Grandaire R4H3 Series, WCH3**4Series Installation Instructions Manual
INSTALLATION INSTRUCTIONS
R−410A Split System Heat Pump
Product Family: R4H3, WCH3**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..................................
Unit Support 2.................................
Refrigeration System 3.........................
Electrical Wiring 8..............................
Defrost System 10.............................
Start−up Procedure 12..........................
Refrigerant Charge 12..........................
Sequence of Operation 16.......................
Maintenance 16................................
R−410A Quick Reference Guide 17...............
!
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
428 01 5301 05 2/6/14
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.
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
When installing, allow sufficient space for airflow
clearance, wiring, refrigerant piping, and service. Allow
24 in. (610 mm) clearance to service end of unit and 48
in. (1219.2 mm) above unit. For proper airflow, a 6 in.
(152.4 mm) clearance on one side of unit and 12 in.
(304.8 mm) on all remaining sides must be maintained.
Maintain a distance of 24 in. (609.6 mm) between units
or 18 in. (457.2 mm) if no overhang within 12 ft.
(3.66m). Position so water, snow, or ice from roof or
eaves cannot fall directly on unit.
On rooftop applications, locate unit at least 6 in.
(152.4mm) above roof surface.
!
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.
2 428 01 5301 05
WARNING
CAUTION
UNIT SUPPORT
NOTE: Unit must be level | 2 degrees {a inch rise or3/8 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.
Specifications subject to change without notice.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
C. FASTENING UNIT DOWN
!
CAUTION
If conditions or local codes require the unit be attached in
place, remove the knockouts in the base pan and install
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
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.
(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.
REFRIGERATION SYSTEM
A. COMPONENT MATCHES
Check to see that the proper system components are in
place, especially the indoor coil.
R−410A outdoor units can only be used with R−410A
specific indoor coils. If there is a refrigerant mis−match,
consult the indoor coil manufacturer to determine if a
refrigerant conversion kit is available for the indoor coil.
This outdoor unit is designed to achieve maximum
efficiency when used with indoor coils that utilize a TXV
refrigerant metering device or Piston with Teflon ring
Figure 2 Tie Down Knockouts
metering device. If any other type of metering device is
installed on the indoor coil, consult the indoor coil
3/8” (10mm) dia. Tie Down Knockouts
In Base Pan (2 places)
View From Top
manufacturer to determine if a conversion kit is available.
Installing with TXV.
When installing a TXV on an indoor coil, follow the
instructions provided with the new TXV.
A typical TXV installation is shown in Figure 1.
Figure 1 Typical TXV Installation
INDOOR
COIL
C
Base
Pan
Depth
EQUALIZER
TUBE
A
Base Pan Width x
Depth
23x23
(584x584)
25−11/16x25−11/16
(652x652)
31−1/8x31−1/8
(791x791)
428 01 5301 05 3
Base Pan Width
Inches (mm)
Tie Down
Knockouts
A B C
7−3/4
(197)
9−1/16
(230)
9−1/16
(230)
4−7/16
(113)18(457)
4−7/16
(113)
6−1/2
(165)
21−1/4
24−5/8
B
Minimum
Mounting Pad
Dimensions
23x23
(584x584)
(540)
(625)
26x26
(660x660)
31−1/2x31−1/2
(800x800)
Specifications subject to change without notice.
SENSING
BULB
TXV
10 O’Clock
7/8
2 O’Clock
SUCTION TUBE
IN. OD & SMALLER
SUCTION
TUBE
LIQUID
TUBE
SENSING BUL
STRAP
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
Installing with Indoor Piston − cooling operation.
(Heat pumps also use an outdoor piston for heating
operation, refer to section F.)
Check piston size shipped with indoor unit to see if it
matches required indoor piston size shown on outdoor
unit rating plate.
If it does not match, replace indoor piston with cooling
piston, according to size marked on outdoor unit rating
plate. (Some outdoor models include a cooling piston in
the accessory bag.)
Heating piston is shipped in the service valve − refer to
section F.
Example fan coils with piston: FEM4P, FSM4P, FSU4P,
FMA4P, FMC4P, FMU4P, WAPM, WAPT, WAPL, WAMA,
WAMC.
See Figure 2.
When changing indoor piston, use a back−up wrench.
Finger tighten hex nut, then tighten with wrench 1/2 turn.
Do not exceed 30 ft−lbs (40.7 N−m).The indoor piston
contains a Teflon ring (or seal) which is used to seat
against the inside of distributor body, and must be
installed properly to ensure proper seating in the direction
for cooling operation.
Figure 2 Indoor (cooling) Piston
BRASS
HEX NUT
TEFLON SEAL
TEFLON RING
PISTON
FLOW IN
COOLING
PISTON
RETAINER
DISTRIBUTOR
BRASS
HEX BODY
B. REFRIGERANT LINE SETS
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).
If outdoor unit is more than 10 feet (3m) 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).
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.
WARNING
STRAINER
!
PRODUCT OPERATION HAZARD
Failure to follow this caution may result in improper product
operation.
If using a TXV in conjunction with a single−phase reciprocating compressor, a compressor start capacitor and relay are
required. Consult outdoor unit pre−sale literature for start assist kit part number.
4 428 01 5301 05
CAUTION
!
UNIT OPERATION HAZARD
Failure to follow this caution may result in improper product operation.
L10S017
Specifications subject to change without notice.
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.
CAUTION
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
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
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 3.
wall.
Figure 3 Routing and Suspending Refrigerant Lines
OUTDOOR WALL INDOOR WALL
CAULK
INSULATION
THROUGH THE WALL SUSPENSION
!
CAUTION
LIQUID TUBE
SUCTION TUBE
HANGER STRAP
(AROUND SUCTION
TUBE ONLY)
1” (25mm) MIN
Figure 4
JOIST
INSULATION
SUCTION TUBE
LIQUID TUBE
Liquid Line Filter−Drier
Installed at Indoor Coil
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.
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
Outdoor units are shipped with an appropriate filter−drier
for installation 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 4.
428 01 5301 05 5
Filter−Drier
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
Specifications subject to change without notice.
38−11−84
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pump
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 5 and follow these steps for piston
installation:
1. Remove plastic cap holding piston in piston body of
liquid service valve.
2. Check that piston size (stamped on side of piston)
matches with number listed on unit rating plate.
Return piston to piston body of liquid service valve
(either direction).
3. Find plastic bag taped to unit containing copper
adapter tube, brass nut, and plastic washer.
4. Install plastic washer in the seat inside piston body.
5. Fit brass nut onto adapter tube and install tube
onto liquid service valve. Tighten nut finger tight,
then wrench additional ½ turn only 15−ft lbs. Over
tightening may damage the plastic washer.
Service valve bodies are brass and suction tube stub is
copper.
helps prevent overheating and damage to valve seals
(refer to Figure 5). Replace valve core when brazing is
completed.
!
FIRE HAZARD
Failure to remove refrigerant and oil charge before
brazing could result in personal injury, death, and/
or property damage.
Refrigerant and oil mixture could ignite and burn
as it escapes and contacts brazing torch. Make
sure the refrigerant charge is properly removed
from both the high and low sides of the system before brazing any component or lines.
Clean line set tube ends with emery cloth or steel brush.
Remove any grit or debris.
Insert line set tube ends into service valve tube stubs.
Apply heat absorbing paste or heat sink product between
service valve and joint. Wrap service valves with a heat
sinking material such as a wet cloth.
Braze joints using a Sil−Fos or Phos−copper alloy.
WARNING
Figure 5
LIQUID SERVICE VALVE
VALVE CORE
G. BRAZING CONNECTIONS
NOTE:
For Liquid Service Valve − Braze lineset to adapter tube
BEFORE bolting adapter to valve. This helps prevent
overheating and damage to plastic washer or o−ring.
For Vapor Service Valve − remove valve core from
schrader port on Service Valve BEFORE brazing. This
6 428 01 5301 05
Liquid Service Valve with Heating
Piston and Adapter Tube
BRASS NUT
ADAPTER TUBE
PLASTIC WASHER
PISTON
PISTON BODY
Vapor Service Valve
!
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Braze with Sil−Fos or Phos−copper alloy on copper−to−copper joints and wrap a wet cloth around
rear of fitting to prevent damage to TXV.
H. EVACUATING LINE SET AND INDOOR COIL
The unit is shipped with a factory refrigerant charge. The
liquid line and suction line service valves have been
closed after final testing at the factory. Do not disturb
these valves until the line set and indoor coil have been
evacuated and leak checked, or the charge in the unit
may be lost.
NOTE: Do not use any portion of the factory charge for
purging or leak testing. The factory charge is for filling the
system only after a complete evacuation and leak check
SERVICE VALVE
has been performed.
!
PRODUCT DAMAGE HAZARD
Failure to follow this caution may result in product
damage.
Never use the outdoor unit compressor as a vacuum pump. Doing so may damage the compressor.
Line set and indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns. If
deep vacuum equipment is not available, the alternate
triple evacuation method may be used by following the
specified procedure.
Specifications subject to change without notice.
CAUTION
CAUTION
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