NCP 1000 Series User manual

Please ll in the following information and le it for

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MODEL NO.______________________________

SERIAL NO.______________________________

INSTALL DATE ___________________________

This unit should be installed in an

Outside Wall For

Thru-The-Wall

Installation Only!

All Units Department of Energy Listed

*Please consult the DOE Compliance Certification Database (https://tinyurl.com/NCPCondensers)

for a list of rated combinations of indoor and outdoor units.

NCP

Series:

1000

3000

4000

5000

Installation Guide

Thru the Wall

Condensing Unit

Read Installation Manual

Prior To Starting The Installation.

This manual must be left with the homeowner for future reference.

HEATING & A/C EQUIPMENT

NATIONAL

COMFORT

PRODUCTS

Thru-the-Wall Comfort for all types of Multi-Family Construction

National Comfort Products

A Division of National Refrigeration and Air Conditioning Products, Inc.

539 Dunksferry Road • Bensalem, PA 19020-5908

(800) 523-7138

www.nationalcomfortproducts.com

HEATING & A/C EQUIPMENT

NATIONAL

COMFORT

PRODUCTS

Go Thru-the-Wa

Installation Guide |Thru the Wall Condensing Units NCP Series 1000/3000/4000/5000

Page

Nomenclature................................................................................................................................................................ 4

Safety Warning ............................................................................................................................................................. 5

Before You Start............................................................................................................................................................ 6

High Voltage and Power Supply.................................................................................................................................... 7

Check for Clearances .................................................................................................................................................... 7

Unit Location Considerations........................................................................................................................................ 7

Refrigerant Piping Limits .............................................................................................................................................. 8

Leak Checking............................................................................................................................................................... 9

Evacuation, Electrical Connections................................................................................................................................ 10

Start Up, Sequence of Operations................................................................................................................................. 11

Refrigerant Charging..................................................................................................................................................... 12

Maintenance, Checkout Procedure................................................................................................................................ 14

Noise, Insulated Sound Cover....................................................................................................................................... 15

Important! Before Removing a Warranty Compressor.................................................................................................. 16

Wiring Diagrams........................................................................................................................................................... 17

Specifications, Dimensional Drawings .......................................................................................................................... 18-19

Matched systems with Cased Coils............................................................................................................................... 20

Matched systems with Air Handlers.............................................................................................................................. 20

Replacement Parts - NCP 1000 Series.......................................................................................................................... 21

Replacement Parts - NCP 3000 Series.......................................................................................................................... 22

Replacement Parts - NCP 4000 Series.......................................................................................................................... 23

Replacement Parts - NCP 5000 Series.......................................................................................................................... 24

Warranty ....................................................................................................................................................................... 25-26

IMPORTANT NOTE: DO NOT DESTROY OR THROW AWAY THIS MANUAL.

IT SHOULD BE KEPT IN A SAFE PLACE FOR FUTURE REFERENCE.

Installation Guide |Thru the Wall Condensing Units NCP Series 1000/3000/4000/5000

Split System Condensing Unit Nomenclature

NCP

NCP = Condensing Unit

Refrigerant

4 = R410A

Capacity

18 = 1.5 Ton

24 = 2 Ton

30 = 2.5 Ton

1000

Series

1000

3000

4000

5000

B A

Option

A = Standard

D = Deluxe

C = Crankcase Htr

L = Low Ambient

Factory Use

Generation

Installation Guide |Thru the Wall Condensing Units NCP Series 1000/3000/4000/5000

Safety Warnings!

This appliance is not intended for use by those (including children)

with reduced physical, sensory or mental capabilities, or lack of

experience and knowledge, unless they have been given supervision

or instructions concerning use of the appliance by a person

responsible for their safety. Children should be supervised to ensure

that they do not play with the appliance.

This appliance is intended to be installed up to 10,000 ft

(3,000 m) above sea level.

This appliance is only compatible with an Indoor unit that uses

R410A refrigerant.

Wheninstalling thisunitwithan indoorevaporatingunit, themaximum

operating pressure is to be considered during the installation. The

maximum operating pressure of the system should not exceed the

value as indicated on the nameplate of this condensing unit.

This model series NCP4*******-** is a PARTIAL UNIT air-

conditioner, complying with PARTIAL UNIT requirements of

the International Standard of UL-60335-2-40, and must only be

connected to the other units that have been confirmed as complying

to corresponding PARTIAL UNIT requirements of the International

Standard of UL-60335-2-40.

This is a safety alert symbol. When you see this symbol on

labels or in manuals, be alert to the potential for personal injury.

Pay particular attention to words such as DANGER, WARNING or

CAUTION.

DANGER indicates an imminently hazardous situation, which will

result in serious injury or death

WARNING indicates a potentially hazardous situation, which could

potentially result in serious injury or death

CAUTION indicates a potentially hazardous situation, which may

result in minor or moderate injury. It is also used to alert against

practices that are unsafe and can result in property damage.

!WARNING

HIGH VOLTAGE! Disconnect ALL power before servicing.

Multiple power sources may be present. Failure to do so may

result in property damage, personal injury or death.

!WARNING

These instructions are intended as an aid to qualied, licensed

service personnel for proper installation, adjustment and operation of

this unit. Read these instructions thoroughly before attempting

installation or operation. Failure to follow these instructions may

result in improper installation, adjustment, service or maintenance

possibly resulting in re, electrical shock, property damage, personal

injury or death.

!WARNING

!CAUTION

Installation and repair of this unit should be performed ONLY by

individuals meeting the requirements of an “entry level technician” as

specied by National Codes. Attempting to install or repair this unit

without such background may result in product damage, personal

injury or death.

Do not use oxygen to purge lines or pressurize system for leak

test. Oxygen reacts violently with oil, which can cause an explosion

resulting in severe personal injury or death.

The unit must be permanently grounded. Failure to do so can cause

electrical shock resulting in severe personal injury or death.

Use care when handling scroll compressors. Some temperatures

could be hot!

Scroll compressors should NEVER be used to evacuate the air

conditioning system. Vacuums this low can cause internal electrical

arcing resulting in a damaged or failed compressor.

“USE COPPER SUPPLY WIRES ONLY”

!WARNING

Extreme caution should be exercised when opening the Liquid Line

Service Valve. Turn counter clockwise until the valve stem just

touches the rolled edge. No torque is required. Failure to follow this

warning will result in abrupt release of system charge and may result

in personal injury and /or property damage.

Installation Guide |Thru the Wall Condensing Units NCP Series 1000/3000/4000/5000

IMPORTANT — This Document is customer property and is to remain

with this unit. Please refer to service information pack upon completion

of work to register the unit’s warranty. These instructions do not cover all

variations in systems or provide for every possible contingency to be met

in connection with the installation. Should further information be desired

or should particular problems arise which are not covered sufficiently for

the purchaser’s purposes, the matter should be referred to your installing

dealer or local distributor before contacting the manufacturer.

The unit must never be placed on its side or upside down as

the compressor oil will run in the cooling circuit and seriously

damage the unit. Base pan must always be on the bottom of

the install.

Note: The manufacturer recommends installing only approved matched

split systems. Our split systems are A.H.R.I. and DOE rated only with

TXV indoor systems. (Please consult the DOE Compliance Certification

Database (https://tinyurl.com/NCPCondensers) for a list of rated

combinations of indoor and outdoor units. Combinations of outdoor

and indoor units that are not rated will require factory testing and listing

with DOE. Please consult the factory.) Some of the benefits of installing

approved matched split systems are maximum efficiency, optimum

performance and the best overall system reliability. Self-equalizing

components are required to reduce compressor starting problems. If

self-equalizing components are not used, field installed hard start kits

will be required. Hard start kits MUST be compatible with compressors.

Hard start kits MUST be compatible with Copeland compressors -

88-106/330 µF/Volts

Start relays to be sized to µF of capacitor used.

Before You Start

ALL phases of this installation must comply with NATIONAL, STATE

AND LOCAL CODES. The manufacturer assumes no responsibility for

equipment installed in violation of any code requirements.

Be sure that the electrical data specied on the unit rating plate

corresponds to what is available at the installation site and NEC for

installation requirements.

This unit MUST be installed in an outside wall for thru-the-wall installation

ONLY. No pad mounts.

Be sure that the electrical service provided to the building can handle the

load imposed by the unit.

Electrical - Low Voltage

Low Voltage Hook-up Diagram

Make all electrical connections in accordance with the National Electrical

Code and any pertinent local codes or ordinances. Use a separate branch

electrical circuit for this unit. Locate a disconnecting means within sight of

and readily accessible to the unit.

a. Line Voltage Connections

b. Connect the single phase power supply to unit contactor

terminal L1 and L2

c. Connect ground wire to lug

d. Low Voltage Connections

Consult the indoor unit installation instructions for thermostat connections.

Use a 2-wire thermostat cable between the units.

When locating the room thermostat, it should be in the natural circulating

path of room air. Avoid locations where the thermostat would be exposed to

cold air infiltration; drafts from windows, doors or other openings leading to

the outside; exposure to air currents from warm-or-cold air registers or to

exposure where the natural circulation of the air is cut off, such as behind

doors, above or below mantels, shelves, etc.

Low Voltage Maximum Wire Length:

Table defines the maximum total length of low voltage wiring from the

condensing unit to the indoor unit and to the thermostat.

24 VOLTS

WIRE SIZE MAX. WIRE LENGTH

18 AWG 150 ft.

16 AWG 225 ft.

14 AWG 300 ft.

Contactor

Field Wiring Low Voltage

White

Red

Blue

Installation Guide |Thru the Wall Condensing Units NCP Series 1000/3000/4000/5000

High Voltage Power Supply

Electrical - High Voltage

NOMINAL

VOLTAGE

MINIMUM

VOLTAGE

MAXIMUM

VOLTAGE

208-230 196 244

!WARNING

LIVE ELECTRICAL COMPONENTS!

During installation, testing, servicing and troubleshooting of this

product, it may be necessary to work with live electrical components.

Failure to follow all electrical safety precautions when exposed to live

electrical components could result in death or serious injury.

The high voltage power supply must agree with the equipment nameplate.

Make certain that the volts, hertz, and phase correspond to that specified on

the unit rating plate, and that the service provided by the utility is sufficient

to handle the additional load imposed by this equipment.

Power wiring must comply with national, state, and local codes.

Follow instructions on unit wiring diagram located on the inside of the

access door, or cabinet and in the wiring diagrams included with the unit.

OFF

Disconnect Switch

Thru-the-Wall

Condensing Unit

Install a separate disconnect

switch at the location of the

through the wall unit.

Ground the unit per national, state,

and local code requirements.

Minimum 48"

Vertical Clearance

Between Units

Minimum 12"

Horizontal Clearance

Between Units

Check for Clearances

Unit Location Considerations

WARNING: Warranty will be void on all units installed behind

brick facades (e.g. pigeon holes) or connected to ductwork

(See Note 1 below). All obstacles added to impede air ow

of the condensing unit will decrease performance, cause

premature equipment failure, and void all warranties. Consult

factory with any questions.

Note 1: No ducts are permitted to be connected to the intake or discharge

of the unit.

In thru-the-wall installation, due to the various types of wall construction,

it is not possible to provide detailed instructions. The following is a list of

general requirements and cautions for installing these units. The unit must

be installed level, both - top front to back and left to right.

1. Masonry walls must have a lintel to support the wall.

2. Extend the unit approximately 3/4"beyond outside surface of the wall.

Optional mounting angles can be purchased from the factory or field

fabricated for locating and mounting the unit in the wall.

Installation Guide |Thru the Wall Condensing Units NCP Series 1000/3000/4000/5000

3. The wall opening across the top and bottom must be flashed. Bottom

flashing to cover the full footprint of unit and extend up 2"on 3 sides. All

openings around the top, sides and bottom must be caulked and sealed.

Care must be taken not to plug the openings in the front of the base pan of

the unit. If the optional wall sleeve is used, caulk the spaces between the

sleeve and the wall. Completely ll the clearance between the unit and

the wall sleeve with a polyurethane foam sealant.

4. During periods of rain and wind the primary drainage path may not be

adequate to handle the load. Secondary precautions may also be required

but not limited to the following:

a. Seal flashing to unit

b. Floor drain

c. Additional field sealing of sheet metal joints

d. Sealing of unused access opening

5. Clearances to air inlets and outlets must be adequate to ensure no air flow

obstructions or recirculation of condenser air flow. Care must be taken to

locate the coil side of the unit away from loose debris that may clog airflow

inlet or outlet.

6. Some architectural designs of buildings will require the unit to be mounted

behind a decorative grille. The performance (capacity and efficiency) of

the unit may be reduced with the use of these decorative grilles. The less

resistive these grilles are to air flow, the better the units performance will be.

Outdoor louvers provided by others must be approved by NCP to maintain

unit performance and warranty.

7. If the unit is mounted behind a decorative grille, one or both of the

following items must be done to eliminate recirculation of air to the unit:

a. The front of the unit must be mounted tight to the inside of the

architectural grille

b. A barrier must be provided to prevent recirculation of air to the unit

(mixing of inlet and outlet air) when the front of the unit is mounted

back from the inside of the architectural grille

8. The unit must not be mounted in dead-end hallways or areas where there

is no fresh outside air circulation. Cool fresh outside air must be provided

for best unit operation. Thru-the-wall units may not be located where hot

exhausts from clothes dryer vents, kitchen vents, steam vents or corrosive

fumes could come in contact with coil side of unit.

9. 30"clearance is required for service accessibility on the inside service

panel.

10. A minimum 48"of vertical clearance and 12"of horizontal clearance

between units is required to minimize recirculation of condenser exhaust

air. For horizontal clearances less than 12", please consult National Comfort

Products.

11. Care must be taken when locating the unit. Locate away form bedrooms

as operational sounds may be objectionable. (See sound cover on page 15)

Refrigerant Piping

1. The maximum length of refrigerant lines from the through the wall unit

to indoor unit should NOT exceed fty (50) feet without contacting National

Comfort Products.

2. The maximum vertical change should not exceed twenty (20) feet without

contacting National Comfort Products.

Maximum Allowable Liquid Line Pressure Drop = 50 PSI

Subtract .43 PSI for each foot of Liquid Lift (if any)

Do Not Exceed this value when selecting Liquid Line

*Call National Comfort Products

for Greater Line Lengths

Air

Handler

or Coil

3. The unit has internally mounted service valves. Field tubing may be

routed through the locations provided in either the top or rear panels. Care

should be taken not to block access to internal components. Seal unused

knockouts with high grade sealant. Gaskets are provided for liquid and

suction lines.

Air

Handler

or Coil

Air

Handler

or Coil

Installation Guide |Thru the Wall Condensing Units NCP Series 1000/3000/4000/5000Installation Guide |Thru the Wall Condensing Units NCP Series 1000/3000/4000/5000

4. Run refrigerant lines as directly as possible. Field piping inside the

condensing unit should not block access to major components. Refrigerant

lines should not be in direct contact with the floor or ceiling joists. Use

insulated or suspension type hangers. When refrigerant lines run through

a wall, seal openings around the lines with a flexible material to avoid

vibration to the structure.

Note: Always use refrigeration grade copper tubing that is internally

clean and dry for refrigerant lines. Use clean hard drawn copper tubing

if no appreciable amount of bending is necessary. If soft copper is used,

avoid sharp bends which may cause a restriction. Always use heat

sink materials during brazing to prevent damage to service valves (See

page 10).

Note: Take precautions to prevent noise within the building structure due

to vibration transmission from the refrigerant lines For example:

When the refrigerant lines have to be fastened to floor joists or other

framing in a structure, use isolation type hangers.

Isolation hangers should also be used when refrigerant lines are run in

stud spaces or enclosed ceilings.

Where the refrigerant lines run through a wall or sill, they should be

insulated and isolated.

Isolate lines from all ductwork.

Minimize the number of 90� turns.

5. Standard refrigeration piping practices must be employed when installing

traps. When installing the condenser below the evaporator, the suction line

must be trapped with an inverted trap the height of the evaporator coil.

Consult the factory when total equivalent length of refrigerant lines exceeds

50 ft.

6. Insulate the vapor line with a minimum 1/2"foam rubber or other type

insulation having an adequate vapor barrier. For indoor units with a TXV,

a liquid line filter drier must be installed (SPORLAN #C-083-S or similar).

Liquid Line

Vapor Line

Insulation

IMPORTANT: The Vapor Line must always be insulated.

DO NOT allow the liquid line and vapor line to come in direct

(metal to metal) contact.

7. Install the refrigerant lines using the following procedure (See Steps 1

thru 4.)

a. Remove the service port caps and Schrader Cores of the liquid line

service valve and the vapor line service valve of the condensing unit.

Connect low pressure dry nitrogen to the liquid line valve service

port.

CAUTION: Dry nitrogen should always be supplied through

the tubing while it is being brazed, as the high temperature

required for brazing will cause oxidation of the copper unless

an inert atmosphere is provided. The ow of dry nitrogen

should continue until the joints have cooled. Always use a

pressure regulator and safety valve to ensure that only low

pressure nitrogen is introduced into the tubing. Only a small

ow is necessary to displace air and prevent oxidation.

b. Provide a heat sink at the service valve such as wrapping a wet rag

around it, to prevent damage during the brazing operation

c. Braze the liquid line to the service valve. Allow the nitrogen to keep

flowing when brazing the refrigerant line until all brazed joints are

completed.

d. Provide a heat sink to the vapor line service valve of the condensing

unit

e. Braze the vapor line to the service valve

f. When tubing installation is complete, seal openings around tubing

where tubing enters the unit cabinet.

Step 1:

The tubing should be cut

square. Make sure it is

round and free of burrs

at the connecting ends.

Clean the tubing to prevent

contaminants from entering

the system.

Step 2:

Wrap a wet rag around the

copper stub of the service

valve before brazing.

Installation Guide |Thru the Wall Condensing Units NCP Series 1000/3000/4000/5000

Step 3:

Flux the copper tube and

insert into the stub. Braze the

joint. No ux is necessary if a

low to zero-silver braze alloy

is used.

Step 4:

After brazing, quench with a

wet rag to cool the joint and

remove any ux residue.

Leak Checking

Leak checking of refrigerant line braze joints and evaporator unit using

dry nitrogen. (See Step 5a)

1. Replace service port cap of the vapor line service valve (cap was removed

for brazing operations).

2. Connect dry nitrogen source to the service port of the liquid line service

valve. Pressurize refrigerant lines and indoor coil to approximately 100 psig.

3. Check for leaks using a liquid soap solution. If any leaks are detected,

purge the nitrogen, repair the leak(s) and repeat the leak check procedure.

Leak checking of refrigerant line braze joints and evaporator unit using

R410a refrigerant. (See Step 5b)

1. Connect R410a source to the service port of the liquid line service valve.

Use of a manifold gauge set will facilitate connecting and disconnecting of

the refrigerant source for leak checking. Pressurize refrigerant lines and

indoor coil with refrigerant gas.

2. Leak check with an electronic leak detector or liquid soap solution. If

any leaks are detected, use a refrigerant recovery system to remove the

refrigerant. Repair the leak(s) and repeat the leak check procedure.

Step 5a:

Step 5b:

Apply liquid soap solution to check for leaks

Bubbles forming in the liquid soap solution indicates a leak

Using a liquid soap solution

Using an electronic leak detector

Leak check with an

electronic leak detector

1. Connect the vacuum pump to the service ports of the liquid line and vapor

line service valves. If the vacuum pump lines do not contain shut-off valves,

hook up the vacuum pump through a manifold gauge set, as the vacuum

pump lines must be closed for step 4 below.

a. If the evacuation is being performed on a new system installation, the

condensing unit service valves should be kept in the closed position.

The vacuum pump will then be able to evacuate the refrigerant lines

and evaporator coil.

Evacuation

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