International Comfort Products N4H4−G, R4H4−B, WCH4−B Installation Manual

INSTALLATION INSTRUCTIONS

R−410A Split System Heat Pumps

N4H4−G / R4H4−B / WCH4−B

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

INSULATION

HANGER STRAP

(AROUND SUCTION

TUBE ONLY)

1” (25.4 mm)

MIN

THROUGH THE WALL

SUSPENSION

LIQUID TUBE

SUCTION TUBE

JOIST

INSULATION

SUCTION TUBE

LIQUID TUBE

A07588

Fig. 1 – Connecting Tubing Installation

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.

428 01 5107 01 03/04/15

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.

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

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.

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.

View From Top

UNIT BASE PAN

Dimension in. (mm)

23 X 23

(585 X 585)

26 X 26

(660 X 660)

31–1/2 X 31–1/2

(800 X 800)

35 X 35

(889 X 889)

TIEDOWN KNOCKOUT LOCATIONS in. (mm)

A B C

7–3/4 (196.8) 4–13/32 (111.9) 18–1/32 (457.9)

9–1/8 (231.8) 4–7/16 (112.7) 21–1/4 (539.8)

9–1/8 (231.8) 6–9/16 (166.7) 24–11/16 (627.1)

9–1/8 (231.8) 6–9/16 (166.7) 28–7/16 (722.3)

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.

FEEDER TUBE

STUB TUBE

DEFROST
THERMOSTAT

A97517

Fig. 3 – Defrost Thermostat Location

2 428 01 5107 01

Specifications subject to change without notice.

Table 1 – Accessory Usage

Accessory

Accumulator Standard Standard Standard

Compressor Start Assist Capacitor and

Relay

Crankcase Heater Ye s

Evaporator Freeze Thermostat Ye s No No

Hard Shutoff TXV Ye s Ye s No

Isolation Relay Ye s No No

Liquid Line Solenoid Valve No See Long–Line Application Guideline No

Low Ambient Switch Ye s 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. .

REQUIRED FOR LOW–AMBIENT

COOLING APPLICATIONS

(Below 555F / 12.85C)

Ye s Ye s No

REQUIRED FOR

LONG LINE APPLICATIONS*

Ye s

REQUIRED FOR

SEA COAST APPLICATIONS

(Within 2 miles / 3.22 km)

No

Make Piping Connections

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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.

!

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

WARNING

CAUTION

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).

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 (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

421 01 5107 01 3

Specifications subject to change without notice.

VALVE CO RE

Y

Fig. 5 – Vapor Service Valve

SERVICE VALVE

A14236

Table 2 – Refrigerant Connections and Recommended Liquid

and Vapor Tube Diameters (In.)

UNIT SIZE

18, 24 3/8 3/8 5/8 5/8
30, 36 3/8 3/8 3/4 3/4
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.

Connection

LIQUID RATED VAPOR

Diameter

Tube

Diameter

Connection

Diameter

Tube

Diameter

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.

!

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.

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.

CAUTION

!

WARNING

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 non−piston rated heat pump with 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®
RINGS

PISTON

PISTON RETAINER

3/4” BRASS HEX BOD

“H” DISTRIBUTOR

A10342

Fig. 6 – Indoor Piston Installation

Install Liquid Line Filter Drier Indoor

Refer to Fig. 7 and install filter drier as follows:

1. Braze 5 in. (127 mm) liquid tube to the indoor coil.

2. Wrap filter drier with damp cloth.

3. Braze filter drier to 5 in. (127 mm) long liquid tube from
step 1.

4. Connect and braze liquid refrigerant tube to the filter drier.

IMPORTANT: Installation of the filter drier in liquid line is
required.

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.

4 428 01 5107 01

Fig. 7 – Liquid Line Filter Drier

Specifications subject to change without notice.

A05227