7 – Electrical Data — CAS090*G/H 60 Hz Units WITHOUT POWERED CONVENIENCE OUTLET VOLTAGE POWER COMPRESSOR OFM (ea) DISCONNECT SIZE RANGE SUPPLY UNIT V ---Ph---Hz MOCP 208/230--- 3--- 60 24.0 460--- 3--- 60 12.6 CAS090*G/H 575--- 3--- 60 Legend and Notes for Table 7 Example: Supply voltage is 230-3-60 LEGEND: Full Load Amps...
Page 16: Step 9 - - Wind Baffles For Low Ambient Controls
Step 9 — Wind Baffles for Low Ambient Control Preliminary Charge — CAS090*H includes the factory installed 32LT Motormaster Before starting the unit, charge liquid refrigerant into the Low Ambient Control. high side of the system through the liquid service valve. The amount of refrigerant added must be at least 80% of the Units with 32LT Motormaster control require the addition operating charge listed in the Physical Data table (Tables 1...
Page 17: Start Unit
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 proper direction: 1.
Page 18 Using plotted operating point: Final Checks — If plotted operating condition is - - Adjust charge by - - Ensure that all safety controls are operating, control panel covers are on, and the service panels are in place. BELOW the curve REDUCE charge ABOVE the curve ADD charge...
Page 19 C14294 Fig. 19 - - Typical CAS090*G/H Wiring Diagram - - 208/230V- - 3PH- - 60Hz Unit Shown 501 01 3600 01 Specifications are subject to change without notice.
Page 20: Operating Sequence
OPERATING SEQUENCE Cooling, Unit With Economizer — Refer to fan coil unit installation instructions and Base Unit Controls economizer accessory installation instructions operating sequences when system is equipped with — Indoor (Supply) Fan accessory economizer. The indoor fan contactor (IFC) is remotely located at the fan Heating —...
Page 21: Service
SERVICE 3. Place terry cloth shop towel inside unit immediately un- der component(s) to be serviced and prevent lubricant Refrigeration System run-offs through the louvered openings in the base pan. 4. Perform required service. CAUTION 5. Remove and dispose of any oil contaminated material per local codes.
Page 22: Comfort Alert Diagnostic Module
SEAT CORE (Part No. EC39EZ067) 1/2-20 UNF RH 0.596 45° 30° WASHER DEPRESSOR PER ARI 720 O-RING 1/2" HEX +.01/-.035 5/8” HEX FROM FACE OF BODY This surface provides a metal to metal seal when 7/16-20 UNF RH torqued into the seat. Appropriate handling is required to not scratch or dent the surface.
Page 23 Table 8 – LED Status Codes Status LED Status LED Description Status LED Troubleshooting Information Green “POWER” Module has power Supply voltage is present at module terminals Red “TRIP” Thermostat demand signal Y 1. Compressor protector is open LED On Solid is present, but the 2.
Page 24: Compressor Protection
Table 9 – 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 25 Condenser Fans Service Valves C14295 Fig. 23 - - CAS090*G/H Exterior Outdoor Coil 32LT Sensor Typical Location High Flow Access Port C14296 Fig. 24 - - CAS090*G/H Interior 501 01 3600 01 Specifications are subject to change without notice.
Page 26: Routine Cleaning Of Round-Tube Plate Fin (Rtpf) Coils
Routine Cleaning of Round-Tube Plate Fin Coils — Environmentally Sound Coil Cleaner Application Instructions: Periodic cleaning with environmentally sound coil cleaner is NOTE: Proper eye protection such as safety glasses is essential to extend the life of RTPF coils. This cleaner is recommended during mixing and application.
Page 27: Fastener Torque Values
FASTENER TORQUE VALUES 9. Interior and exterior finned areas must be thoroughly cleaned. Table 10 – Torque Values 10. Finned surfaces should remain wet with cleaning Compressor mounting bolts 65--- 75 in–lbs solution for 10 minutes. (734–847 N–cm) 11. Ensure surfaces are not allowed to dry before rinsing. Condenser fan motor mounting bolts 20 2 in–lbs Reapply cleaner as needed to ensure 10-minute satur-...
Page 28: Troubleshooting
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.
Page 29: Air Conditioner & Heat Pump With R- -410A
APPENDIX A APPENDIX B Air Conditioner & Heat Pump with R- -410A Wiring Diagram List — Quick Reference Guide Electrical Diagram Unit Characteristics Number S R-410A refrigerant operates at 50 percent to 70 percent 208/230---3---60 38AU000026 higher pressures than R-22. Be sure that servicing equipment and replacement components are designed to 460---3---60 38AU000027...
Page 30 Wind baffles are required to prevent wind cross currents Troubleshooting — from causing abnormally low condensing temperatures. OBSERVATION POSSIBLE REMEDY Fans won’t start All fans: Use 20- - gauge sheet metal to fabricate wind baffles (see Check power & wiring Fig.
Page 31 C10800 Fig. 27 - - Wind Baffles 501 01 3600 01 Specifications are subject to change without notice.
Page 32 Table 11 – Wind Baffle Dimension DIMENSIONS --- INCHES UNIT BAFFLE LEFT SIDE CAS090*H BACK RIGHT SIDE DIMENSIONS --- MM UNIT BAFFLE LEFT SIDE BACK 1016 1035 1054 CAS090*H RIGHT SIDE 501 01 3600 01 Specifications are subject to change without notice.
Page 33 501 01 3600 01 Specifications are subject to change without notice.
Page 34 Copyright 2019 International Comfort Products Replaces: 501 01 3600 00 Lewisburg, TN 37091 USA 501 01 3600 01 10-19 Specifications are subject to change without notice.
Page 35: 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 36 INDOOR UNIT ENTERING-AIR WB (wet bulb) TEMP INDOOR UNIT LEAVING-AIR DB TEMP INDOOR UNIT LEAVING-AIR WB TEMP COMPRESSOR AMPS (L1/L2/L3) NOTES: Copyright 2019 International Comfort Products Replaces: 501 01 3600 00 Lewisburg, TN 37091 USA 501 01 3600 01 Specifications are subject to change without notice.

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