25HCB3, 25HCC5
Comfortt Series Heat Pumps
with Puronr Refrigerant
1 --- 1 / 2 To 5 N o m i n a l To n s
Installation Instructions
NOTE: Read the entire instruction manual before starting the
installation.
INSTALLATION RECOMMENDATIONS
NOTE: In some cases noise in the living area has been traced to
gas pulsations from improper installation of equipment.
SAFETY CONSIDERATIONS
1. Locate unit away from windows, patios, decks, etc. where
unit operation sound may disturb customer.
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.
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.
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.
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.)
!
!
Recognize safety information. This is the safety--alert symbol
.
8. Ensure that tubing insulation is pliable and completely
surrounds vapor tube.
When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.
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.
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.
OUTDOOR WALL
CAULK
INDOOR WALL
LIQUID TUBE
SUCTION TUBE
INSULATION
!
WARNING
THROUGH THE WALL
ELECTRICAL SHOCK HAZARD
JOIST
Failure to follow this warning could result in personal injury
or death.
HANGER STRAP
(AROUND SUCTION
TUBE ONLY)
INSULATION
SUCTION TUBE
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.
1” (25.4 mm)
MIN
LIQUID TUBE
SUSPENSION
A07588
!
CAUTION
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.
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.
IMPORTANT: Maximum liquid--line size is 3/8--in. OD for all
residential applications including line line.
Table 1 – Accessory Usage
REQUIRED FOR LOW---AMBIENT
REQUIRED FOR
SEA COAST APPLICATIONS
(Within 2 miles / 3.22 km)
Standard
REQUIRED FOR
LONG LINE APPLICATIONS*
Accessory
COOLING APPLICATIONS
(Below 55°F / 12.8°C)
Standard
Accumulator
Ball Bearing Fan Motor
Compressor Start Assist Capacitor and
Relay
Standard
No
Yes{
No
Yes
Yes
No
Crankcase Heater
Yes
No
Yes
Evaporator Freeze Thermostat
Hard Shutoff TXV
Yes
Yes
Yes
No
Yes
No
No
Yes
No
Isolation Relay
See Long---Line Application
Guideline
Liquid Line Solenoid Valve
No
No
Motor Master® Control or
Low Ambient Switch
Yes
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.
{ Additional requirement for Low---Ambient Controller (full modulation feature) MotorMasterr Control.
Table 2 – Refrigerant Connections and Recommended Liquid
and Vapor Tube Diameters (In.)
Outdoor Unit Connected To Factory Approved Indoor
Unit
Outdoor unit contains correct system refrigerant charge for
operation with approved ARI rated indoor unit when connected by
15 ft (4.57 m) of field--supplied or factory--accessory tubing, and
factory supplied filter drier. Check refrigerant charge for maximum
efficiency.
LIQUID
RATED VAPOR*
UNIT SIZE
Connection
Tube
Connection
Tube
Diameter
3/8
Diameter
Diameter
5/8
Diameter
018, 024
030, 036
042, 048
060, 061
3/8
3/8
3/8
3/8
5/8
3/4
3/8
3/8
3/8
3/4
7/8
7/8
7/8
1--1/8
Refrigerant Tubing and Sweat Connections
*
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.
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.
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. (6.1 m) vertical differential, refer to the Residential Piping and Longline
Guideline using Puron refrigerant.
!
CAUTION
Install Liquid Line Filter Drier Indoor
Refer to Fig. 5 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.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
3. Braze filter drier to 5 in. (127 mm) long liquid tube from
step 1.
Service valves must be wrapped in a heat--sinking material
such as a wet cloth while brazing.
4. Connect and braze liquid refrigerant tube to the filter drier.
Remove plastic retainer holding outdoor piston in liquid service
valve, leaving the piston and piston retainer inside the valve.
Connect sweat/flare adapter provided, to valve. (See Fig. 4.)
Connect refrigerant tubing to fittings on outdoor unit vapor and
liquid service valves. Service valves are closed from factory and
ready for brazing. 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. Refrigerant tubing and indoor coil are now ready for
leak testing. This check should include all field and factory joints.
A05227
Fig. 5 -- Liquid Line Filter Drier
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage
or improper operation.
Installation of filter drier in liquid line is required.
A05226
Fig. 4 -- Liquid Service Valve
3
NOTE: Install branch circuit disconnect of adequate size per NEC
to handle unit starting current. Locate disconnect within sight from
and readily accessible from unit, per Section 440--14 of NEC.
Evacuate Refrigerant Tubing and Indoor Coil
!
CAUTION
Route Ground and Power Wires
UNIT DAMAGE HAZARD
Remove access panel to gain access to unit wiring. Extend wires
from disconnect through power wiring hole provided and into unit
control box.
Failure to follow this caution may result in equipment
damage or improper operation.
Connect Ground and Power Wires
Never use the system compressor as a vacuum pump.
Connect ground wire to ground connection in control box for
safety. Connect power wiring to contactor as shown in Fig. 7.
Refrigerant tubes and indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns. The alternate
triple evacuation method may be used (see triple evacuation
procedure in service manual). Always break a vacuum with dry
nitrogen.
!
WARNING
ELECTRICAL SHOCK HAZARD
Deep Vacuum Method
Failure to follow this warning could result in personal injury or
death.
The deep vacuum method requires a vacuum pump capable of
pulling a vacuum of 500 microns and a vacuum gage capable of
accurately measuring this vacuum depth. The deep vacuum method
is the most positive way of assuring a system is free of air and
liquid water. A tight dry system will hold a vacuum of 1000
microns after approximately 7 minutes. See Fig. 6.
The unit cabinet must have an uninterrupted or unbroken
ground to minimize personal injury if an electrical fault should
occur. The ground may consist of electrical wire or metal
conduit when installed in accordance with existing electrical
codes.
5000
4500
Connect ground wire to ground connection in control box for
safety. Connect power wiring to contactor as shown in Fig. 7.
4000
DISCONNECT
LEAK IN
SYSTEM
PER N.E.C. AND/OR
LOCAL CODES
3500
3000
2500
2000
1500
1000
500
CONTACTOR
FIELD POWER
WIRING
VACUUM TIGHT
TOO WET
BLUE
3 PHASE ONLY
FIELD GROUND
WIRING
TIGHT
DRY SYSTEM
GROUND
LUG
A94025
A95424
Fig. 7 -- Line Connections
0
1
2
3
4
5
6
7
MINUTES
Connect Control Wiring
A95424
Route 24v control wires through control wiring grommet and
connect leads to control wiring. See Thermostat Installation
Instructions for wiring specific unit combinations. (See Fig. 8.)
Fig. 6 -- Deep Vacuum Graph
Final Tubing Check
Use No. 18 AWG color--coded, insulated (35°C minimum) wire. If
thermostat is located more than 100 ft (30.5 m) from unit, as
measured along the control voltage wires, use No. 16 AWG
color--coded wire to avoid excessive voltage drop.
All wiring must be NEC Class 1 and must be separated from
incoming power leads.
IMPORTANT: Check to be certain factory tubing on both indoor
and outdoor unit has not shifted during shipment. Ensure tubes are
not rubbing against each other or any sheet metal. Pay close
attention to feeder tubes, makings sure wire ties on feeder tubes are
secure and tight.
Be sure field wiring complies with local and national fire, safety,
and electrical codes, and voltage to system is within limits shown
on unit rating plate. Contact local power company for correction of
improper voltage. See unit rating plate for recommended circuit
protection device.
NOTE: Operation of unit on improper line voltage constitutes
abuse and could affect unit reliability. See unit rating plate. Do not
install unit in system where voltage may fluctuate above or below
permissible limits.
Use furnace transformer, fan coil transformer, or accessory
transformer for control power, 24v/40va minimum.
NOTE: Use of available 24v accessories may exceed the
minimum 40va power requirement. Determine total transformer
loading and increase the transformer capacity or split the load with
an accessory transformer as required.
Final Wiring Check
IMPORTANT: Check factory wiring and field wire connections
to ensure terminations are secured properly. Check wire routing to
ensure wires are not in contact with tubing, sheet metal, etc.
Make Electrical Connections
!
WARNING
Compressor Crankcase Heater
When equipped with a crankcase heater, furnish power to heater a
minimum of 24 hr before starting unit. To furnish power to heater
only, set thermostat to OFF and close electrical disconnect to
outdoor unit.
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury or
death.
Do not supply power to unit with compressor terminal box
cover removed.
A crankcase heater is required if refrigerant tubing is longer than
80 ft. (24.4 m), or when outdoor unit is 20 ft. (6.1 m) below the
indoor unit. Refer to the Residential Piping and Long Line
Guideline.
NOTE: Use copper wire only between disconnect switch and unit.
4
HEAT
PUMP
TYPICAL
FAN COIL
Install Electrical Accessories
HP THERMOSTAT
Refer to the individual instructions packaged with kits or
accessories when installing.
R
C
R
R
C
24 VAC HOT
24 VAC COM
HEAT STAGE 2
Start--Up
C
*
!
W2
CAUTION
W2
W2
*
*
E
W3
G
COOL/HEAT
STAGE 1
PERSONAL INJURY HAZARD
Y
Y
Failure to follow this caution may result in personal
injury.
G
INDOOR FAN
Wear safety glasses, protective clothing, and gloves when
handling refrigerant and observe the following:
S Front seating service valves are equipped with Schrader valves.
O
E
RVS COOLING
O
EMERGENCY
HEAT
IF AVAILABLE
*
LEGEND
!
CAUTION
24-V FACTORY WIRING
24-V FIELD WIRING
ENVIRONMENTAL HAZARD
FIELD SPLICE CONNECTION
OUTDOOR THERMOSTAT
EMERGENCY HEAT RELAY
SUPPLEMENTAL HEAT RELAY
ODT
Failure to follow this caution may result in environmental
damage.
EHR
SHR
Federal regulations require that you do not vent refrigerant to
the atmosphere. Recover during system repair or final unit
disposal.
A02325 / A97413
Fig. 8 -- Generic Wiring Diagrams
(See Thermostat Installation Instructions
for specific unit combinations)
!
CAUTION
UNIT OPERATION AND SAFETY HAZARD
Failure to follow this caution may result in personal injury,
equipment damage or improper operation.
Sequence of Operation
S Do not overcharge system with refrigerant.
S Do not operate unit in a vacuum or at negative pressure.
S Do not disable low pressure switch in scroll compressor
applications.
NOTE: Defrost control board is equipped with 5 minute lockout
timer that is initiated upon any interruption of power.
Turn on power to indoor and outdoor units. Transformer is
energized.
Cooling
S Compressor dome temperatures may be hot.
On a call for cooling, thermostat makes circuits R--O, R--Y, and
R--G. Circuit R--O energizes reversing valve, switching it to
cooling position. Circuit R--Y sends low voltage through the
safeties and energizes the T1 terminal on the circuit board. If the
compressor has been off for 5 minutes, or power has not been
cycled for 5 minutes, the OF2 relay and T2 terminal will energize.
This will close the contactor, and start the outdoor fan motor and
compressor.
Follow these steps to properly start up system:
1. After system is evacuated, fully open liquid and vapor
service valves.
2. Unit is shipped with valve stem(s) front seated (closed) and
caps installed. Replace stem caps after system is opened to
refrigerant flow (back seated). Replace caps finger--tight and
tighten with wrench an additional 1/12 turn.
When the cycle is complete, R--Y is turned off, stopping the
compressor and outdoor fan. The 5 minute time guard begins
counting. Compressor will not come on again until this delay
expires. In the event of a power interruption, the time guard will
not allow another cycle for 5 minutes.
3. Close electrical disconnects to energize system.
4. Set room thermostat at desired temperature. Be sure set
point is below indoor ambient temperature.
5. Set room thermostat to HEAT or COOL and fan control to
ON or AUTO mode, as desired. Operate unit for 15
minutes. Check system refrigerant charge.
NOTE: If the indoor blower off delay is enabled, it will run up to
an additional 90 seconds to increase system efficiency.
Heating
On a call for heating, thermostat makes circuits R--Y and R--G.
Circuit R--Y sends low voltage through the safeties and energizes
the T1 terminal on the circuit board. T1 energizes the defrost logic
circuit. If the compressor has been off for 5 minutes, or power
has not been cycled for 5 minutes, the OF2 relay and T2 terminal
will energize. This will close the contactor, start the outdoor fan
motor and compressor.
When the cycle is complete, R--Y is turned off , stopping the
compressor and outdoor fan. The 5 minute time guard begins
counting. Compressor will not come on again until this time delay
expires. In the event of a power interruption, the time guard will
not allow another cycle for 5 minutes.
5
Quiet Shift
Check Charge
Quiet shift is a field selectable defrost mode (factory set to OFF),
which will eliminate occasional noise that could be heard at the
start of defrost cycle and restarting of heating cycle. It is selected
by placing DIP switch 3 on defrost board (see Fig. 9) in the ON
position.
Factory charge amount and desired subcooling are shown on unit
rating plate. Charging method is shown on information plate inside
unit. To properly check or adjust charge, conditions must be
favorable for subcooling charging. Favorable conditions exist
when the outdoor temperature is between 70_F and 100_F
(21.11_C and 37.78_C), and the indoor temperature is between
70_F and 80_F (21.11_C and 26.67_C). Follow the procedure
below:
When Quiet Shift switch is placed in ON position, and a defrost is
initiated, the following sequence of operation will occur. Reversing
valve will energize, compressor will turn off for 30 seconds, and
then turn back on to complete defrost. At the start of heating after
conclusion of defrost, reversing valve will de--energize,
compressor will turn off for another 30 seconds, and the fan will
turn off for 40 seconds, before starting in the heating mode.
Unit is factory charged for 15ft (4.57 m) of lineset. Adjust charge
by adding or removing 0.6 oz/ft (.018 kg/m) of 3/8 liquid line
above or below 15ft (4.57 m) respectively.
For standard refrigerant line lengths (80 ft/24.38 m or less), allow
system to operate in cooling mode at least 15 minutes. If conditions
are favorable, check system charge by subcooling method. If any
adjustment is necessary, adjust charge slowly and allow system to
operate for 15 minutes to stabilize before declaring a properly
charged system.
If the indoor temperature is above 80_F (26.67_C), and the
outdoor temperature is in the favorable range, adjust system charge
by weight based on line length and allow the indoor temperature to
drop to 80_F (26.67_C) before attempting to check system charge
by subcooling method as described above.
If the indoor temperature is below 70_F (21.11_C), or the outdoor
temperature is not in the favorable range, adjust charge for line set
length above or below 15ft (4.57 m) only. Charge level should then
be appropriate for the system to achieve rated capacity. The charge
level could then be checked at another time when the both indoor
and outdoor temperatures are in a more favorable range.
Defrost
The defrost control is a time/temperature control which has field
selectable settings of 30, 60, 90, or 120 minutes, factory set to 90
minutes. These settings represent the amount of time that must pass
after closure of the defrost thermostat before the defrost sequence
begins.
The defrost thermostat senses coil temperature throughout the
heating cycle. When the coil temperature reaches the defrost
thermostat setting of approximately 32_F (0_C), it will close,
which energizes the DFT terminal and begins the defrost timing
sequence. When the DFT has been energized for the selected time,
the defrost cycle begins. Defrost cycle is terminated when defrost
thermostat opens, or automatically after 10 minutes.
Defrost Speedup
To initiate a forced defrost, speedup pins (J1) must be shorted with
a flat head screwdriver for 5 seconds and RELEASED. If the
defrost thermostat is open, a short defrost cycle will be observed
(actual length depends on Quiet Shift switch position). When Quiet
Shift is off, only a short 30 second defrost cycle is observed. With
Quiet Shift ON, the speedup sequence is one minute; 30 second
compressor off period followed by 30 seconds of defrost with
compressor operation. When returning to heating mode, the
compressor will turn off for an additional 30 seconds and the fan
for 40 seconds.
NOTE: If line length is beyond 80 ft (24.38 m) or greater than 20
ft (6.10 m) vertical separation, See Long Line Guideline for
special charging requirements.
Heating Check Chart Procedure
To check system operation during heating cycle, refer to the
Heating Check Chart on outdoor unit. This chart indicates whether
a correct relationship exists between system operating pressure and
air temperature entering indoor and outdoor units. If pressure and
temperature do not match on chart, system refrigerant charge may
not be correct. Do not use chart to adjust refrigerant charge.
If the defrost thermostat is closed, a complete defrost cycle is
initiated. If the Quiet Shift switch is turned on, the compressor will
be turned off for two 30 second intervals as explained previously.
Final Checks
IMPORTANT: Before leaving job, be sure to do the following:
1. Ensure that all wiring is routed away from tubing and sheet
metal edges to prevent rub--through or wire pinching.
2. Ensure that all wiring and tubing is secure in unit before
adding panels and covers. Securely fasten all panels and
covers.
3. Tighten service valve stem caps to 1/12--turn past finger
tight.
4. Leave Owner’s Manual with owner. Explain system
operation and periodic maintenance requirements outlined
in manual.
HK32EA003
5. Fill out Dealer Installation Checklist and place in customer
file.
Speedup
Pins
Quiet
Shift
Defrost interval
DIP switches
A05378
CARE AND MAINTENANCE
Fig. 9 -- Defrost Control
Table 3 – Defrost Control Speedup--Timing Sequence
For continuing high performance and to minimize possible
equipment failure, periodic maintenance must be performed on this
equipment.
Frequency of maintenance may vary depending upon geographic
areas, such as coastal applications. See Users Manual for
information.
6
PURONR (R--410A) QUICK REFERENCE GUIDE
S Puron refrigerant operates at 50--70 percent higher pressures than R--22. Be sure that servicing equipment and replacement
components are designed to operate with Puron
S Puron refrigerant cylinders are rose colored.
S Recovery cylinder service pressure rating must be 400 psig, DOT 4BA400 or DOT BW400.
S Puron systems should be charged with liquid refrigerant. Use a commercial type metering device in the manifold hose when
charging into suction line with compressor operating
S Manifold sets should be 700 psig high side and 180 psig low side with 550 psig low--side retard.
S Use hoses with 700 psig service pressure rating.
S Leak detectors should be designed to detect HFC refrigerant.
S Puron, as with other HFCs, is only compatible with POE oils.
S Vacuum pumps will not remove moisture from oil.
S Do not use liquid--line filter driers with rated working pressures less than 600 psig.
S Do not leave Puron suction line filter driers in line longer than 72 hours.
S Do not install a suction--line filter drier in liquid line.
S POE oils absorb moisture rapidly. Do not expose oil to atmosphere.
S POE oils may cause damage to certain plastics and roofing materials.
S Wrap all filter driers and service valves with wet cloth when brazing.
S A factory approved liquid--line filter drier is required on every unit.
S Do NOT use an R--22 TXV.
S If indoor unit is equipped with an R--22 TXV or piston metering device, it must be changed to a hard shutoff Puron TXV.
S Never open system to atmosphere while it is under a vacuum.
S When system must be opened for service, recover refrigerant, evacuate then break vacuum with dry nitrogen and replace filter
driers. Evacuate to 500 microns prior to recharging.
S Do not vent Puron into the atmosphere.
S Do not use capillary tube coils.
S Observe all warnings, cautions, and bold text.
S All indoor coils must be installed with a hard shutoff Puron TXV metering device.
7
C a t a l o g N o : 2 5 H C B --- C --- 3 S I
Copyright 2010 Carrier Corp. S 7310 W. Morris St. S Indianapolis, IN 46231
Printed in U.S.A.
Edition Date: 01/10
R e p l a ce s: 2 5 HC B 3 --- 5 --- 2 SI
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
8
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