International Comfort Products CCH9, CCH6, HCH9, TCH9, HCH6 Installation Manual
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INSTALLATION INSTRUCTIONS
R−410A Two−Stage Split System Heat Pumps
CCH9, HCH9, TCH9
CCH6, HCH6, TCH6
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 manuals 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.
Signal Words in Manuals
The signal word WARNING is used throughout this
manual in the following manner:
WARNING
WARNING
!
The signal word CAUTION is used throughout this
manual in the following manner:
!
Signal Words on Product Labeling
Signal words are used in combination with colors
and/or pictures on product labels.
CAUTION
TABLE OF CONTENTS
Safety Considerations 2...........................
Installation Recommendations 2...................
Installation 2.....................................
Start−up Procedure 7.............................
System Functions & Sequence of Operation 9.......
Defrost 10.......................................
Troubleshooting 11...............................
Status Codes 15.................................
R−410A Quick Reference Guide 17.................
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal injury and/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.
!
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.
CAUTION
428 01 1701 00 2/23/12
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pumps
SAFETY CONSIDERATIONS
Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical
Figure 1
OUTDOOR WALL INDOOR WALL
Connecting Tube Installation
Avoid contact between tubing and structureNOTE:
CAULK
LIQUID TUBE
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
INSULATION
THROUGH THE WALL
HANGER STRAP
(AROUND VAPOR
TUBE ONLY)
VAPOR TUBE
JOIST
INSULATION
VAPOR TUBE
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
1″ (25.4 mm)MIN.
SUSPENSION
LIQUID TUBE
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.
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.
INSTALLATION
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.
(25.4 mm) 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.
2 428 01 1701 00
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 your local distributor for
details and PE (Professional Certification), if required by local
authorities.
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 may require wind
baffles. Consult the Low−Ambient pressure switch installation
instructions for wind baffle construction.
NOTE: Unit must be level to within ±2 (±3/8 in./ft..) per
compressor manufacturer specifications.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pumps
Clearance Requirements
When installing, allow sufficient space for airflow clearance,
wiring, refrigerant piping, and service. Allow 24 in. (610 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 one 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. Position so water, snow, or ice
from roof or eaves cannot fall directly on unit.
Figure 2 Tie Down Knockouts
3/8-in. (9.53 mm) Dia.
Tiedown Knockouts in
Basepan(2) Places
View From Top
UNIT BASE PAN
Dimension
35 X 35 9–1/8 (231.8) 6–9/16 (166.7) 28–7/16 (722.3)
On rooftop applications, locate unit at least 6 in. (152.4 mm)
above roof surface.
TIEDOWN KNOCKOUT LOCATIONS in. (mm)
A B C
Operating Ambient
The minimum outdoor operating ambient in cooling mode is
55°F (12.78C), and the maximum outdoor operating ambient
in cooling mode is 125°F (51.67C). At line voltage of 208V
(or below) and an outdoor ambient of 120°F (48.9°C) (and
above), the compressor operates in low stage The maximum
outdoor operating ambient in heating mode is 66° F
(18.89C). This unit is not approved for low ambient
cooling applications.
Elevate Unit
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Unit must be kept free of an accumulation of water and/or
ice in the basepan.
CAUTION
Make Piping Connections
!
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.
Do not leave system open to atmosphere any longer than
minimum required for installation. POE oil in compressor is
extremely susceptible to moisture absorption. Always keep
ends of tubing sealed during installation.
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 more than
36 in. (914.4 mm).
!
PERSONAL DAMAGE HAZARD
Failure to follow this warning may result in equipment
damage or improper operation.
To prevent damage to unit or service valves, observe the
following:
Use a brazing shield.
Wrap service valves with wet cloth or use a heat sink
material.
WARNING
CAUTION
WARNING
Elevate unit per local climate and code requirements to
provide clearance above estimated snowfall level and ensure
adequate drainage of unit. If using accessory support feet,
use installation instructions from kit for installation.
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
To prevent damage to the unit, ensure that it is located
with the supports such that the unit is stable in all
circumstances including adverse conditions.
428 01 1701 00 3
CAUTION
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/24.38 m, substantial capacity and performance
losses can occur. Following the recommendations in the
Long Line Applications Guideline will reduce these losses.
Refer to Table 1 for accessory requirements. Refer to Table 2
for field tubing diameters.
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.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pumps
Table 1 − Accessory Usage
REQUIRED FOR SEA COAST
Accessory
REQUIRED FOR LONG LINE
APPLICATIONS* (Over 80 ft. / 24.38 m)
APPLICATIONS
(within 2 miles/3.22 km)
Accumulator Yes, Standard Standard
Compressor Start Assist Capacitor and Relay Yes No
Crankcase Heater Yes, Standard No
Liquid Line Solenoid Valve See Long Line Applications Guideline No
Support Feet 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 Long Line Applications Guideline.
Table 2 − Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters (In.)
RATED VAPOR
LIQUID
UNIT SIZE
Connection Diameter Tube Diameter Connection Diameter Rated Tube Diameter
624, 924 3/8 3/8 3/4 3/4
636, 936 3/8 3/8 7/8 7/8
648, 948, 660, 960 3/8 3/8 7/8 1−1/8
* Units are rated with 25 ft. (7.6 m) of lineset. See Specification sheet for performance data when using different size and length linesets.
Notes:
1. Do not apply capillary tube or fixed orifice indoor coils to these units.
2. For Tubing Set lengths between 80 and 200 ft. (24.38 and 60.96 m) horizontal or 35 ft. (10.7 m) vertical differential 250 ft. (76.2 m) Total Equivalent Length),
refer to the Long Line Applications Guideline.
up to 80 ft. (24.38 m)*
Use of the AHRI Certified
TM Mark indicates a
manufacturer’s
participation in the
program For verification
of certification for individual
products, go to
www.ahridirectory.org.
ISO 9001:2000
REGISTERED
This product has been designed and manufactured to meet
Energy Star® criteria for energy efficiency when matched
with appropriate coil components. However, proper
refrigerant charge and proper air flow are critical to achieve
rated capacity and efficiency. Installation of this product
should follow all manufacturing refrigerant charging and air
flow instructions. Failure to confirm proper charge and
air flow may reduce energy efficiency and shorten
equipment life.
4 428 01 1701 00
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pumps
Outdoor Unit Connected to Factory Approved
Indoor Unit
These outdoor units are carefully evaluated and listed with
specific indoor coils for proper system performance.
Install Adapter Tube
1. Remove plastic retainer holding outdoor piston in liquid
service valve.
2. Check outdoor piston size with matching number listed
on unit rating plate.
3. Locate plastic bag taped to unit containing adapter
tube.
4. Remove Teflon® seal from bag and install on open
end of liquid service valve. (See Fig. 3.)
5. Remove adapter tube from bag and connect threaded
nut to liquid service valve. Tighten nut finger−tight and
then with wrench an additional 1/2 turn (15 ft−lb). DO
NOT OVER TIGHTEN!
Figure 3
Liquid Service Valve
!
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.
!
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.
Evacuate Refrigerant Tubing and Indoor Coil
!
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Never use the system compressor as a vacuum pump.
CAUTION
CAUTION
CAUTION
Install Liquid Line Filter Drier Indoor
Refer to Fig. 4 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) liquid tube from
step 1.
4. Connect and braze liquid refrigerant tube to the filter
drier.
Figure 4
Liquid Line Filter Drier
Refrigerant tubes and indoor coil should be evacuated using
the recommended deep vacuum method of 500 microns. An
alternate triple evacuation method may be used.
IMPORTANT: Always break a vacuum with dry nitrogen.
Deep Vacuum Method
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. (See Fig.5)
Figure 5
5000
4500
4000
3500
3000
2500
2000
MICRONS
1500
1000
500
01234567
Deep Vacuum Graph
LEAK IN
SYSTEM
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
MINUTES
A95424
Triple Evacuation Method
The triple evacuation method should only be used when
system does not contain any water in liquid form and vacuum
pump is only capable of pulling down to 28 inches of mercury
Refrigerant Tubing and Sweat Connections
Use refrigerant grade tubing. Service valves are closed from
factory and ready for brazing. After wrapping service valves
with a wet cloth, braze sweat connections using industry
accepted methods and materials. Consult local code
requirements. Refrigerant tubing and indoor coil are now
ready for leak testing . This check should include all field and
factory joints.
428 01 1701 00 5
(711mm Hg). Refer to Fig. 6 and proceed is as follows:
1. Pull system down to 28 inches of mercury (711mm Hg)
and allow pump to continue operating for an additional
15 minutes.
2. Close manifold valves or valve at vacuum pump and
shut off vacuum pump.
3. Connect a nitrogen cylinder and regulator to system
and fill with nitrogen until system pressure is 2 psig.
INSTALLATION INSTRUCTIONS R−410A Split System Heat Pumps
4. Close nitrogen valve and allow system to stand for 1
hour. During this time, dry nitrogen will diffuse
throughout the system absorbing moisture.
5. Repeat this procedure as indicated in Figure 6.
6. After the final evacuate sequence, confirm there are no
leaks in the system. If a leak is found, repeat the entire
process after repair is made.
Figure 6
BREAK VACUUM WITH DRY NITROGEN
BREAK VACUUM WITH DRY NITROGEN
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM
Triple Evacuation Sequence
EVACUATE
WAIT
EVACUATE
WAIT
EVACUATE
CHARGE SYSTEM
Route Ground and Power Wires
Remove access panel to gain access to unit wiring. Extend
wires from disconnect through power wiring hole provided
and into unit control box.
!
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
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.
WARNING
Connect Ground and Power Wires
Connect ground wire to ground connection in control box for
safety. Connect power wiring to contactor as shown in Fig. 7.
Figure 7
DISCONNECT
PER N. E. C. AND/OR
LOCAL CODES
FIELD POWER
WIRING
Line Power Connections
CONTACTOR
Final Tubing Check
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, making sure
wire ties on feeder tubes are secure and tight.
Make Electrical Connections
!
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.
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.
NOTE: Use copper wire only between disconnect switch and
unit.
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.
6 428 01 1701 00
WARNING
Connect Control Wiring
This unit is capable of communication with an Observer Wall
Control, or will operate using standard 24v 2−stage
thermostat. Route 24v control wires through control wiring
grommet and connect leads to control board. When an
Observer Wall Control is available, connect DX+ and DX−
connections only. If a 2−stage thermostat is used, connect to
the Y1, Y2, W1, and O connections. Refer to the wiring label
for further clarification.
Use No. 18 AWG color−coded, insulated (35C minimum)
wire. If thermostat is located more than 100 ft. (30.48 m)
from unit, as measured along the control voltage wires, use
No. 16 AWG color−coded, insulated wire to avoid excessive
voltage drop.
All wiring must be NEC Class 1 and must be separated from
incoming power leads.
Use furnace transformer, fan coil transformer, or accessory
transformer for control power, 24−v/40−va minimum.
NOTE: Use of available 24−v accessories may exceed the
minimum 40−va power requirement. Determine total
transformer load 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.
FIELD GROUND
WIRING
GROUND
LUG
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