American Standard 4A7A6024 Assembly instructions

© 2005 American Standard Inc. All Rights Reserved
Since the manufacturer has a policy of continuous product
and product data improvement, it reserves the right to
change design and specifications without notice.
11-AC16D1-3
IMPORTANT — This Document is customer property and is to remain with this unit. Please return to service information pack
upon completion of work.
These instructions do not cover all variations in systems
nor provide for every possible contingency to be met in
connection with installation. All phases of this installa-
tion must comply with NATIONAL, STATE AND LOCAL
CODES. Should further information be desired or should
particular problems arise which are not covered sufficiently for
the purchaser’s purposes, the matter should be referred to your
installing dealer or local distributor.
A. GENERAL
The following instructions cover 4A7A6 Condensing Units. See
special wiring and sequence of operation on page 5.
NOTICE: These outdoor units may be used with indoor
units equipped with Thermostatic Expansion Valve only.
▲ WARNIN
G
:
These units use R-410A refrig-
erant which operates at 50% to 70% higher pressures than
R-22. Use only R-410A approved service equipment. Re-
frigerant cylinders are painted a “Rose” color to indicate
the type of refrigerant and may contain a “dip” tube to
allow for charging of liquid refrigerant into the system.
All R-410A systems use a POE oil that readily absorbs
moisturefromtheatmosphere.Tolimitthis“hygroscopic”
action, the system should remain sealed whenever pos-
sible. Never break a vacuum with air and always change
the driers when opening the system for component
replacement.
Check for transportation damage after unit is uncrated. Report
promptly, to the carrier, any damage found to the unit.
To determine the electrical power requirements of the unit, refer
to the nameplate of the unit. The electrical power available must
agree with that listed on the nameplate.
B. LOCATION & PREPARATION OF THE UNIT
1. When removing unit from the pallet, notice the tabs on the
basepan. Remove tabs by cutting with a sharp tool as shown in
Figure 2 (see page 2).
2. The unit should be set on a level support pad at least as large
as the unit base pan, such as a concrete slab. If this is not the
application used please refer to application bulletin
“ALG16-APG**-EN” (* denotes latest revision).
3. The support pad must NOT be in direct contact with any
structure. Unit must be positioned a minimum of 12" from any
wallorsurroundingshrubberytoinsureadequateairflow. Clear-
Condensing Units
Models: 4A7A6024,36,48, & 60B1000A
CAUTION
!
UNIT CONTAINS R-410A REFRIGERANT!
R-410A OPERATING PRESSURE EXCEEDS THE
LIMIT OF R-22. PROPER SERVICE EQUIPMENT IS
REQUIRED. FAILURE TO USE PROPER SERVICE
TOOLS MAY RESULT IN EQUIPMENT DAMAGE OR
PERSONAL INJURY.
SERVICE
USE ONLY R-410A REFRIGERANT AND
APPROVED POE COMPRESSOR OIL.
INSTALLER'S GUIDE
ALL phases of this installation must comply with NATIONAL, STATE AND LOCAL CODES
TOP DISCHARGE — UNRESTRICTED
5 FT. ABOVE UNIT
1

PAGE 2 Pub. No. 11-AC16D1-3
INSTALLER'S GUIDE
ance must be provided in front of control box (access panels) &
any other side requiring service access to meet National Electri-
cal Code. Also, the unit location must be far enough away from
any structure to prevent excess roof run-off water from pouring
directly on the unit. Do not locate unit(s) close to bedroom(s).
4. The top discharge area must be unrestricted for at least
five (5) feet above the unit.
5. When the outdoor unit is mounted on a roof, be sure the roof
will support the unit’s weight. Properly selected isolation is
recommended to prevent transmission to the building structure.
6. The maximum length of refrigerant lines from outdoor to
indoor unit should NOT exceed eighty (80) feet.
7. If outdoor unit is mounted above the air handler, maximum
lift should not exceed twenty-five (25) feet (suction line). If air
handler is mounted above condensing unit, maximum lift should
not exceed twenty-five (25) feet (liquid line).
8. Locate and install indoor coil or air handler in accordance
with instruction included with that unit.
C. INSTALLING REFRIGERANT LINES
▲ CAUTION:
Ifusingexisting refrigerant lines
make certain that all joints are brazed, not soldered.
Condensing units have provisions for braze connections.
Pressure taps are provided on the service valves of outdoor unit
for compressor suction and liquid pressures.
The indoor end of the recommended refrigerant line sets may be
straight or with a 90 degree bend, depending upon situation
requirements. This should be thoroughly checked out before
ordering refrigerant line sets.
The gas line must always be insulated.
▲ CAUTION:
In scroll compressor applica-
tions, dome temperatures may be hot. Do not touch top of
compressor, may cause minor to severe burning.
The units are factory charged with the system charge required
when using fifteen (15) feet of connecting line. Unit nameplate
charge is the same.
Final refrigerant charge adjustment is necessary. Use the
Charging Charts in the outdoor unit Service Facts.
1. Determine the most practical way to run the lines.
2. Consider types of bends to be made and space limitations.
NOTE: Largediameter tubing will be verydifficult to rebend once
it has been shaped.
3. Determine the best starting point for routing the refrigerant
tubing — INSIDE OR OUTSIDE THE STRUCTURE.
4. Provide a pull-thru hole of sufficient size to allow both liquid
and gas lines.
5. Be sure the tubing is of sufficient length.
6. Uncoil the tubing — do not kink or dent.
7. Route the tubing making all required bends and properly
secure the tubing before making connections.
8. To prevent a noise within the building structure due to
vibration transmission from the refrigerant lines, the following
precautions should be taken:
a. When the refrigerant lines have to be fastened to floor
joists or other framing in a structure, use isolation type hangers.
b. Isolation hangers should also be used when refrigerant
lines are run in stud spaces or enclosed ceilings.
c. Where the refrigerant lines run through a wall or sill, they
should be insulated and isolated.
d. Isolate the lines from all ductwork.
D. SERVICE VALVE OPERATION
BRASS LIQUID LINE SERVICE VALVE
The Brass Liquid Line Service Valve is factory shipped in the
seated position to hold factory charge. The pressure tap service
port (when depressed) opens only to the field brazing side of the
valve when the valve is in the seated position. The liquid line
valve is not a back seating valve (see WARNING that follows).
▲ WARNIN
G
:
Extreme caution should be ex-
ercised when opening the Liquid Line Service Valve.
Turn valve stem counterclockwise only until the stem
contacts the rolled edge. (See Figure 3) No torque is
required.
BASEPAN TAB REMOVAL
2
LIQUID LINE SERVICE VALVE
3

Pub. No. 11-AC16D1-3 PAGE 3
INSTALLER'S GUIDE
CAP 1/4 TURN ONLY
COUNTERCLOCKWISE
FOR FULL OPEN
POSITION
VALVE STEM
GAS LINE CONNECTION
UNIT SIDE
OF VALVE
CAP
BODY
COOLING
CORE
PRESSURE TAP PORT
GAS LINE SERVICE VALVE
BRASS GAS LINE SERVICE VALVE
The Brass Gas Line Service Valve is shipped in the closed
position to hold the factory refrigerant charge. The pressure tap
service port (when depressed) opens only to the field brazing side
when the valve is in the closed position.
The Gas Line Service Valve is full open with a 1/4 turn. See
Figure 4.
BRAZING REFRIGERANT LINES
1. Remove lower access cover to access service valves.
2. Before brazing, remove plugs from external copper stub
tubes. Clean internal and external surfaces of stub tubes prior
to brazing.
3. Cut and fit tubing, minimizing the use of sharp 90° bends.
4. Insulate the entire gas line and its fittings.
5. Do NOT allow uninsulated liquid line to come in direct
contact with bare gas line.
6. Precautions should be taken to avoid heat damage to
the pressure tap valve core during brazing. It is recom-
mended that the pressure tap port valve core be removed
and a wet rag wrapped around the valve body.
NOTICE: Use care to make sure that no moisture enters
pressure tap port, while wet rag is being used.
NOTICE: Precautions should be taken to avoid heat
damage to basepan during brazing. It is recommended to
keep the flame directly off of the basepan.
7. Use a Dry Nitrogen Purge and Brazing Alloy without flux
whenbrazing the field line to thecopperfactory connection. Flow
dry nitrogen into either valve pressure tap port, thru the tubing
and out the other port while brazing.
8. Braze using accepted good brazing techniques.
LEAK CHECK
IMPORTANT: Replace pressure tap port valve core be-
fore attaching hoses for evacuation.
After the brazing operation of refrigerant lines to both the
outdoor and indoor unit is completed, the field brazed connec-
tions must be checked for leaks. Pressurize through the service
valve ports, the indoor unit and field refrigerant lines with dry
nitrogen to 300 psi. Use soap bubbles or other leak-checking
methods to see that all field joints are leak-free! If not, release
pressure; then repair!
SYSTEM EVACUATION
NOTE: Since the outdoor unit has a refrigerant charge, the gas
and liquid line valves must remain closed.
1. Upon completion of leak check, evacuate the refrigerant lines
and indoor coil before opening the gas and liquid line valves.
2. Attach appropriate hoses from manifold gauge to gas and
liquid line pressure taps.
NOTE: Unnecessary switching of hoses can be avoided and
complete evacuation of all lines leading to sealed system can be
accomplished with manifold center hose and connecting branch
hose to a cylinder of R-410A and vacuum pump.
3. Attach center hose of manifold gauges to vacuum pump.
4. Evacuate until the micron gauge reads no higher than
350 microns.
5. Close off valve to vacuum pump and observe the micron
gauge. If gauge pressure rises above 500 microns in one (1)
minute, then evacuation is incomplete or system has a leak.
6. If vacuum gauge does not rise above 500 microns in one (1)
minute, the evacuation should be complete.
7. With vacuum pump and micron gauge blanked off, open valve
on R-410A cylinder and charge refrigerant lines and indoor coil
with vapor to tank pressure of R-410A supply.
NOTE: DO NOT VENT REFRIGERANT INTO THE
ATMOSPHERE.
8. Close valve on R-410A supply cylinder. Close valves on
manifold gauge set and remove refrigerant charging hoses from
liquid and gas pressure tap ports.
NOTE: A 3/16" Allenwrenchis required to openliquidlineservice
valve. A 1/4" Open End or Adjustable wrench is required to open
gas line valve. A 3/4" Open End wrench is required to take off the
valve stem cap.
9. The liquid line shut-off valve can now be opened. Remove
shut-off valve cap. Fully insert hex wrench into the stem and
back out counterclockwise until valve stem just touches rolled
edge (approximately five [5] turns) observing WARNING state-
ment on page 2. See Figure 3.
10. Replace liquid service pressure tap port cap and valve stem
cap. These caps MUST BE REPLACED to prevent leaks.
Replace valve stem and pressure tap cap finger tight, then
tighten an additional 1/6 turn.
11. The gas valve can now be opened. Open the gas valve by
removing the shut-off valve cap and turning the valve stem
1/4 turn counterclockwise, using 1/4" Open End or Adjustable
wrench. See Figure 4.
4

PAGE 4 Pub. No. 11-AC16D1-3
INSTALLER'S GUIDE
12. The gas valve is now open for refrigerant flow. Replace valve
stem cap to prevent leaks. Again, these caps MUST BE RE-
PLACED to prevent leaks. Replace valve stem and pressure tap
capfinger tight, then tightenanadditional1/6turn. See Figure 4.
If refrigerant lines are longer than 15 feet and/or a different
size than recommended, it will be necessary to adjust system
refrigerant charge upon completion of installation. See unit
Service Facts.
E. ELECTRICAL CONNECTIONS
▲ WARNIN
G
:
When installing or servicing
this equipment, ALWAYS exercise basic safety precau-
tions to avoid the possibility of electric shock.
1. Power wiring and grounding of equipment must comply with
local codes.
2. Power supply must agree with equipment nameplate.
3. Install a separate disconnect switch at the outdoor unit.
4. Ground the outdoor unit per local code requirements.
5. Provide flexible electrical conduit whenever vibration trans-
mission may create a noise problem within the structure.
6. The use of color coded low voltage wire is recommended to
simplify connections between the outdoor unit, the thermostat
and the indoor unit.
Table 1 — NEC Class II Control Wiring
7. Table 1 defines maximum total length of low voltage wiring
from outdoor unit, to indoor unit, and to thermostat.
8. Mount the indoor thermostat in accordance with instructions
included with the thermostat. Wire per appropriate hook-up
diagram (included in these instructions).
F. COMPRESSOR START-UP
After all electrical wiring is complete, SET THE THERMOSTAT
SYSTEMSWITCH IN THE OFFPOSITION SO COMPRESSOR
WILL NOT RUN, and apply power by closing the system main
disconnect switch. This will activate the compressor sump heat
(where used). Do not change the Thermostat System Switch
until power has been applied for one (1) hour. Following this
procedure will prevent potential compressor overload trip at the
initial start-up.
G. OPERATIONAL AND CHECKOUT PROCEDURES
Final phases of this installation are the unit Operational and
Checkout Procedures which are found in this instruction on
page 8. To obtain proper performance, all units must be operated
and charge adjustments made in accordance with procedures
found in the Service Facts.
24 VOLTS
WIRE SIZE MAX. WIRE LENGTH
18 AWG 150 FT
16 AWG 225 FT.
14 AWG 300 FT.
H. ELECTRIC HEATERS
Electric heaters, if used, are to be installed in the air handling
device according to the instructions accompanying the air han-
dler and the heaters.
I. START CONTROL
Some models have quick start components which are factory
installed. For models that do not have factory installed start
components, provisions are made for a field installed start kit
accessory. When adding an accessory, follow the instructions
provided with the kit.
J. OUTDOOR THERMOSTAT
An outdoor thermostat TAYSTAT250A may be field installed.
For data, see wiring diagram attached to unit and instruction
sheet packaged with outdoor thermostat.
K. SEACOAST SALT SHIELD
The4A7A6 models are shippedwith a black SeacoastSalt Shield.
Removal of the shield will potentially shorten the life of the joints
in the outdoor coil.
L. TROUBLESHOOTING
REFRIGERANT CIRCUIT
Liquid Pressure Too High
Liquid Pressure Too Low
Suction Pressure Too High
Suction Pressure Too Low
Liquid Refrig. Floodback TXV System
Liquid Refrig. Floodback Capillary Tube System
I.D. Coil Frosting
Compressor Runs Inadequate or No Cooling
ELECTRICAL
Compressor & O.D. Fan Do Not Start
Compressor Will Not Start But O.D. Fan Runs
O.D. Fan Won’t Start
Compressor Hums But Won’t Start
Compressor Cycles on IOL
I.D. Blower Won’t Start
SYSTEM FAULTS
P - Primary Causes S - Secondary Causes
P
P
P
S
S
P
S
S
S
S
S
S
S
P
S
S
S
S
P
P
P
P
S
S
S
S
S
S
S
P
P
P
P
S
P
P
S
S
S
P
P
P
P
P
P
P
P
P
P
S
S
S
S
P
P
PP
P
S
S
PSPSS S S S
S
S
P
P
P
P
P
S
P
P
POWERSUPPLY
HIGHVOLTAGEWIRING
COMPR. IOL
RUNCAPACITOR
STARTCAPACITOR
STARTRELAY
CONTACTORCONTACTS
LOWVOLTAGEWIRING
CONTROLTRANSFORMER
CONTACTORCOIL
LOWVOLTAGEFUSE
STUCKCOMPRESSOR
INEFFICIENTCOMPRESSOR
REFRIGERANT UNDERCHARGE
REFRIGERANT OVERCHARGE
EXCESSIVEEVAP. LOAD
NONCONDENSABLES
RESTRICTEDO.D. AIRFLOW
O.D. AIR RECIRCULATION
TXVSTUCKOPEN
SUPERHEAT
RESTRICTEDI.D. AIRFLOW
REF. CIRCUIT RESTRICTIONS
O.D. FANSPEEDSWITCH
TROUBLESHOOTING CHART — WHAT TO CHECK

Pub. No. 11-AC16D1-3 PAGE 5
INSTALLER'S GUIDE
FIELD HOOK-UP DIAGRAMS FOR 4A7A6 MODELS ONLY
Notes:
1. Be sure power supply agrees with equipment nameplate.
2. Power wiring and grounding of equipment must comply with local codes.
3. Low voltage wiring to be No. 18 AWG minimum conductor.
4. If outdoor thermostat (ODT) is not used, connect W2 to W3
(See Note B below).
5. Be sure the jumper between “R” and “BK” is cut or removed.
6. With “O” and “Y/ Y2” energized, indoor fan is at 80% airflow.
7. With “O”, “Y/ Y2” and “BK” energized, indoor fan is at 100% airflow.
LEGEND
FACTORY WIRING FIELD WIRING
REQUIRED WIRING
Refer to Field Hook-up Diagrams above.
4A7A6 units require 80% airflow with “Y1” (first stage),
100% airflow with “Y2” (second stage).
Note A – The installer must jumper at the LVTB “R” to “O”.
Note B – Cut /remove the factory installed “BK” jumper (See Figures 1 & 2)
Connect “Y1” from thermostat to “Y/Y2” at VS Air Handler/VS Furnace to “Y1” at Outdoor Unit.
Connect “Y2” from thermostat to “BK” at VS Air Handler/VS Furnace to “Y2” at Outdoor Unit.
G O B W3
W3
W2
W2
W1
W1
RBK
BK
T Y Ylo
Ylo
Jumper
1
ON
OFF
W14
BK JUMPER
2
12
BLK/TWIN
BLK/TWIN
W2
W2
W1
W1
R
R
G
G
B
B
Y
Y
YLO
YLO
O
O
The Factory installed jumper between
“R” and “BK” on the Furnace circuit
board must be cut.
See Note B.
FURNACEAIR HANDLER
12
See
Note A
See
Note A
See Note B

PAGE 6 Pub. No. 11-AC16D1-3
INSTALLER'S GUIDE
From Dwg. D152862 Rev. 17
4A7A6 OUTLINE DRAWING
NOTE: ALL DIMENSIONS ARE IN MM (INCHES).
MODELS BASE A B C D E F G H J K
4A7A6024B 3 933 (36-3/4) 829 (32-5/8) 756 (29-3/4) 5/8 5/16 143 (5-5/8) 92 (3-5/8) 210 (8-1/4) 79 (3-1/8) 508 (20)
4A7A6036B 4 841 (33-1/8)) 946 (37-1/4) 870 (34-1/4) 3/4 3/8 152 (6) 98 (3-7/8) 219 (8-5/8) 86 (3-3/8) 508 (20)
4A7A6048B 4 1045 (41-1/8) 946 (37-1/4) 870 (34-1/4) 7/8 3/8 152 (6) 98 (3-7/8) 219 (8-5/8) 86 (3-3/8) 508 (20)
4A7A6060B 4 1045 (41-1/8) 946 (37-1/4) 870 (34-1/4) 7/8 3/8 152 (6) 98 (3-7/8) 219 (8-5/8) 86 (3-3/8) 508 (20)

Pub. No. 11-AC16D1-3 PAGE 7
INSTALLER'S GUIDE
MOUNTING HOLE LOCATION
NOTE: ALL DIMENSIONS ARE IN MM (INCHES).
NOTE: For model base size, see table on page 6. From Dwg. 21D152989 Rev. 0

PAGE 8 Pub. No. 11-AC16D1-3
P.I. 1/05
INSTALLER'S GUIDE
CHECKOUT PROCEDURE
After installation has been completed, it is recommended that the entire system be checked against the
following list:
1. Refrigerant Line, Leak checked........................................................................................................... [ ]
2. Suction Lines and Fittings properly insulated ...................................................................................... [ ]
3. Have all Refrigerant Lines been secured and isolated properly? ........................................................ [ ]
4. Have passages through masonry been sealed? If mortar is used, prevent mortar from
coming into direct contact with copper tubing...................................................................................... [ ]
5. Verify tightness of all electrical connects ............................................................................................. [ ]
6. Observe outdoor fan during on cycle for clearance and smooth operation ......................................... [ ]
7. Indoor coil drain line drains freely. Pour water into drain pan.............................................................. []
8. Supply registers and return grilles open and unobstructed ................................................................. [ ]
9. Return air filter installed....................................................................................................................... [ ]
10. Thermostat thermometer is accurate. Check against a reliable thermometer. Adjust
per instructions with thermostat........................................................................................................... [ ]
11. Is correct speed tap being used? (Indoor blower motor) ..................................................................... [ ]
12. Operate complete system in each mode to insure safe operation. ..................................................... [ ]
INDOOR THERMOSTAT
SWITCH SETTING
11
Fan Switch
TO CHECK Off Cool Heat Auto On
COMPONENT OPERATION
Indoor Outdoor Compressor 3 Comp. Furnace
Blower Fan Runs Sump Heat
Runs Runs Heater Comes On
Step
No.
CHECKOUT PROCEDURE WITH MAIN POWER DISCONNECTS CLOSED (ON)
1 Also set thermostat dial to call for cooling or heating as necessary.
2 Check only necessary if heating unit is used for indoor section and wiring has been disturbed during installation of cooling
equipment.
3 When applicable.
1 Sump Heat X X X
2 Indoor Fan Operation X X X X
3 Cooling Operation X X X X X X
4 Checking Performance X X X X X X
& Charge USE CHARTS ATTACHED TO O.D. UNIT
5 Heating 2 XX X X X
6 Inform owner on how to operate system and what to expect of it. At the same time deliver Owner’s Use and Care Booklet.
Technical Literature - Printed in U.S.A.
American Standard Inc.
Troup Highway
Tyler, TX 75707-9010