International comfort products PH4E Series, PH4E24, PH4E36, PH4E30, PH4E48 Installation Instructions Manual
516 01 2502 02 09−14−10
PACKAGED HEAT PUMP UNITS
Installation Instructions
PH4E Series
400V−3Ph−50Hz
International Comfort Products, LLC
Lewisburg, TN. 37091
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 2...............................
INTRODUCTION 2..........................................
RECEIVING AND INSTALLATION 2...........................
Check Equipment 2........................................
Identify Unit 2............................................
Inspect Shipment 2.......................................
Provide Unit Support 2......................................
Roof Curb 2.............................................
Slab Mount 3............................................
Provide Clearances 3.......................................
Rig and Place Unit 3........................................
Inspection 3.............................................
Rigging/Lifting of Unit 7...................................
Select and Install Ductwork 7................................
Converting Horizontal Discharge Units to Downflow
(Vertical) Discharge Units 8................................
Provide for Condensate Disposal 8...........................
Install Electrical Connections 9...............................
High−Voltage Connections 9...............................
Control Voltage Connections 10............................
Standard Connections 10..................................
Transformer Protection 10.................................
Special Procedures for 420−v Operations 10.................
Accessory Electric heaters Installation 10....................
Sequence of Operation 10.................................
PRE−START−UP 13.........................................
START−UP 13..............................................
Checking Cooling & Heating Control Operation 13............
Check for Refrigerant Leaks 13.............................
PAGE
Start−Up Adjustments 13..............................
Checking & Adjusting Refrigerant Charge 14...........
Indoor Airflow & Airflow Adjustments 15...............
Defrost Control 16.....................................
Quiet Shift 16......................................
Defrost 17.........................................
MAINTENANCE 17...................................
Air Filter 17...........................................
Indoor Blower and Motor 17............................
Outdoor Coil, Indoor Coil, & Condensate Drain Pan 18.....
Outdoor Fan 18.......................................
Electrical Controls and Wiring 18........................
Refrigerant Circuit 19..................................
Indoor Airflow 19......................................
Metering Devices− Piston 19
...........................
Pressure Switches 20..................................
Loss of Charge Switch 20..............................
High Pressure Switch 20...............................
Copeland Scroll compressor (R−410A Refrigerant) 20......
Refrigerant System 20.................................
Refrigerant 20.....................................
Compressor Oil 20.................................
Servicing Systems on Roofs with Synthetic Materials 20.
Liquid Line Filter Drier 20............................
R−410A Refrigerant Charging 20.....................
System Information 21.................................
Loss of Charge Switch 21...........................
Check Defrost Thermostat 21........................
TROUBLESHOOTING 23..............................
START−UP CHECKLIST 24............................
FIGURE 1 PH4E PACKAGED HEAT PUMP
SAFETY CONSIDERATIONS
Installation and servicing of this equipment can be hazardous
due to mechanical and electrical components. Only trained and
qualified personnel should install, repair, or service this
equipment.
Untrained personnel can perform basic maintenance functions
such as cleaning and replacing air filters. All other operations
must be performed by trained service personnel. When working
on this equipment, observe precautions in the literature, on tags,
and on labels attached to or shipped with the unit and other
safety precautions that may apply.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have a 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,
the current editions of the National Electrical Code (NEC) NFPA
70.
In Canada refer to the current editions of the Canadian Electrical
Code CSA C22.1.
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 or servicing system, always turn off
main power to system and install lockout tag. There
may be more than one disconnect switch. Turn off
accessory heater power switch if applicable.
!
CUT HAZARD
Failure to follow this caution may result in personal
injury.
When removing access panels (see FIGURE 18) or
performing maintenance functions inside your unit, be
aware of sharp sheet metal parts and screws.
Although special care is taken to reduce sharp edges
to a minimum, be extremely careful when handling
parts or reaching into the unit.
CAUTION
INTRODUCTION
The PH4E heat pump is fully self−contained and designed for
outdoor installation. (See FIGURE 1) Standard units are shipped
in a horizontal−discharge configuration for installation on a
ground level slab. Standard units can be converted to downflow
(vertical) discharge configurations for rooftop applications.
RECEIVING AND INSTALLATION
Step 1 — Check Equipment
Identify Unit
The unit model number and serial number are stamped on the
unit identification plate. Check this information against shipping
papers.
Inspect Shipment
Inspect for shipping damage before removing packaging
material. If unit appears to be damaged or is torn loose from its
anchorage, have it examined by transportation inspectors before
removal. Forward claim papers directly to transportation
company. Manufacturer is not responsible for any damage
incurred in transit. Check all items against shipping list.
Immediately notify the nearest equipment distributor if any item is
missing. To prevent loss or damage, leave all parts in original
packages until installation.
If the unit is to be mounted on a curb in a downflow application,
review Step 5 to determine which method is to be used to
remove the downflow panels before rigging and lifting into place.
The panel removal process may require the unit to be on the
ground.
.
Step 2 — Provide Unit Support
Roof Curb
Install accessory roof curb in accordance with instructions
shipped with curb (See FIGURE 5). Install insulation, cant strips,
roofing, and flashing. Ductwork must be attached to curb.
IMPORTANT: The gasketing of the unit to the roof curb is critical
for a watertight seal. Install gasketing material supplied with the
roof curb. Improperly applied gasketing also can result in air
leaks and poor unit performance.
Curb should be level to within 1/4 in. (6 mm) (See FIGURE 9).
This is necessary for unit drain to function properly. Refer to
accessory roof curb installation instructions for additional
information as required.
Accessory kits are available to aid in installing a new metal base
rail unit on a old roof curb.
Accessory kit number CPADCURB001A00, (small chassis) and
accessory kit number CPADDURB002A00, (large chassis)
includes roof curb adapter and gaskets for the perimeter seal
and duct openings. No additional modifications to curb are
required when using this kit.
2
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!
CAUTION
UNIT STRUCTURAL DAMAGE HAZARD
Failure to follow this caution may result in property
damage
Ensure there is sufficient clearance for saw blade
when cutting the outer horizontal flange of the roof
curb so there is no damage to the roof or flashing.
Slab Mount
Place the unit on a solid, level concrete pad that is a minimum of
4 in. (102 mm) thick with 2 in. (51 mm) above grade (See
FIGURE 2). The slab should extend approximately 2 in. (51 mm)
beyond the casing on all 4 sides of the unit. Do not secure the
unit to the slab except when required by local codes.
FIGURE 2 Slab Mounting Detail
2˝
(50.8mm)
OPTIONAL
RETURN
AIR
OPENING
EVAP. COIL COND. COIL
OPTIONAL
SUPPLY
AIR
OPENING
Step 3 — Provide Clearances
The required minimum service clearances are shown in
FIGURE 3 and FIGURE 4. Adequate ventilation and outdoor air
must be provided. The outdoor fan draws air through the outdoor
coil and discharges it through the top fan grille. Be sure that the
fan discharge does not recirculate to the outdoor coil. Do not
locate the unit in either a corner or under an overhead
obstruction. The minimum clearance under a partial overhang
(such as a normal house overhang) is 48 in. (1219 mm) above
the unit top. The maximum horizontal extension of a partial
overhang must not exceed 48 in. (1219 mm).
IMPORTANT: Do not restrict outdoor airflow. An air restriction at
either the outdoor−air inlet or the fan discharge may be
detrimental to compressor life.
Do not place the unit where water, ice, or snow from an
overhang or roof will damage or flood the unit. Do not install the
unit on carpeting or other combustible materials. Slab−mounted
units should be at least 4 in. (102 mm) above the highest
expected water and runoff levels. Do not use unit if it has been
under water.
Step 4 — Rig and Place Unit
Rigging and handling of this equipment can be hazardous for
many reasons due to the installation location (roofs, elevated
structures, etc.).
Only trained, qualified crane operators and ground support staff
should handle and install this equipment.
When working with this equipment, observe precautions in the
literature, on tags, stickers, and labels attached to the
equipment, and any other safety precautions that might apply.
Training for operators of the lifting equipment should include, but
not be limited to, the following:
1. Application of the lifter to the load, and adjustment of the
lifts to adapt to various sizes or kinds of loads.
2. Instruction in any special operation or precaution.
3. Condition of the load as it relates to operation of the lifting
kit, such as balance, temperature, etc.
Follow all applicable safety codes. Wear safety shoes and work
gloves.
Inspection
Prior to initial use, and at monthly intervals, all rigging shackles,
clevis pins, and straps should be visually inspected for any
damage, evidence of wear, structural deformation, or cracks.
Particular attention should be paid to excessive wear at hoist
hooking points and load support areas. Materials showing any
kind of wear in these areas must not be used and should be
discarded.
!
WARNING
UNIT FALLING HAZARD
Failure to follow this warning could result in personal
injury or death.
Never stand beneath rigged units or lift over people.
1. Leave top shipping skid on the unit for use as a spreader
bar to prevent the rigging straps from damaging the unit. If
the skid is not available, use a spreader bar of sufficient
length to protect the unit from damage.
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FIGURE 3
MODEL SIZE 24−36 DIMENSIONS
4
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FIGURE 4
MODEL SIZE 48 DIMENSIONS
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FIGURE 5 ROOF CURB DIMENSIONS
G
HVAC unit
base rails
Anchor screw
Flashing field
supplied
Roofing material
field supplied
Cant strip
field supplied
*Provided with roofcurb
HVAC unit
basepan
ROOF CURB DETAIL
B
C
Sealing
Gasket
Roofcurb
Wood nailer*
Roofcurb*
Insulation
(field supplied)
A09090
G
C
F
A
SMALL/COMMON CURB
SUPPLY
AIR
B
H
D
Dashed lines show cross support
location for large basepan units.
E
A09413
SMALL
BASE
UNIT
A
F
RETURN
E
AIR
LARGE
BASE
UNIT
D
UNIT PLACEMENT ON
H
COMMON CURB
Unit
Size
Small or
Large
Large
LARGE CURB
CATALOG
NUMBER
CPRFCURB010A00 11 (279)
CPRFCURB011A00 14 (356)
CPRFCURB012A00 11 (279)
CPRFCURB013A00 14 (356)
A
IN. (mm)
B (small base)
IN. (mm)*
10 (254)
14 (356)
A09415
B (large base)
IN. (mm)*CIN. (mm)DIN. (mm)EIN. (mm)FIN. (mm)GIN. (mm)HIN. (mm)
14 (356) 16 (406)
* Part Numbers CPRCURB010A00 and CPRCURB011A00 can be used on both small and large basepan units. The cross supports must be located based on
whether the unit is a small basepan or a large basepan.
NOTES:
1. Roof curb must be set up for unit being installed.
2. Seal strip must be applied, as required, to unit being installed.
3. Roof curb is made of 16−gauge steel.
4. Attach ductwork to curb (flanges of duct rest on curb).
5. Insulated panels: 1−in. (25 mm) thick fiberglass 1 lb. density.
SMALL OR LARGE BASE UNIT
47.8
(1214)
32.4 (822)
43.9
(1116)
2.7 (69)
30.6
(778)
42.2
(1072)
A09094
(1170)
46.1
6
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FIGURE 6
PH4E Suggested Rigging
CAUTION - NOTICE TO RIGGERS
PRUDENCE - AVIS AUX MANIPULATEUR
PANNEAUX D'ACCES DOIT ÊTRE EN PLACE POUR MANIPULATION.
Use top skid as spreader bar. / Utiliser la palette du haut comme barre de répartition
ACCESS PANELS MUST BE IN PLACE WHEN RIGGING.
DUCTS
MINIMUM HEIGHT: 36" (914.4 mm)
HAUTEUR MINIMUM
SEAL STRIP MUST BE IN
UNIT HEIGHT
HAUTEUR D'UNITÉ
DETAIL A
SEE DETAIL A
VOIR DÉTAIL A
RIGGING WEIGHTS (SMALL CABINET) RIGGING WEIGHTS (LARGE CABINET)
Unit
Rigging Weight 314 142.4 335 152.0 343 155.6 Rigging Weight 373 169.2
NOTE: See dimensional drawing for corner weight distribution.
!
WARNING
24 30 36
lb kg lb kg lb kg lb kg
PROPERTY DAMAGE HAZARD
Failure to follow this warning could result in personal
injury or death.
When straps are taut, the clevis should be a minimum
of 36 in. (914 mm) above the unit top cover.
Rigging/Lifting of Unit (See FIGURE 6)
Lifting holes are provided in base rails as shown.
1. Attach shackles, clevis pins, and straps to the base rails
of the unit. Be sure materials are rated to hold the weight
of the unit (See FIGURE 6).
2. Attach a clevis of sufficient strength in the middle of the
straps. Adjust the clevis location to ensure unit is lifted
level with the ground.
VOIR DÉTAIL A
PERSONAL INJURY HAZARD
Failure to follow this warning could result in personal
injury or death.
For vertical supply and return units, tools or parts could
drop into ductwork Install a 90 degree turn in the
return ductwork between the unit and the conditioned
space. If a 90 degree elbow cannot be installed,
grille of sufficient strength and density should be
installed to prevent objects from falling into the
conditioned
90 degree elbow in supply duct.
When designing and installing ductwork, consider the following:
1. All units should have field−supplied filters or accessory
After the unit is placed on the roof curb or mounting pad, remove
the top skid.
Step 5 — Select and Install Ductwork
The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
non−residence type air conditioning and ventilating systems,
NFPA
90A or residence−type, NFPA 90B and/or local codes and
ordinances.
Select and size ductwork, supply−air registers, and return air
grilles
according to ASHRAE (American Society of Heating,
Refrigeration, and Air Conditioning Engineers)
2. Avoid abrupt duct size increases and reductions. Abrupt
IMPORTANT: Use flexible connectors between ductwork and
unit to prevent transmission of vibration. Use suitable gaskets to
ensure weather tight and airtight seal. When electric heat is
installed, use fireproof canvas (or similar heat resistant material)
connector between ductwork and unit discharge connection. If
flexible duct is used, insert a sheet metal sleeve inside duct.
Heat resistant duct connector (or sheet metal sleeve) must
extend 24−in. (610 mm) from electric heater element.
PLACE BEFORE PLACING
UNIT ON ROOF CURB
!
WARNING
space. Units with electric heaters require
filter rack installed in the return−air side of the unit.
Recommended sizes for filters are shown in Table 1.
change in duct size adversely affects air performance.
BANDE SCELLANT DOIT ÊTRE
EN PLACE AVANT DE PLACER
L'UNITÉ SUR LA BASE DE TOIT
50CY502286 2.0
Unit
48
then a
recommendations.
The unit has duct flanges on the supply− and return−air
openings on the side of the unit.
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3. Size ductwork for cooling air quantity (cfm). The minimum
air quantity for proper electric heater operation is listed in
Table 2. Heater limit switches may trip at air quantities
below those recommended.
4. Seal, insulate, and weatherproof all external ductwork.
Seal, insulate and cover with a vapor barrier all ductwork
passing through conditioned spaces. Follow latest Sheet
Metal and Air Conditioning Contractors National
Association (SMACNA) and Air Conditioning Contractors
Association (ACCA) minimum installation standards for
residential heating and air conditioning systems.
5. Secure all ducts to building structure. Flash, weatherproof,
and vibration−isolate duct openings in wall or roof
according to good construction practices.
CONFIGURING UNITS FOR DOWNFLOW (VERTICAL)
DISCHARGE
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before performing service or maintenance operations
on the system, turn off main power to unit and install
lockout tag.
1. Open all electrical disconnects and install lockout tag
before starting any service work.
2. Remove horizontal (metal) ductcovers to access vertical
(downflow) discharge duct knockouts in unit basepan.
(See FIGURE 7.)
3. To remove downflow return and supply knockout covers,
break front and right side connecting tabs with a screw
driver and hammer. Push cover down to break rear and
left side tabs.
NOTE: These panels are held in place with tabs similar to an
electrical knockout. Reinstall horizontal duct covers (FIGURE 7)
shipped on unit from factory. Insure openings are air and
watertight.
NOTE: The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
nonresidence−type air conditioning and ventilating systems,
NFPA 90A or residence−type, NFPA 90B; and/or local codes
and ordinances.
Adhere to the following criteria when selecting, sizing, and
installing the duct system:
1. Units are shipped for side shot installation.
2. Select and size ductwork, supply−air registers, and
return−air grilles according to American Society of
Heating, Refrigeration and Air Conditioning Engineers
(ASHRAE) recommendations.
3. Use flexible transition between rigid ductwork and unit to
prevent transmission of vibration. The transition may be
screwed or bolted to duct flanges. Use suitable gaskets to
ensure weather−tight and airtight seal.
4. All units must have field−supplied filters or accessory filter
rack installed in the return−air side of the unit.
Recommended sizes for filters are shown in Table 1.
5. Size all ductwork for maximum required airflow (either
heating or cooling) for unit being installed. Avoid abrupt
duct size increases or decreases or performance may be
affected.
6. Adequately insulate and weatherproof all ductwork located
outdoors. Insulate ducts passing through unconditioned
space, and use vapor barrier in accordance with latest
issue of Sheet Metal and Air Conditioning Contractors
National Association (SMACNA) and Air Conditioning
Contractors of America (ACCA) minimum installation
standards for heating and air conditioning systems.
Secure all ducts to building structure.
7. Flash, weatherproof, and vibration−isolate all openings in
building structure in accordance with local codes and
good building practices.
FIGURE 7 Supply and Return Duct Opening
Horizontal Duct Covers
Basepan
Downflow
(Vertical)
Supply
Knockout
Basepan
Downflow
(Vertical)
Return
Knockout
Step 6 — Provide for Condensate Disposal
NOTE: Ensure that condensate−water disposal methods comply
with local codes, restrictions, and practices.
The PH4E units dispose of condensate through a 3/4 in. NPT
female fitting that exits on the compressor end of the unit.
Condensate water can be drained directly onto the roof in
rooftop installations (where permitted) or onto a gravel apron in
ground level installations. Install a field−supplied condensate
trap at end of condensate connection to ensure proper drainage.
Make sure that the outlet of the trap is at least 1 in. (25 mm)
lower than the drain−pan condensate connection to prevent the
pan from overflowing. Prime the trap with water. When using a
gravel apron, make sure it slopes away from the unit.
If the installation requires draining the condensate water away
from the unit, install a field−supplied 2 −in. (51mm) trap at the
condensate connection to ensure proper drainage. Condensate
trap is available as an accessory or is field−supplied. Make sure
that the outlet of the trap is at least 1 in. (25 mm) lower than the
unit drain−pan condensate connection to prevent the pan from
overflowing. Connect a drain tube using a minimum of
field−supplied 3/4−in. PVC or field−supplied 3/4−in. copper pipe
at outlet end of the 2−in. (51 mm) trap. (See FIGURE 8) Do not
undersize the tube. Pitch the drain tube downward at a slope of
at least 1 in. (25 mm) every 10 ft (3 m) of horizontal run. Be sure
to check the drain trough for leaks. Prime the trap at the
beginning of the cooling season start−up.
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