ICP NXH518GKA100, NXH524GKA100, NXH530GKA100, NXH536GKA100, NXH537GKA100 Installation Guide

INSTALLATION INSTRUCTIONS R- 410A Split System Heat Pumps

N4H4 / R4H4 / WCH4 / NXH5

These instructions must be read and understood completely before attempting installation.

NOTE: Read the entire instruction manual before starting the installation.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury, or property damage. Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory–authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing, and work gloves. Use quenching cloth for brazing operations. Have fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit. Consult local building codes and current editions of the National Electrical Code (NEC) NFPA 70. In Canada, refer to current editions of the Canadian electrical code CSA 22.1.

Recognize safety information. This is the safety–alert symbol !! . When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury.

Understand these signal words; DANGER, WARNING, and CAUTION. These words are used with the safety–alert symbol. DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will result in enhanced installation, reliability, or operation.

!WARNING

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.

!WARNING

EXPLOSION HAZARD

Failure to follow this warning could result in death, serious personal injury, and/or property damage.

Never use air or gases containing oxygen for leak testing or operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to an explosion.

INSTALLATION RECOMMENDATIONS

NOTE: In some cases noise in the living area has been traced to gas pulsations from improper installation of equipment.

1.Locate unit away from windows, patios, decks, etc. where unit operation sound may disturb customer.

2.Ensure that vapor and liquid tube diameters are appropriate for unit capacity.

3.Run refrigerant tubes as directly as possible by avoiding unnecessary turns and bends.

4.Leave some slack between structure and unit to absorb vibration.

5.When passing refrigerant tubes through the wall, seal opening with RTV or other pliable silicon–based caulk (see Fig. 1).

6.Avoid direct tubing contact with water pipes, duct work, floor joists, wall studs, floors, and walls.

7.Do not suspend refrigerant tubing from joists and studs with a rigid wire or strap which comes in direct contact with tubing (see Fig. 1).

8.Ensure that tubing insulation is pliable and completely surrounds vapor tube.

9.When necessary, use hanger straps which are 1 in. wide and conform to shape of tubing insulation (see Fig. 1).

10.Isolate hanger straps from insulation by using metal sleeves bent to conform to shape of insulation.

OUTDOOR WALL		INDOOR WALL

CAULK

LIQUID TUBE

	INSULATION	SUCTION TUBE
	THROUGH THE WALL
		JOIST
	HANGER STRAP
	(AROUND SUCTION	INSULATION
	TUBE ONLY)
		SUCTION TUBE

1” (25.4 mm)
MIN								LIQUID TUBE
	SUSPENSION
								A07588

Fig. 1 – Connecting Tubing Installation

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When outdoor unit is connected to factory–approved indoor unit, outdoor unit contains system refrigerant charge for operation with AHRI rated indoor unit when connected by 15 ft. (4.57 m) of field–supplied or factory accessory tubing. For proper unit operation, check refrigerant charge using charging information located on control box cover and/or in the Check Charge section of this instruction.

IMPORTANT: Maximum liquid–line size is 3/8–in. OD for all residential applications including long line.

IMPORTANT: Always install the factory–supplied liquid–line filter drier. Obtain replacement filter driers from your distributor or branch.

INSTALLATION

IMPORTANT: Effective January 1, 2015, all split system and packaged air conditioners must be installed pursuant to applicable regional efficiency standards issued by the Department of Energy.

!CAUTION

CUT HAZARD

Failure to follow this caution may result in personal injury.

Sheet metal parts may have sharp edges or burrs. Use care and wear appropriate protective clothing and gloves when handling parts.

Check Equipment and Job Site

Unpack Unit

Move to final location. Remove carton taking care not to damage unit.

Inspect Equipment

File claim with shipping company prior to installation if shipment is damaged or incomplete. Locate unit rating plate on unit corner panel. It contains information needed to properly install unit. Check rating plate to be sure unit matches job specifications.

Install on a Solid, Level Mounting Pad

If conditions or local codes require the unit be attached to pad, tie down bolts should be used and fastened through knockouts provided in unit base pan. Refer to unit mounting pattern in Fig. 2 to determine base pan size and knockout hole location.

For hurricane tie downs, contact distributor for details and PE Certification (Professional Engineer), if required.

On rooftop applications, mount on level platform or frame. Place unit above a load–bearing wall and isolate unit and tubing set from structure. Arrange supporting members to adequately support unit and minimize transmission of vibration to building. Consult local codes governing rooftop applications.

Roof mounted units exposed to winds above 5 mph may require wind baffles. Consult the Service Manual – Residential Split System Air Conditioners and Heat Pumps for wind baffle construction.

NOTE: Unit must be level to within ±2° ( 3/8 in/ft, 9.5 mm/m) per compressor manufacturer specifications.

Elevate Unit

!CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

Unit must be kept free of an accumulation of water and/or ice in the basepan.

Elevate unit per local climate and code requirements to provide clearance above estimated snowfall level and ensure adequate drainage of unit. If using accessory support feet, use installation instructions from kit for installation.

!CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

To prevent damage to the unit, ensure that it is located with the supports such that the unit is stable in all circumstances including adverse conditions.

Clearance Requirements

When installing, allow sufficient space for airflow clearance, wiring, refrigerant piping, and service. Allow 24 in. (609.6 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 1 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. (3.66 m). Position so water, snow, or ice from roof or eaves cannot fall directly on unit.

NOTE: 18” (457.2 mm) clearance option described above is approved for outdoor units with wire grille coil guard only. Units with louver panels require 24” (609.6 mm) between units.

On rooftop applications, locate unit at least 6 in. above roof surface.

3/8–in. (9.53 mm) Dia. Tiedown Knockouts in Basepan(2) Places

View From Top

	UNIT BASE PAN	TIEDOWN KNOCKOUT LOCATIONS in. (mm)
	Dimension in. (mm)	A	B	C
	23 X 23	7–3/4 (196.8)	4–13/32 (111.9)	18–1/32 (457.9)
	(585 X 585)
	26 X 26	9–1/8 (231.8)	4–7/16 (112.7)	21–1/4 (539.8)
	(660 X 660)
	31–1/2 X 31–1/2	9–1/8 (231.8)	6–9/16 (166.7)	24–11/16 (627.1)
	(800 X 800)
	35 X 35	9–1/8 (231.8)	6–9/16 (166.7)	28–7/16 (722.3)
	(889 X 889)
				A05177
	Fig. 2 – Tiedown Knockout Locations

Operating Ambient

The minimum outdoor operating ambient in cooling mode without accessory is 55°F (12.78°C), and the maximum outdoor operating ambient in cooling mode is 125°F (51.67°C). The maximum outdoor operating ambient in heating mode is 66 °F (18.89°C).

Check Defrost Thermostat

Check defrost thermostat to ensure it is properly located and securely attached. There is a liquid header with a distributor and feeder tube going into outdoor coil. At the end of the one of the feeder tubes, there is a 3/8 in. O.D. stub tube approximately 2 in. (50.8 mm) long (see Fig. 3). The defrost thermostat should be located on stub tube. Note that there is only one stub tube used with liquid header, and on most units it is the bottom circuit.

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FEEDER TUBE

STUB TUBE

			DEFROST
			THERMOSTAT
				A97517
		Fig. 3 – Defrost Thermostat Location
		Table 1 – Accessory Usage
		REQUIRED FOR LOW–AMBIENT	REQUIRED FOR	REQUIRED FOR
	Accessory	COOLING APPLICATIONS		SEA COAST APPLICATIONS
			LONG LINE APPLICATIONS*
		(Below 55 F / 12.8 C)		(Within 2 miles / 3.22 km)
	Accumulator	Standard	Standard	Standard
	Compressor Start Assist Capacitor and	Yes	Yes	No
	Relay
	Crankcase Heater	Yes	Yes	No
	Evaporator Freeze Thermostat	Yes	No	No
	Hard Shutoff TXV	Yes	Yes	No
	Isolation Relay	Yes	No	No
	Liquid Line Solenoid Valve	No	See Long–Line Application Guideline	No
	Low Ambient Switch	Yes	No	No
	Support Feet	Recommended	No	Recommended

* For tubing line sets between 80 and 200 ft. (24.38 and 60.96 m) and/or 20 ft. (6.09 m) vertical differential, refer to Residential Piping and Longline Guideline. .

Make Piping Connections

!WARNING

PERSONAL INJURY AND ENVIRONMENTAL HAZARD

Failure to follow this warning could result in personal injury or death.

Relieve pressure and recover all refrigerant before system repair or final unit disposal.

Use all service ports and open all flow–control devices, including solenoid valves.

!CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

If ANY refrigerant tubing is buried, provide a 6–in (152.4 mm). vertical rise at service valve. Refrigerant tubing lengths up to 36–in (914.4 mm). may be buried without further special consideration. Do not bury lines longer than 36 in (914.4 mm).

Outdoor units may be connected to indoor section using accessory tubing package or field–supplied refrigerant grade tubing of correct size and condition. For tubing requirements beyond 80 ft, substantial capacity and performance losses can occur. Following the recommendations in the Residential Piping and Long Line Guideline will reduce these losses. Refer to Table 1 for accessory requirements. Refer to Table 2 for field tubing diameters.

There are no buried–line applications greater than 36 in. (914.4 mm)

If refrigerant tubes or indoor coil are exposed to atmosphere, they must be evacuated to 500 microns to eliminate contamination and moisture in the system.

Outdoor Unit Connected To Factory Approved Indoor Unit

Outdoor unit contains approximate system refrigerant charge for operation with approved AHRI rated indoor unit when connected by 15 ft (4.57 m) of field–supplied or factory–accessory tubing, and factory supplied filter drier. Some indoor units require additional subcooling to achieve optimal heating performance. Using Table 5 or 6 – Additional Subcooling Required, check refrigerant charge for maximum efficiency

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 Fig. 4 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).

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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 [15ft lbs (20.3 N- m)]. Over tightening may damage the plastic washer and service valve’s piston body.

BRASS NUT

ADAPTER TUBE

PLASTIC WASHER

PISTON

PISTON BODY

LIQUID SERVICE VALVE

A14235

Fig. 4 – Liquid Service Valve with Heating Piston and Adapter Tube

SERVICE VALVE

VALVE CORE

A14236

Fig. 5 – Vapor Service Valve

Brazing Connections

Connect vapor tube to fitting on outdoor unit vapor service valves (see Table 2). Connect liquid tubing to adapter tube on liquid service valve. Use refrigerant grade tubing.

!CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage or improper operation.

Service valves must be wrapped in a heat–sinking material such as a wet cloth while brazing.

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.

After wrapping service valve with a wet cloth, tubing set can be brazed to service valve using either silver bearing or non–silver bearing brazing material. Do not use soft solder (materials which melt below 800°F/427°C). Consult local code requirements.

NOTE: Some outdoor units contain a mechanical fitting at the liquid distributor. This connection is not field serviceable and should not be disturbed.

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 helps prevent overheating and damage to valve seals (refer to Fig. 5). Replace valve core when brazing is completed.

!WARNING

FIRE HAZARD

Failure to following this warning 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 SilFos or Phoscopper alloy.

Table 2 – Refrigerant Connections and Recommended Liquid

and Vapor Tube Diameters (In.)

	LIQUID		RATED VAPOR
UNIT SIZE
	Connection	Tube	Connection	Tube
	Diameter	Diameter	Diameter	Diameter
18, 24, 30	3/8	3/8	3/4	3/4
36, 42, 48	3/8	3/8	7/8	7/8
60	3/8	3/8	7/8	1–1/8

*Units are rated with 25 ft. (7.6 m) of lineset. See Product Data sheet for performance data when using different size and length linesets.

Notes:

1.Do not apply capillary tube indoor coils to these units.

2.For Tubing Set lengths between 80 and 200 ft. (24.38 and 60.96 m) horizontal or 20 ft. (6.09 m) vertical differential 250 ft. (76.2 m) Total Equivalent Length, refer to the Residential Piping and Longline Guideline – Air Conditioners and Heat Pumps using R- 410A refrigerant.

Installing with Indoor Piston

Heat pumps with piston indoor ratings are shipped with the correct piston size in the accessory bag. Check piston size shipped with indoor unit to see if it matches required indoor piston size. If it does not match, replace indoor piston with correct piston size which is listed on the rating plate.

NOTE: Heat pumps without piston indoor ratings may be installed as a replacement component in a piston system. When installing a nonpiston rated heat pump with a piston indoor the correct indoor piston must be installed. When not listed on the rating plate the correct piston size is listed in the product data. Replacement pistons can be ordered from Replacement Components.

13/16” BRASS HEX NUT
		TEFLON® SEAL
			TEFLON®				3/4” BRASS HEX BODY
			RINGS					“H” DISTRIBUTOR

PISTON

PISTON RETAINER

A10342

Fig. 6 – Indoor Piston Installation

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