International Comfort Products RHH036, RHH048, RHH060 Installation Manual

INSTALLATION INSTRUCTIONS

R−410A Single Package Rooftop Heat Pump

RHH036−060

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 manual 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.

TABLE OF CONTENTS

SAFETY CONSIDERATIONS 2.................

INSTALLATION 4.............................

Step 1 − Plan for Unit Location 4................

Step 2 − Plan for Sequence of Unit Installation 5..

Step 3 − Inspect Unit 5........................

Step 4 − Provide Unit Support 5.................

Step 5 − Field Fabricate Ductwork 7.............

Step 6 − Rig and Place Unit 7...................

Step 7 − Convert to Horizontal and Connect

Ductwork 8...........................

Step 8 − Install Outside Air Hood 9..............

Step 9 − Install External condensate Trap &

Piping 10..............................

Step 10 − Make Electrical Connections 11.........

Step 11 − Adjust Factory−Installed Options 26.....

Step 12 − Install Accessories 27.................

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:

CAUTION

Signal Words on Product Labeling

Signal words are used in combination with colors and/or pictures or product labels.

WARNING

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 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.

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SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical

shock or other conditions which may cause 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 and work gloves. Use quenching cloths for brazing operations and have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions attached to the unit. Consult local building codes and appropriate national electrical codes (in USA, ANSI/NFPA70, National Electrical Code (NEC); in Canada, CSA C22.1) for special requirements. It is important to 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 the signal words DANGER, WARNING, CAUTION, and NOTE. 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.

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could cause personal injury or death.

Before performing service or maintenance operations on unit, turn off main power switch to unit and install lockout tag. Ensure electrical service to rooftop unit agrees with voltage and amperage listed on the unit rating plate. Unit may have more than one power switch.

WARNING

UNIT OPERATION AND SAFETY HAZARD

Failure to follow this warning could cause personal injury, death and/or equipment damage.

Puronr (R−410A) refrigerant systems operate at higher pressures than standard R−22 systems. Do not use R−22 service equipment or components on Puron refrigerant equipment.

WARNING

PERSONAL INJURY AND ENVIRONMENTAL HAZARD

Failure to follow this warning could cause personal injury or death.

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

Wear safety glasses and gloves when handling refrigerants. Keep torches and other ignition sources away from refrigerants and oils.

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, safety glasses and gloves when handling parts and servicing heat pump units.

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Vertical Connections / Economizer

Horizontal Connections / Economizer

RHH036

RHH048

RHH060

Fig. 1 — Unit Dimensional Drawing − RHH036 − 060

C1024

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C10242

RHH036 225 130495 59 118 54 118 54 35 ⅜ [ 899 ]

RHH048 263 161580 73 147 67 130 59 RHH060 277 165610 75 152 69 141 64

139 59

142 64

152 69

35 ½ [ 902 ]

35 ¾ [ 527 ]

23 ⅜ [ 594] 21 ⅞ [ 556]

22 ½ [ 572]

18 ⅜ [ 467 ]

20 ½ [ 521 ] 20 ¾ [ 527 ]

Fig. 1 − Unit Dimensional Drawing –RHH036 − 060 (cont.)

INSTALLATION

Jobsite Survey

Complete the following checks before installation.

1. Consult local building codes and the NEC (National Electrical Code) ANSI/NFPA 70 for special installation requirements.

2. Determine unit location (from project plans) or select unit location.

3. Check for possible overhead obstructions which may interfere with unit lifting or rigging.

Step 1 — Plan for Unit Location

Select a location for the unit and its support system (curb or other) that provides for the minimum clearances required for safety. This includes the clearance to combustible surfaces, unit performance and service access below, around and above unit as specified in unit drawings. See Fig. 2.

NOTE: Consider also the effect of adjacent units. Unit may be installed directly on wood flooring or on Class

A, B, or C roof−covering material when roof curb is used. Do not install unit in an indoor location. Do not locate air

inlets near exhaust vents or other sources of contaminated air.

C102

C10243

18” (457)

42" (1067)

Required bottom condensate drain connection. Otherwise, 36” (914mm) for condensate connection.

18" (457)

1C07459

Fig. 2 − Service Clearance Dimensional Drawing

Although unit is weatherproof, avoid locations that permit water from higher level runoff and overhangs to fall onto the unit.

Select a unit mounting system that provides adequate height to allow for removal and disposal of frost and ice that will form during the heating−defrost mode as well as allow installation of condensate trap per requirements. Refer to Step 9 — Install External Condensate Trap and Line – for required trap dimensions.

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Roof Mount —

Check building codes for weight distribution requirements. Unit operating weight is shown in Table 1.

Table 1 – Operating Weights

RHH UNITS LB (KG)

Component 036 048 060

Base Unit 495 (225) 580 (263) 610 (277)

Economizer

Vertical 80 (36) 80 (36) 80 (36)

Horizontal 105 (48) 105 (48) 105 (48)

Powered Outlet 32 (15) 32 (15) 32 (15)

Curb

14−in / 356 mm 110 (50) 110 (50) 110 (50)

24−in / 610 mm 145 (66) 145 (66) 145 (66)

Step 2 — Plan for Sequence of Unit Installation

The support method used for this unit will dictate different sequences for the steps of unit installation. For example, on curb−mounted units, some accessories must be installed on the unit before the unit is placed on the curb. Review the following for recommended sequences for installation steps.

Curb−Mounted Installation —

Install curb Install field−fabricated ductwork inside curb Install accessory thru−base service connection package

(affects curb and unit) (refer to accessory installation instructions fo)r details

Prepare bottom condensate drain connection to suit planned condensate line routing (refer to Step 9 for details)

Rig and place unit Install outdoor air hood Install condensate line trap and piping Make electrical connections Install other accessories

Pad−Mounted Installation —

Prepare pad and unit supports Check and tighten the bottom condensate drain

connection plug Rig and place unit Convert unit to side duct connection arrangement Install field−fabricated ductwork at unit duct openings Install outdoor air hood Install condensate line trap and piping Make electrical connections Install other accessories

Frame−Mounted Installation —

Frame−mounted applications generally follow the sequence for a curb installation. Adapt as required to suit specific installation plan.

Step 3 — Inspect unit

Inspect unit for transportation damage. File any claim with transportation agency.

Confirm before installation of unit that voltage, amperage and circuit protection requirements listed on unit data plate agree with power supply provided.

Step 4 — Provide Unit Support

Roof Curb Mount —

Accessory roof curb details and dimensions are shown in Fig. 3. Assemble and install accessory roof curb in accordance with instructions shipped with the curb.

NOTE: The gasketing of the unit to the roof curb is critical for a watertight seal. Install gasket supplied with the roof curb as shown in Fig. 3. Improperly applied gasket can also result in air leaks and poor unit performance.

Curb should be level. This is necessary for unit drain to function properly. Unit leveling tolerances are show in Fig.

4. Refer to Accessory Roof Curb Installation Instructions for additional information as required.

Install insulation, cant strips, roofing felt, and counter flashing as shown. Ductwork must be attached to curb and

not to the unit. The accessory thru−the−base power package must be installed before the unit is set on the roof curb.

If electric and control wiring is to be routed through the basepan, attach the accessory thru−the−base service connections to the basepan in accordance with the accessory installation instructions.

Slab Mount (Horizontal Units Only) —

Provide a level concrete slab that extends a minimum of 6 in. (150 mm) beyond unit cabinet. Install a gravel apron in front of condenser coil air inlet to prevent grass and foliage from obstructing airflow.

NOTE: Horizontal units may be installed on a roof curb if required.

Alternate Unit Support (In Lieu of Curb or Slab Mount) —

A non−combustible sleeper rail can be used in the unit curb support area. If sleeper rails cannot be used, support the long sides of the unit with a minimum of 3 equally spaced 4−in. x 4−in. (102 mm x 102 mm) pads on each side.

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ROOFCURB ACCESSORY

CRRFCURB001A02

CRRFCURB002A02

1' - 2" [356]

2' - 0" [610]

UNIT SIZE

RHH036 - 060

Fig. 3 — Roof Curb Details

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Fig. 3 − Roof Curb Details

MAXIMUM ALLOWABLE

DIFFERENCE IN. (MM)

A-B

0.5” (13)

Fig. 4 − Unit Leveling Tolerances

B-C

1.0” (25)

A-C

1.0” (25)

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Step 5 — Field Fabricate Ductwork

Cabinet return-air static pressure (a negative condition) shall not exceed 0.35 in. wg (87 Pa) with economizer or

0.45 in. wg (112 Pa) without economizer.

For vertical ducted applications, secure all ducts to roof curb and building structure. Do not connect ductwork to

unit.

Insulate and weatherproof all external ductwork, joints, and roof openings with counter flashing and mastic in accordance with applicable codes.

Ducts passing through unconditioned spaces must be insulated and covered with a vapor barrier.

WARNING

PERSONAL INJURY HAZARD

Failure to follow this warning could cause personal injury.

For vertical supply and return units, tools or parts could drop into ductwork and cause an injury. Install a 90−degree turn in the return ductwork between the unit and the conditioned space. If a 90−degree elbow cannot be installed, then a grille of sufficient strength and density should be installed to prevent objects from falling into the conditioned space. Due to electric heater, supply duct will require 90−degree elbow.

Step 6 — Rig and Place Unit

Keep unit upright and do not drop. Spreader bars are not required if top crating is left on unit. Rollers may be used to move unit across a roof. Rigging materials under unit

(cardboard or wood) must be removed PRIOR to placing

→

the unit on the roof curb. Level by using unit frame as a reference. See Table 1 and Fig. 5 for additional information.

Lifting holes are provided in base rails as shown in Fig. 5. Refer to rigging instructions on unit.

C10244

If a plenum return is used on a vertical unit, the return should be ducted through the roof deck to comply with applicable fire codes.

For Units with Accessory Electric Heaters —

Horizontal applications require a minimum clearance to combustible surfaces of 1−in (25 mm) from duct for first 12−in (305 mm) away from unit. Vertical applications do not require a minimum clearance.

Minimum clearance not required around ductwork.

Outlet grilles must not lie directly below unit discharge.

NOTE: A 90−degree elbow must be provided in the ductwork to comply with UL (Underwriters Laboratories) code for use with electric heat.

UNIT DAMAGE HAZARD

Failure to follow this caution may result in equipment damage.

All panels must be in place when rigging. Unit is not designed for handling by fork truck.

Before setting the unit onto the curb, recheck gasketing on curb.

CAUTION

517

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NOTES:

UNIT

RHH036 725 330 74.5 1890 38.5 980 33.5 850

RHH048 845 384 74.5 1890 37.5 955 41.5 1055

RHH060 900 409 74.5 1890 37.5 955 41.5 1055

1. Dimensions in ( ) are in millimeters.

2. Hook rigging shackles through holes in base rail, as shown in detail “A.” Holes in base rails are centered around the unit center of gravity. Use wooden top to prevent rigging straps from damaging unit.

MAX WEIGHT

LB KG IN MM IN MM IN MM

A B C

Fig. 5 − Rigging Details

Positioning on Curb —

Position unit on roof curb so that the following clearances are maintained: 1/4 in. (6.4 mm) clearance between the roof curb and the base rail inside the front and rear, 0.0 in. clearance between the roof curb and the base rail inside on the duct end of the unit. This will result in the distance between the roof curb and the base rail inside on the condenser end of the unit being approximately equal to Fig. 3, section C−C.

C06005

DIMENSIONS

Although unit is weatherproof, guard against water from higher level runoff and overhangs.

After unit is in position, remove the compressor access panel. Holding the blocking between compressors with one hand, cut the strapping. Carefully remove the blocking without damaging tubing, wiring, or controls. Remove the strapping and replace the access panel.

Fig. 6 − Horizontal Conversion Panels

Remove all shipping materials and top skid. Recycle or dispose of all shipping materials.

Field−supplied flanges should be attached to horizontal duct openings and all ductwork should be secured to the

Step 7 — Convert to Horizontal and Connect Ductwork (when required)

Unit is shipped in the vertical duct configuration. Unit without factory−installed economizer or return air smoke detector option may be field−converted to horizontal

flanges. Insulate and weatherproof all external ductwork, joints, and roof or building openings with counter flashing and mastic in accordance with applicable codes.

Do not cover or obscure visibility to the unit’s informative data plate when insulating horizontal ductwork.

ducted configuration. To convert to horizontal configuration, remove screws from side duct opening covers and remove covers. Using the same screws, install covers on vertical duct openings with the insulation−side down. Seals around duct openings must be tight. See Fig. 6.

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