Grandaire W4A4S - User Manual

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Installation Instructions

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

SAFETY CONSIDERATIONS

IMPORTANT: This appliance shall only be installed by EPA qualified

personnel having appropriate certification. This appliance is not

intended for use by persons (including children) with reduced physical,

sensory or mental capabilities or lack of experience and knowledge,

unless they have been given supervision or instruction concerning use of

the appliance by a person responsible for their safety.

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 would 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.

GENERAL

NOTE: In some cases noise in the living area has been traced to gas

pulsations from improper installation of equipment.

1. This unit is intended to be installed in a location that is 10,000 feet

(3000 meters) above sea level or lower.

2. Locate unit away from windows, patios, decks, etc. where unit

operation sound may disturb customer.

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

capacity.

4. Run refrigerant tubes with no bends with centerline bend radius less

than 2.5 times the external pipe diameter.

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

6. When passing refrigerant tubes through the wall, seal opening with

RTV or other pliable silicon-based caulk. (See Fig. 1.)

7. Avoid direct tubing contact with water pipes, duct work, floor

joists, wall studs, floors, and walls.

8. 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).

9. Ensure that tubing insulation is pliable and completely surrounds

vapor tube.

10. When necessary, use hanger straps which are 1 in. (25 mm) wide

and conform to shape of tubing insulation. (See Fig. 1.)

11. Isolate hanger straps from insulation by using metal sleeves bent to

conform to shape of insulation.

12. Provision shall be made for expansion and contraction of long runs

of piping.

13. Piping and fittings shall be protected as far as possible against

adverse environmental effects. For example, the accumulation of

dirt and debris.

14. Piping should be installed to reduce the likelihood of hydraulic

shock damaging the system.

15. Certified piping and components must be used in order to protect

against corrosion.

16. Flexible pipe elements shall be protected against mechanical

damage, excessive stress by torsion, or other forces. They should be

checked for mechanical damage annually.

17. Piping material, routing, and installation shall be include protection

from physical damage in operation and service, and be in

compliance with the national and local codes and standards of the

installation site.

18. When setting up refrigerant piping, precautions shall be taken to

avoid excessive vibration or pulsation

W4A4S, W4A5S

SPLIT-SYSTEM AIR CONDITIONERS

WITH R-410A REFRIGERANT

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

personal injury or death.

Never use air or any gas containing oxygen for leak

testing or operating refrigerant compressors. Never

allow compressor suction pressure to operate in a

vacuum with service valves closed. See service

manual for pump-down instructions.

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This document provides installation instructions for W4A4S and W4A5S split-system air conditioners that use R-410A refrigerant.

Function Description

These units are split-system air conditioners designed to provide cooling. They are intended for installation by EPA-qualified personnel with appropriate certification. The installation process involves making piping connections, electrical connections, and charging the system with refrigerant. The units are designed to operate efficiently and reliably when installed according to the provided guidelines.

Important Technical Specifications

Refrigerant: R-410A
Installation Altitude: Intended for installation at locations 10,000 feet (3000 meters) above sea level or lower.
Refrigerant Tubing:
- Recommended diameters for liquid and vapor tubes are specified in Table 1, with sizes varying by unit capacity (18, 24, 30, 36, 42, 43, 48, 49, 60, 61).
- Units are rated with 25 ft. (7.6 m) of lineset.
- Maximum liquid-line size is 3/8-in. OD for all residential applications, including long line.
- Refrigerant tubing lengths up to 36 inches (914 mm) may be buried without special consideration, but no buried lines greater than 36 inches (914 mm) are allowed.
- For tubing set lengths between 80 and 200 ft. (24 and 61 m) horizontal or 35 ft. (11 m) vertical differential (total equivalent length), refer to the Residential Piping and Long Line Guideline.
Clearance Requirements:
- 24 in. (610 mm) clearance to service end of unit.
- 48 in. (1219 mm) above unit.
- 6-in. (152 mm) clearance on one side of unit.
- 12-in. (305 mm) clearance on all remaining sides.
- Minimum distance of 24 in. (610 mm) between units, or 18 in. (457 mm) if no overhang within 12 ft. (3.67 m) for units with wire grille coil guard only. Units with louver panels require 24 in. (610 mm) between units.
- Rooftop applications: locate unit at least 6 in. (152 mm) above roof surface.
Operating Ambient: Minimum outdoor operating ambient in cooling mode without accessory is 55°F (13°C).
Electrical:
- Requires a branch circuit disconnect of adequate size per NEC to handle unit starting current.
- Use copper wire only between disconnect switch and unit.
- Control wiring: No. 18 AWG color-coded, insulated (35°C minimum) wire. If thermostat is located more than 100 ft. (30 m) from unit, use No. 16 AWG.
- Control power: Furnace transformer, fan coil transformer, or accessory transformer for control power, 24v/40va minimum.
Piston Size: The piston included with FMA, FMC, and FMU fan coils is unique and cannot be replaced with the piston shipped with the outdoor unit. Refer to the AHRI Directory for compatibility.
Subcooling Temperatures: Table 2 provides R-410A required liquid line temperatures for various liquid pressures and subcooling values.
Superheat Charging: Table 3 provides superheat values for different outdoor and evaporator entering air wet-bulb temperatures.
Required Suction-Line Temperature: Table 4 provides required suction-line temperatures based on superheat and suction pressure.
Accessories: Table 6 lists required accessories for low-ambient cooling, long line applications, and sea coast applications, including ball bearing fan motor, compressor start assist capacitor and relay, crankcase heater, evaporator freeze thermostat, hard shut-off TXV, liquid line solenoid valve, low-ambient pressure switch, support feet, and winter start control.

Usage Features

Safety: The manual emphasizes safety considerations, including warnings for electrical shock, explosion, and personal injury. It advises wearing safety glasses, protective clothing, and work gloves, and having a fire extinguisher available during brazing.
Installation Location: Units should be located away from windows, patios, and decks to minimize noise disturbance.
Vibration Absorption: Refrigerant tubes should be run with no sharp bends, and some slack should be left between the structure and the unit to absorb vibration.
Moisture and Contamination Control: Openings where refrigerant tubes pass through walls should be sealed with RTV or pliable silicon-based caulk. If refrigerant tubes or indoor coil are exposed to atmosphere, they must be evacuated to 500 microns to eliminate contamination and moisture.
Mounting: Units should be installed on a solid, level mounting pad. For rooftop applications, they should be mounted on a level platform or frame, above a load-bearing wall, and isolated from the structure.
Refrigerant Charging:
- Units with cooling mode TXV require charging by the subcooling method.
- Units with indoor pistons require charging by the superheat method.
- The procedure for charging with indoor pistons is valid when indoor airflow is within ±21 percent of its rated CFM.
- Optimum performance is achieved when the operating charge produces 10°F suction superheat at the suction service valve with 95°F (35°C) outdoor ambient and 80°F (27°C) dry bulb (67°F / 19°C wet bulb) indoor temperature (DOE "A" test conditions) at rated airflow.
3-Phase Monitor (for 3-Phase Units Only): A small circuit board monitors line voltage. A flashing LED indicates a phase problem (e.g., reversed phase), requiring the interchange of two field-wiring leads on the unit contactor.
Crankcase Heater: If equipped, power should be supplied to the crankcase heater a minimum of 24 hours before starting the unit, especially if refrigerant tubing is longer than 80 ft. (24 m) or if the outdoor unit is 35 ft. (6 m) below the indoor unit.
System Start-Up: After evacuation, fully open liquid and vapor service valves. Replace valve stem caps finger-tight and tighten with a wrench an additional 1/12 turn. Close electrical disconnects to energize the system. Set the room thermostat to the desired temperature (below indoor ambient) and the fan control to ON or AUTO mode. Operate the unit for 15 minutes and check the refrigerant charge.

Maintenance Features

Periodic Maintenance: For continuing high performance and to minimize possible equipment failure, periodic maintenance must be performed. The frequency of maintenance may vary depending on geographic areas, such as coastal applications. Refer to the Owner's Manual for detailed information.
Filter Drier: Always install the factory-supplied liquid-line filter drier. If replacing, refer to the Product Replacement Parts List for the appropriate part number.
Leak Testing: After brazing, the refrigerant tubing and indoor coil should be leak tested. This involves evacuating the unit to 500 microns and ensuring the pressure does not rise above 1500 microns in 10 minutes when isolated from the pump.
Deep Vacuum Method: The recommended method for evacuation is the deep vacuum method (500 microns), which is the most positive way to assure a system is free of air and liquid water. A tight dry system will hold a vacuum of 1000 microns for approximately 7 minutes.
Repairing Refrigerant Circuit: When breaking into the refrigerant circuit for repairs, the refrigerant must be safely removed using a recovery pump certified for flammable refrigerants. The circuit should then be purged with nitrogen gas, evacuated to 1500 microns, and the vacuum broken with a nitrogen purge before cutting or brazing.
Final Checks: Before leaving the job, ensure all wiring is routed away from tubing and sheet metal edges, all wiring and tubing are secure, service valve stem caps are tightened, and the Owner's Manual is left with the customer with an explanation of system operation and periodic maintenance requirements. The Dealer Installation Checklist should be filled out and placed in the customer file.

Grandaire W4A4S Specifications

General

Brand	Grandaire
Model	W4A4S
Category	Air Conditioner
Language	English