Day and Night R4H3, R4H4, WCH3**4, WCH**4 Installation Instructions Manual
INSTALLATION INSTRUCTIONS
R−410A Split System Heat Pump
Product Family: R4H3, R4H4, WCH3**4, WCH**4
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,
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 manuals 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.
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:
!
Signal Words on Product Labeling
Signal words are used in combination with colors
and/or pictures on product labels.
WARNING
CAUTION
TABLE OF CONTENTS
Inspect New Unit 2...............................
Safety Considerations 2...........................
Location 2.......................................
Clearances 2 − 3.................................
Unit Support 4...................................
Refrigeration System 5 − 9........................
Electrical Wiring 8 − 10............................
Defrost System 11 − 12...........................
Start−up Procedure 13............................
Refrigerant Charge 13 − 17.........................
Sequence of Operation 17.........................
Maintenance 17..................................
R−410A Quick Reference Guide 18.................
!
DEATH, PERSONAL INJURY, AND/OR PROPERTY
DAMAGE HAZARD
Failure to carefully read and follow this warning
could result in equipment malfunction, property
damage, personal injury and/or death.
Installation or repairs made by unqualified persons could result in equipment malfunction, property damage, personal injury and/or death.
The information contained in this manual is intended for use by a qualified service technician familiar with safety procedures and equipped with
the proper tools and test instruments.
Installation must conform with local building
codes and with the National Electrical Code
NFPA70 current edition or Canadian Electrical
Code Part 1 CSA C.22.1.
WARNING
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INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
INSPECT NEW UNIT
After uncrating unit, inspect thoroughly for hidden
damage. If damage is found, notify the transportation
company immediately and file a concealed damage
claim.
SAFETY CONSIDERATIONS
Consult a qualified installer, service agency, or the
dealer/distributor for information and assistance. The
qualified installer must use factory authorized kits and
accessories when modifying this product. Refer to the
individual instructions packaged with the kit or accessory
when installing.
The weight of the product requires careful and proper
handling procedures when lifting or moving to avoid
personal injury. Use care to avoid contact with sharp or
pointed edges.
Follow all safety codes. Wear safety glasses, protective
clothing, and work gloves. Use a heat sinking material −
such as a wet rag − during brazing operations. Keep a fire
extinguisher available. Consult local codes and the
National Electric Code (NEC) for special requirements.
Improper installation, adjustment, alteration, service or
maintenance can void the warranty.
!
CUT HAZARD
Failure to follow this caution may result in property damage.
Sheet metal parts may have sharp edges or burrs.
Use care and wear appropriate protective clothing
and gloves when handling parts.
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in
personal injury or death.
Before installing, modifying or servicing system,
main electrical disconnect switch must be in the
OFF position. There may be more than 1
disconnect switch. Lock out and tag switch with a
suitable warning label.
!
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property damage
R−410A systems operate at higher pressures than
R−22 systems. When working with R−410A systems, use only service equipment and replacement components specifically rated or approved
for R−410A service.
CAUTION
WARNING
CAUTION
LOCATION
Check local codes for regulations concerning zoning,
noise, platforms, and other issues.
Locate unit away from fresh air intakes, vents, or
bedroom windows. Noise may carry into the openings
and disturb people inside.
Locate unit in a well drained area, or support unit high
enough so that water runoff will not enter the unit.
Locate unit away from areas where heat, lint, or exhaust
fumes will be discharged onto unit (as from dryer vents).
Locate unit away from recessed or confined areas where
recirculation of discharge air may occur (refer to
CLEARANCES section of this document).
Roof−top installation is acceptable providing the roof will
support the unit and provisions are made for water
drainage and noise/vibration dampening.
NOTE: Roof mounted units exposed to wind may require
wind baffles. Consult the manufacturer for additional
information.
CLEARANCES
Nominal minimum clearances are 48 inches (1.2m)
above unit for discharge air and 18 inches (457mm) on
each side of the coil for intake air. Clearance on any one
side of the coil (normally between unit and structure) may
be reduced to 6 inches. Nominal minimum clearances are
based on a solid parallel object such as a wall or roof
overhang.
The clearance may be reduced for a single object with
small surface area, such as the end of a wall, outside
corner of a wall, fence section, post, etc. As a general
rule, the minimum clearance from the unit should equal
the width of the object. For example, a 6 inch (152mm)
fence post should be a minimum of 6 inches (152mm)
from the unit.
Do not install unit under roof overhangs unless gutters are
present. A minimum vertical clearance of 48 (1.2m)
inches is required to the overhang.
Inside corner locations on single story structures require
evaluation. Large overhanging soffits may cause air
recirculation in a corner area even though recommended
minimum clearances are maintained. As a guide, locate
the unit far enough out so that half of the discharge grille is
out from under the soffit.
When placing two or more units side−by−side, provide a
minimum of 18 inches (457mm) between units.
Provide minimum service clearance of 24 inches
(610mm) from control box corner and side service panel.
Refer to Figure 1.
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INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
Figure 1 Clearances (various examples)
24”
(610mm)
Service
Wall
6”
(152mm)
18”
(457mm)
Wall
6”
(152mm)
18”
(457mm)
18”
(457mm)
Wall
24”
(610mm)
Service
Wall
6”
(152mm)
18”
(457mm)
Wall
6”
(152mm)
24”
(610mm)
Service
18”
(457mm)
24”
(610mm)
Service
4”
(102mm)
(457mm)
18”
(152mm)
18”
(102mm)
wide fence
Wall
24”
(610mm)
Service
4”
24”
(610mm)
Service
18”
(457mm)
18”
(457mm)
6”
(152mm)
6”
(152mm)
Post
24”
(610mm)
Service
18”
(457mm)
428 01 5302 00 3
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
UNIT SUPPORT
NOTE: Unit must be level " 2 degrees {inch rise or 3/8
fall per foot of run (10mm rise or fall per 305 mm of run) } or
compressor may not function properly.
A. GROUND LEVEL INSTALLATION
The unit must be level and supported above grade by
beams, platform, or a pad. Platform or pad can be of open or
solid construction but should be of permanent materials
such as concrete, bricks, blocks, steel, or pressure− treated
timbers approved for ground contact. Soil conditions must
be considered so that the platform or pad does not shift or
settle and leave the unit partially supported. Minimum pad
dimensions are shown in Figure 2.
If beams or an open platform are used for support, it is
recommended that the soil be treated or area be graveled
to reduce the growth of grasses and weeds.
To minimize vibration or noise transmission, it is
recommended that supports not be in contact with the
building structure. However, slabs on grade constructions
with an extended pad are normally acceptable.
!
CAUTION
C. FASTENING UNIT DOWN
If conditions or local codes require the unit be attached in
place, remove the knockouts in the base pan and install
tie down bolts through the holes (refer to Figure 2).
Contact local distributor for hurricane hold−down details and
the P.E. (Professional Engineer) certification, when required.
!
CAUTION
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property damage.
Inadequate unit support may cause excessive vibration,
noise, and/or stress on the refrigerant lines, leading to refrigerant line failure.
Figure 2 Tie Down Knockouts
3/8” (10mm) dia. Tie Down Knockouts
In Base Pan (2 places)
View From Top
PROPERTY DAMAGE HAZARD
Failure to follow this caution may result in property damage.
Top surface of platform must be above estimated snowfall level to prevent snow blocking coil and to allow water
melt to drain from unit.
B. ROOF TOP INSTALLATION
This type of installation is not recommended on wood
frame structures where low noise levels are required.
Supporting structure or platform for the unit must be level.
If installation is on a flat roof, locate unit minimum 6 inches
(152mm) above roof level.
Place the unit over one or more load bearing walls. If there
are several units, mount them on platforms that are
self−supporting and span several load bearing walls. These
suggestions are to minimize noise and vibration
transmission through the structure. If the structure is a home
or apartment, avoid locating the unit over bedrooms or study.
NOTE: When unit is to be installed on a bonded
guaranteed roof, a release must be obtained from the
building owner to free the installer from all liabilities.
A
Base Pan Width x
Depth
23x23
(584x584)
25−11/16x25−11/16
(652x652)
31−1/8x31−1/8
(791x791)
35x35
(889x889)
Base Pan Width
Inches (mm)
Tie Down
Knockouts
A B C
7−3/4
(197)
9−1/16
(230)
9−1/16
(230)
9−1/16
(230)
4−7/16
(113)18(457)
4−7/16
(113)
6−1/2
(165)
6−1/2
(165)
21−1/4
(540)
24−5/8
(625)
28−3/8
(722)
Base
Pan
Depth
C
B
Minimum
Mounting Pad
Dimensions
23x23
(584x584)
26x26
(660x660)
31−1/2x31−1/2
(800x800)
35x35
(889x889)
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INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
REFRIGERATION SYSTEM
A typical TXV installation is shown in Figure 3.
Figure 3 Typical TXV Installation
INDOOR
EQUALIZER
TUBE
SENSING
BULB
TXV
SENSING BULB
(EITHER SIDE)
SUCTION
8 O’CLOCK 4 O’CLOCK
B. REFRIGERANT LINE SETS
RECOMMENDED REFRIGERANT LINE SET DIAMETERS
Model Size 18 24 30 36 42 48 60
Rated Vapor** 5/8 5/8 3/4 3/4 7/8 7/8 1−1/8
Liquid 3/8
** Units are rated with 0−80 ft (0−24 m) of lineset length. See Vapor Line
Sizing and Cooling Capacity Loss table when using other sizes and
lengths of lineset.
The refrigerant line set must be properly sized to assure
maximum efficiency and proper oil circulation.
Refer to Product Specifications and Long Line
Applications Guideline for line set sizing.
NOTE: Total line set length must not exceed 200 feet
(61m).
NOTE: A crankcase heater must be used when the
refrigerant line length exceeds 80 feet (24.4m) or when
the outdoor unit is at least 20 feet (6.09m) below the
indoor unit.
If outdoor unit is more than 10 feet higher than the indoor
coil, refer to the Long Line Applications Guideline for
instructions.
NOTE: When the outdoor unit is higher than the indoor
coil, the vertical separation must not exceed 100 feet
(30m).
NOTE: When the outdoor unit is lower than the indoor
coil, the vertical separation must not exceed 50 feet
(15.2m).
COIL
SUCTION
TUBE
LIQUID
TUBE
STRAP
TUBE
If it is necessary to add refrigerant line in the field, use
dehydrated or dry, sealed, deoxidized, copper
refrigeration tubing. Do not use copper water pipe.
Do not remove rubber plugs or caps from copper tubing
until connections are ready to be made.
Be extra careful when bending refrigeration tubing.
Tubing can “kink” easily, and if this occurs, the entire
length of tubing must be replaced.
!
PERSONAL INJURY HAZARD
Failure to relieve system pressure could result in
personal injury and/or death.
Relieve pressure and recover all refrigerant before
servicing existing equipment, and before final unit
disposal. Use all service ports and open all flow−
control devices, including solenoid valves.
Federal regulations require that you do not vent
refrigerant to the atmosphere. Recover during
system repair or final unit disposal.
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper product operation.
Do not leave system open to atmosphere any longer than absolutely required for installation. Internal system components − especially refrigerant
oils − are extremely susceptible to moisture contamination. Keep ends of tubing sealed during
installation until the last possible moment.
C. ROUTING AND SUSPENDING REFRIGERANT
LINES
Run refrigerant lines as straight and direct as possible,
avoiding unnecessary bends and turns. Always insulate
the entire suction line. Both lines should be insulated
when routed through an attic or when routed through an
underground raceway.
When routing refrigerant lines through a foundation or
wall, do not allow refrigerant lines to come in direct
contact with the building structure. Make openings large
enough so that lines can be wrapped with extra insulation.
Fill all gaps with RTV caulk. This will prevent noise
transmission between the tubing and the foundation or
wall.
Along floor or ceiling joists, suspend refrigerant lines so
that they do not contact the building structure, water
pipes, or ductwork. Use insulated or suspension type
hangers. Metal straps must be at least 1” (25mm) wide to
avoid cutting into the tube insulation. Keep the liquid and
suction lines separate. Refer to Figure 4.
WARNING
CAUTION
428 01 5302 00 5
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
Figure 4 Routing and Suspending Refrigerant Lines
OUTDOOR WALL INDOOR WALL
!
CAULK
INSULATION
THROUGH THE WALL SUSPENSION
CAUTION
LIQUID TUBE
SUCTION TUBE
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper product operation.
Do not bury more than 36” (1m) of line set underground. Refrigerant may migrate to cooler buried
section during extended periods of unit shut−
down, causing refrigerant slugging and possible
compressor damage at start−up.
If ANY section of the line set is buried underground, provide a minimum 6” (152mm) vertical
rise at the service valve.
HANGER STRAP
(AROUND SUCTION
TUBE ONLY)
1” (25mm) MIN
Figure 5
JOIST
INSULATION
SUCTION TUBE
LIQUID TUBE
Liquid Line Filter−Drier
Installed at Indoor Coil
D. OUTDOOR UNIT HIGHER THAN INDOOR UNIT
Proper oil return to the compressor should be maintained
with suction gas velocity. If velocities drop below 1500
fpm (feet per minute), oil return will be decreased. To
maintain suction gas velocity, do not upsize vertical
suction risers.
E. LIQUID LINE FILTER−DRIER
NOTE: It is recommended that an appropriate filter−drier
be installed in the liquid line.
Leave the plugs in the tube ends until the filter−drier is
installed. The optimal location for the filter−drier is close
to the indoor coil. Heat pump filter−driers are “bi−flow”
type. Either end can be pointed towards indoor coil. Refer
to Figure 5.
Filter−Drier
38−11−84
F. SERVICE VALVES
Service valves are closed and plugged from the factory.
Outdoor units are shipped with a refrigerant charge
sealed in the unit. Leave the service valves closed until all
other refrigerant system work is complete or the charge
will be lost. Leave the plugs in place until line set tubing is
ready to be inserted.
Heat pumps require a piston metering device in the liquid
service valve for proper heating operation. Piston is
shipped in the piston body of the liquid service valve,
temporarily held in place with a plastic cap. Do not remove
the plastic cap until line set tubing is ready to be installed.
Refer to Figure 6 and follow these steps for piston
installation:
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