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1. DIAPHRAGM BYPASS TXV H Nm m PUSHRODS FEEDER TUBES S TWN LN INN NINY Cr COIL a E OUTLET lt lt MA i NEEDLE TR VALVE SPRING S l XY DISTRIBUTOR aa BULB CHECK VALVE OPEN x BYPASS TUBE EXTERNAL EQUALIZER TUBE A88405 Fig 39 TXV in Heating Mode 31 CAUTION Wear safety glasses and gloves when work ing on refrigerants and when using brazing torch A 3 When accumulator is exposed remove it from system with tubing cutter 4 Scratch matching marks on tubing stubs and old accumu lator Scratch matching marks on new accumulator Un braze stubs from old accumulator and braze into new accumulator 5 Thoroughly rinse any flux residue from joints and paint with corrosion resistant coating such as zinc rich paint 6 Reinstall accumulator into system with copper slip cou plings 7 Evacuate and charge system 8 Pour and measure oil quantity if any from old accumula tor If more than 20 percent of oil charge is trapped in accumulator add oil to compressor to make up for this loss XII CONTAMINANT REMOVAL Proper evacuation of a unit removes non condensibles and assures a tight dry system before charging The 2 methods used to evacuate a system are the deep vacuum metho
2. A91445 Fig 30 High Speed Windings If a system has lost all or most of its charge system must be pressurized again up to approximately 150 Ib minimum This can be done by adding refrigerant using normal charging procedures or it may be pressurized with nitrogen less expensive than refrigerant Nitrogen also leaks faster than R 22 and is not absorbed by refrigeration oil Nitrogen cannot however be detected by a leak detector See Fig 32 COOLING CYCLE REVERSING VALVE ENERGIZED OUTDOOR FAN a INDOOR COIL C ACCUMULATOR 3 y n 4 SUCTION SERVICE PORT AT SERVICE VALVE CLG CYCLE TRAINER gt WLLL S OUTDOOR STRAINER oF SUCTION LIQUID LINE METERING SERVICE PRESSURE SWITCH PORT HEAT PUMP BYPASSING ACCESSORY LIQUID LINE SERVICE PORT FILTER DRIER DUAL FLOW AT SERVICE VALVE CLG CYCLE A88400 Fig 31 Heat Pump Refrigerant Flow Diagrams 25 CAUTION Due to the high pressure of nitrogen it should never be used without a pressure regulator on the tank Leaks in a system pressurized with refrigerant can be spotted with a leak detector which detects extremely small refrigerant leaks This discussion assumes that system is pressurized with either all refrigerant or a mixture of nitrogen and refrigerant If system has been operating for some time
3. TABLE 5 FUNCTION LIGHT CODE AND DISPLAY LOCATION T STAT Constant flash No pause DEFINITION No demand Stand by POSSIBLE CAUSE 1 flash w pause Low speed operation 2 flashes w pause High speed operation 3 flashes w pause Ambient thermistor failure 4 flashes w pause Coil thermistor failure 3 flashes pause 4 flashes Thermistor out of range Thermistor drift wrong location Incorrect wiring Incorrect refrigerant charge Dirty indoor outdoor coil 5 flashes w pause Pressure switch trip LM1 LM2 Dirty outdoor coil Refrigerant overcharge Wrong indoor coil 6 flashes w pausef Compressor PTC s out of limit Low refrigerant charge Compressor mechanical problem Dirty indoor outdoor coil Constant light No pause No flash Board Failure Eguipment or electrical service not grounded Function light signal order of importance in case of multiple signal reguest 1 is most important T Signal at thermostat will occur after 3 consecutive attempted restarts and lockout has occurred t Will be energized if pressure switch remains open for 1 hr Check both thermistors to determine which is faulty F Five Minute Time Delay The 2 speed control logic contains a 5 minute time delay that prevents the unit from short cycling after a thermostat off cycle or power interruption The unit can be forced to operate immediately by momentarily touching a
4. b Remove all flux residue with brush and water while material is still hot 2 Use sil fos or phos copper for copper to copper only No flux is required 3 Silver solder is used on copper to brass copper to steel or copper to copper Flux is required when using silver solder Fluxes should be used carefully Avoid excessive applica tion and do not allow fluxes to enter into the system 5 Proper brazing temperature of copper is when it is heated to a dull red color This section of brazing is not intended to teach a technician how to braze There are books and classes which teach and refine brazing techniques The basic points above are listed only as a reminder IV SERVICE VALVES Service valves provide a means for holding original factory charge in outdoor unit prior to hookup to indoor coil They also contain gage ports for measuring system pressures and provide shut off convenience for certain types of repairs See Fig 33 Two types of service valves are used in outdoor residential equipment The first type is a front seating valve which has a service port that contains a Schrader fitting The service port is always pressurized after the valve is moved off the front seat position A88401 Fig 32 Leak Detector 26 The second type is a combination front seating back seating valve which has a metal to metal seat in both the open and closed positions When it is fully back seated the s
5. This plate also provides a surface to attach the wiring schematic superheat charging tables with instructions and warning labels The plate has 2 tabs on the top edge that are bent down at slightly more than 90 When the information plate is removed these tabs can be inserted into 2 mating slots in the bottom front edge of the control box and the plate will hang down forming a lower front panel See Fig 3 This is convenient where access to the controls is required while the unit is operating The information plate on the small size casing completely covers the opening below the control box On larger models the information plate may not cover the entire opening In this instance the top cover can be removed and placed on its side to cover the additional space VO AES IEEE EE e DELE NEL N AN zna i SSS s Z 277 T nm S NET o Oy SSAC SSSA SSSR S SS TA IMA a UR v IN y WUO M y flee M PEP pur pum pun le NNI cum iram Pg A94003 4 Remove nuts holding fan motor to wire basket 3 Lift wire basket from unit ig 1 Basic Cabinet Designs Fi IV CONTROL BOX COVER CUBE TEARDROP PRODUCTS This panel contains much of the same information as the informa 5 Remove motor and fan blade assembly tion plate mentioned previously but is designed only to cover the control box 6 Pull wires thro
6. Compressor Removal and Replacement COPELAND SCROLL COMPRESSOR 17 Features Troubleshooting Discharge Thermostat Discharge Solenoid Valve MILLENNIUM SCROLL COMPRESSOR 18 Features Compressor Protection Troubleshooting TWO SPEED SYSTEM 1 cerent 19 e Cautions and Warnings System Functions Factory Defaults Major Components LED Function Malfunction Lights Troubleshooting REFRIGERATION SYSTEM 1 1 cscs sreeeeteneeneenes 24 Refrigeration Cycle Leak Detection Brazing Service Valves e Check Flo Rater Bypass Type Heat Pumps Only Reversing Valve Thermostatic Expansion Valves TXV Thermostatic Expansion Valve Bi Flow TXV Coil Removal Liquid Line Strainer Heat Pumps Only e Accumulator Contaminant Removal System Charging Checking Charge Care and Maintenance TROUBLESHOOTING CHARTS 1 36 Air Conditioning Heat Pump Cooling Heat Pump Heating UNIT IDENTIFICATION I PRODUCT NUMBER STAMPED ON UNIT RATING PLATE The unit product number has 16 positions containing groups of numbers and letters that indicate specific information about the unit Listed below is the breakdown of the 16 positions Positions 1 2 and 3 Product Series Example A 500 series number indicates a split system condensing unit and a 600 series number indicates a split system heat pu
7. See Fig 6 It is a resistor wired in parallel with the run capacitor As current flows through the PTC at start up it heats up As it heats up its resistance increases greatly until it effectively lowers the current through it to an extremely low value This in effect removes it from the circuit Capacitance mfd 12 5 22 5 OHMS 12 5 OHM BEIGE COLOR 25 45 OHMS 20 36 OHMS D 20 OHM 25 OHM BLUE COLOR BLUE COLOR A88414 Fig 6 PTC Devices After system shutdown resistor cools and resistance value returns to normal until next time system starts If indoor coil does not have a bleed type expansion device it may be necessary to remove start thermistor and replace with accessory start capacitor and relay Consult pre sale literature for application of start kits Thermistor device is adeguate for most conditions however in systems where off cycle is short device cannot cool fully and becomes less effective as a start device It is an easy device to troubleshoot 1 Shut off all power to system 2 Check thermistor with ohmmeter as described below 3 Shut off all power to unit 4 Remove PTC from unit Wait at least 10 minutes for PTC to cool to ambient temperature 5 Measure resistance of PTC with ohmmeter as shown in Fig 6 The cold resistance RT of any PTC device should be approxi mately 100 180 percent of device ohm rating 12 5 ohm PTC z 12 5 22 5 ohm resistance beige color 25 ohm PTC z 25
8. on shutdown The white oil Sontex 200LT used in the scroll is compatible with 3GS oil which can be used if additional oil is required See Table 3 for oil recharge requirements Scroll Gas Flow Compression in the scroll is created by the interaction of an orbiting spiral and a stationary spiral Gas enters an outer opening as one of the spirals orbits N G Ww si Ue 3 Ni As the spiral continues to orbit the gas is compressed into an increasingly smaller pocket The open passage is sealed off as gas is drawn into the spiral M W ss 5 Wen S A SS AN By the time the gas arrives at the center port discharge pressure has been reached Actually during operation all six gas passages are in various stages of compression at all times resulting in nearly con tinuous suction and discharge A90198 Fig 20 Scroll Compressor Refrigerant Flow ll TROUBLESHOOTING Troubleshooting mechanical or electrical problems in a scroll compressor is the same as for a reciprocating compressor except that a scroll compressor should never be allowed to pump into a vacuum If a pumpdown procedure is used the scroll compressor is capable of pumping into a vacuum very quickly which could cause fusite arcing and compressor failure See Section IV of Reciprocating Compressor for removal and replacement Ill DISCHARGE THERMOSTAT Some scroll compressors have a discharge thermostat that recip rocating compressors do n
9. 20 difference between well temperature and dome temperature If the temperature approaches 270 F repair system problem such as low charge blocked condenser coil etc If the temperature does not approach 270 F replace discharge thermostat REPLACING DISCHARGE THERMOSTAT To replace the discharge thermostat refer to the Installation Instructions packaged with the replacement discharge thermostat kit See Fig 21 IV DISCHARGE SOLENOID VALVE Some larger units equipped with scroll compressors contain a solenoid valve that is piped between the discharge tube and suction tube of the compressor The purpose of the solenoid valve is to cause a rapid pressure equalization around the compressor thus reducing the normal shut down sound created by reverse rotation of the scroll The solenoid valve is normally closed and is wired across high voltage line 1 to load terminals of the contactor See Fig 11 The solenoid valve assembly also requires a check valve piped in the discharge tube between the solenoid valve tee and the condenser coil or reversing valve on heat pumps The purpose of the check valve is to prevent refrigerant from bypassing through the solenoid valve into the suction tube when the unit cycles off MILLENNIUM SCROLL COMPRESSOR l FEATURES The scroll compressor pumps refrigerant through the system by the interaction of a stationary and an orbiting scroll See Fig 20 The scroll compressor has no dynamic suction or d
10. 3 Loosen nut and remove liquid line flare connection from Check Flo Rater 4 Pull retainer out of body being careful not to scratch flare sealing surface If retainer does not pull out easily carefully use locking pliers to remove it 5 Slide piston out by inserting a small soft wire with small kinks through metering hole Do not damage metering hole sealing surface around piston cones or fluted portion of piston 6 Clean piston refrigerant metering hole 7 Install a new retainer O ring or retainer assembly before reassembling bypass type Check Flo Rater FEEDER PISTON ORIENT AS SHOWN TUBES BRASS STRAINER HEXNUT NI PISTON TEFLON i us RETAINER SEAL HEX BODY 1992 PRODUCTION A91138 PISTON BODY PISTON PISTON RETAINER PRODUCTION EXCEPT 1992 A94004 Fig 34 Check Flo Rater Components B Reliant Endura and Cube Products Produced in 1992 1 Shut off power to unit 2 Reclaim outdoor unit refrigerant 3 Loosen brass hex nut and remove line from brass hex body 4 Slide piston out by inserting a small soft wire with small kinks through metering hole Do not damage metering hole sealing surface around piston cones or fluted portion of piston 5 Clean piston refrigerant metering hole 6 Always replace Teflon seal with new seal Never try to reuse old seals 7 Reassemble brass nut and brass hex body Be sure orienta tion is as shown in Fig 34 VI REVERSING VALVE In heat pumps changeover bet
11. 45 ohm resistance blue color 20 ohm PTC lt 20 36 ohm resistance blue color If PTC resistance is appreciably less than rating or more than 200 percent higher than rating device is defective If thermistor is good and compressor does not start 1 Disconnect thermistor from starting circuit 2 Give compressor a temporary capacitance boost see next section 3 Run compressor for 10 minutes shut off and allow system pressure to equalize 4 Reconnect start thermistor 5 Try restarting compressor without boost capacitor If after 2 attempts compressor does not start remove thermistor Add an accessory start capacitor relay package B Temporary Capacitance Boost There are times when a temporary capacitance boost is needed to get compressor started See Fig 7 Do not under any circum stances attach temporary boost capacitor directly across compres sor terminals Serious personal injury can result Exercise extreme caution with this procedure when high voltage power is on If compressor motor does not start it may be due to low line voltage improper pressure equalization or weak run capacitor Check each possibility and attempt capacitance boosting before adding auxil jary start capacitor and relay NOTE Do not use start capacitor and relay on units with Millennium scroll compressors Turn off power 2 Check compressor for ground or open If it is not proceed 3 Obtain a start capacitor approved by comp
12. F Notice temperature at for more accurate reading which ohmmeter reading goes from to zero ohms 3 Turn on power to outdoor unit Thermostat contacts close at this point 4 Restart unit in heating o ilu di TOP COVER an 3 IN SMALL amp MEDIUM BASE UNITS 4 IN LARGE BASE UNIT FROM DISCHARGE LOUVER TO TOP OF FAN BLADE FAN ORIFICE FAN BLADE Ni T STAR BURST TOP A88347 Fig 15 Fan Position 6 Short between the speed up terminals using a small slotted screwdriver 7 Unit changes over to defrost within 21 sec depending on timing cycle setting Liquid line temperature rises to range where defrost thermostat contacts open Temperature range is from 75 F to 85 F Resistance goes from zero to o when contacts open 8 If either opening or closing temperature does not fall within above ranges or thermostat sticks in 1 position replace thermostat to ensure proper defrost operation C CES0130024 Defrost Control Some heat pumps built in 1993 and later incorporated a new defrost control similar to the CES0110063 except the 5 minute cycle protector has been removed This control is used on heat pump units with reciprocating compressors where short cycle protection is not required Troubleshooting this control will be the same as the CES0110063 control except for the cycle protector function The CES0130024 control is identical to the CES0110063 except the T2 terminal and cycle protector logic have been
13. SCHEMATIC DIAGRAM i LADDER FORM C1 EXT LOW MAIN START T8 23 A91446 Fig 29 Low Speed Windings REFRIGERATION SYSTEM l REFRIGERATION CYCLE In a refrigeration system refrigerant moves heat from 1 place to another It is useful to understand flow of refrigerant in a system In a straight cooling system compressed hot gas leaves compres sor and enters condensing coil As gas passes through condenser coil it rejects heat and condenses into liquid The liquid leaves condensing unit through liquid line and enters metering device at indoor coil As it passes through metering device it becomes a gas liquid mixture As it passes through indoor coil it absorbs heat and refrigerant and is again compressed to a hot gas The cycle then repeats In a heat pump the basic cycle is the same See Fig 31 Reversing valve in system decides which coil indoor or outdoor becomes evaporator or condenser It rejects heat into the home after heat is absorbed by outdoor evaporator coil thus the home is heated In cooling cycle the indoor coil becomes the evaporator It absorbs heat from the home and rejects it through the outdoor condenser coil thus the home is cooled A unique feature of the heat pump is that metering devices are designed to meter refrigerant in 1 direction of flow and allow refrigerant to pass unh
14. and turning thermostat to heat or cool Check voltage at coil with voltmeter Reading should be between 20v and 30v Contactor should pull in if voltage is correct and coil is good If contactor does not pull in change contactor 4 With high voltage power off and contacts pulled in check for continuity across contacts with ohmmeter A very low or zero resistance should be read Higher readings could indicate burned or pitted contacts which may cause future failures Ill CAPACITORS CAUTION Capacitors can store electrical energy when power is off Electrical shock can result if you touch the capacitor terminals and discharge the stored energy A Exercise extreme caution when working near capacitors With power off discharge stored energy by shorting across the capacitor terminals with a 15 000 ohm 2 watt resistor NOTE If bleed resistor is wired across start capacitor it must be disconnected to avoid erroneous readings when ohmmeter is applied across capacitor See Fig 5 CAUTION Always check capacitors with power off Attempting to troubleshoot a capacitor with power on can AN be dangerous Defective capacitors may explode when power is applied Insulating fluid inside is combustible and may ignite causing burns Capacitors are used as a phase shifting device to aid in starting certain single phase motors Check capacitors as follows 1 After power is off discharge capacitors as outlined above Discon
15. assistance The qualified in staller or agency must use factory authorized kits or accessories when modifying this product INTRODUCTION This service manual enables a service technician to service repair and maintain a family of similar air conditioners and heat pumps It covers standard single speed products and 2 speed products only For variable speed products refer to the respective service manuals TABLE OF CONTENTS UNIT IDENTIFICATION eee 2 Product Number Stamped on Unit Rating Plate Serial Number Identification CABINET eerte e hte e ted 2 Remove Top Cover Reliant Endura Products Prior to January 1992 Remove Fan Motor Assembly Reliant Endura Products Prior to January 1992 Information Plate Reliant Endura Products e Control Box Cover Cube Teardrop Products Remove Top Cover All Products After January 1 1992 SM01 02 3 SM01 02 4 3 1 94 Cancels e Remove Fan Motor Assembly AII Products After January 1 1992 ELECTRICAL irn E D See es esate RE 3 Aluminum Wire Contactors e Capacitors Cycle Protector Crankcase Heater Time Delay Relay Pressure Switches Defrost Thermostats e Defrost Control Board Fan Motors Service Alarm Control Board e Outdoor Thermostat s Compressor Plug Low Voltage Terminals RECIPROCATING COMPRESSOR 1 14 Mechanical Failures Electrical Failures System Clean Up After Burnout
16. attempts to start it draws locked rotor current and cycles off on the internal protection Locked rotor current is measured by applying a clamp on ammeter around common blk lead of the compressor on a single phase compressor or any 1 of the leads on a 3 phase compressor Current drawn when it attempts to start is then measured LRA locked rotor amp value is stamped on compressor nameplate If compressor draws locked rotor amps and all other external sources of problems have been eliminated compressor must be replaced Because compressor is a sealed unit it is impossible to determine exact mechanical failure However complete system should be checked for abnormalities such as incorrect refrigerant charge restrictions insufficient airflow across indoor or outdoor coil etc which could be contributing to the failure B Runs Does Not Pump In this type of failure compressor motor runs and turns compres sor but compressor does not pump the refrigerant A clamp on ammeter on common leg of a single phase compressor or any 1 BRISTOL CARLYLE COPELAND LEAD 3 BLUE BLK TECUMSEH LEAD 1 BLK LEAD 2 YEL LEAD 3 BLUE YEL MILLENNIUM LEAD 1 BLK v gt zA LEAD 3 BLUE LEAD 2 YEL A94002 Fig 18 Compressor Plug lead of a 3 phase compressor shows a very low current draw much lower than RLA rated load amps value stamped on compressor nameplate Because no refrigerant is bei
17. charge protector The liguid line is the low side of the system in heating mode It operates identically to low pressure switch except it opens at 7 psi when the heating piston is in the liguid valve or 27 psi when the heating piston is in the liguid line Troubleshooting and removing this switch is identical to procedures used on other switches Observe same safety precautions Vill DEFROST THERMOSTATS Defrost thermostat signals heat pump that conditions are right for defrost or that conditions have changed to terminate defrost It is a thermally actuated switch clamped to outdoor coil to sense its temperature Normal temperature range is closed at 30 3 F and open at 80 5 F NOTE The defrost thermostat must be located on the liquid side of the outdoor coil on the bottom circuit and as close to the coil as possible IX DEFROST CONTROL BOARD Solid state defrost boards used on heat pumps replace electrome chanical timer and defrost relay found on older defrost systems The defrost control board can be field set to check need for defrost every 30 50 or 90 minutes of operating time by connecting the jumper labeled W1 on the circuit board to the terminal for the defrost time desired The board is set at factory for 90 minutes The defrost period is field selectable depending upon geographic areas and defrost demands Two types of defrost boards are used Their functions are described in the sections to follow Troubleshootin
18. install jumper wire on the speed up termi nals 4 n n n n n a a a a a a a a a HK32FA003 HK32FA006 A88402 Fig 12 Jumper DFT and R Terminals 7 Unit changes over to defrost within 90 sec depending on timing cycle setting Liquid line temperature rises to range where defrost thermostat contacts open Temperature range is from 75 F to 85 F Resistance goes from zero to so when contacts open 8 If either opening or closing temperature does not fall within above ranges or thermostat sticks in 1 position replace thermostat to ensure proper defrost operation B CES0110063 Defrost Control Some heat pumps built in 1991 and later incorporate a new defrost control The screw terminals found on the previous control board have been replaced by a connector plug with stripped wire leads This control board also contains the feature that allows the heat pump to restart in defrost if the room thermostat is satisfied during defrost The board also contains a 5 minute cycle protector that prevents the unit from short cycling after it cycles off or after a power interruption To troubleshoot the board perform the follow ing items 1 Turn thermostat to OFF Shut off all power to outdoor unit 2 Remove control box cover for access to electrical compo nents and defrost control board 3 Disconnect defrost thermostat leads from control board and connect to ohmmeter Thermo
19. jumper between the speed up terminals of the control board See Fig 22 and 23 The speed up feature will not bypass any other function or time delay G Two Minute Low Speed Minimum If the unit has not operated within the past 30 minutes the unit operates for a minimum of 2 minutes in low speed upon the next thermostat high or low demand H Crankcase Heater Operation The 2 speed control energizes the crankcase heater during the unit s off cycle when the outdoor ambient is below 75 F l Outdoor Fan Motor Operation The 2 speed control energizes the outdoor fan any time the compressor is operating The outdoor fan remains energized during the 1 minute speed change time delay and if a pressure switch or compressor PTC overload should trip HEAT PUMPS After the termination of a defrost cycle the outdoor fan delays coming on for 20 sec This allows the refrigeration system to recover the outdoor coil heat and minimize the steam cloud effect J Second Stage Latching When low speed cooling operation no longer satisfies the first stage of the indoor thermostat the indoor temperature will increase by 2 until second stage is energized After high speed cooling satisfies second stage it returns to low speed cooling operation If desired the installer may select to have high speed cooling by energizing Y1 High speed will stay energized until Y 1 is satisfied This eliminates the temperature drop between the first and second s
20. make first check for a leak visually Since refrigerant carries a small quantity of oil traces of oil at any joint or connection is an indication that refrigerant is leaking at that point A simple and inexpensive method of testing for leaks is to use soap bubbles Any solution of water and soap may be used Soap solution is applied to all joints and connections in system A small pinhole leak is located by tracing bubbles in soap solution around leak Use electronic leak detector to check for leaks This unquestion ably is the most efficient and easiest method for checking leaks There are various types of electronic leak detectors Generally speaking they are all portable most are lightweight and consist of a box with several switches and a probe or sniffer Detector is turned on and probe is passed around all fittings and connections in system Leak is detected by either a movement of a pointer on detector dial by a buzzing sound or a light In all instances when a leak is found system charge must be bled down and leak repaired before final charging and operation After leak testing or leak is repaired evacuate system and recharge with correct refrigerant charge Ill BRAZING When brazing is required in the refrigeration system certain basics should be remembered The following are a few of the basic rules 1 Clean joints make the best joints To clean a Remove all oxidation from surfaces to a shiny finish before brazing
21. the furnace interface option is done by connecting the factory supplied jumper to the ON position of the 3 terminal connectors See Fig 22 When the option is selected the heat pump will be locked out of operation any time there is a thermostat demand for W2 or the outdoor ambient is below the balance point POT setting selection See Fig 23 When the unit requires defrost auxiliary heat W2 energizes the furnace After defrost is terminated the heat pump shuts down and the furnace satisfies the thermostat To utilize this function the economic and or thermal balance point must be determined See the appropriate heat pump balance point work sheet available from your distributor or branch P Balance Point This feature can be used in 2 different options furnace interface or electric heat staging Refer to the Furnace Interface section for its application If the heat pump is installed with a fan coil with multistages of electric heat this option can be used to stage the banks of heat by outdoor ambient This eliminates the need for accessory outdoor thermostats When using this option to stage electric heat first stage is energized by a W2 demand and second stage is energized by a W3 demand Select the W3 desired temperature by rotating the balance point POT See Fig 23 Temperatures that may be selected are 10 15 20 25 30 35 40 and 45 F The POT is factory set at 45 F Q Low Speed Heating with Auxiliar
22. usually less than 10 ohms each reading appears to be approximately 0 ohm If resistance remains at 1000 ohms an open or break exists and compressor should be replaced A CAUTION Be sure internal line break overload is not temporarily open D Ground Circuit To determine if a wire has broken or come in direct contact with shell causing a direct short to ground 1 Be sure all power is off 16 2 Discharge all capacitors 3 Remove wires from terminals C S and R 4 On hermetic compressors allow crankcase heaters to re main on for several hours before checking motor to ensure windings are not saturated with refrigerant 5 Use an ohmmeter on R X 10 000 ohm scale A megohm meter may be used in place of ohmmeter Follow manufac turer s instructions 6 Place 1 meter probe on ground or on compressor shell Make a good metal to metal contact Place other probe on terminals C S and R in seguence 7 Note meter scale 8 If reading of zero or low resistance is obtained motor is grounded Replace compressor A compressor of 1 ton capacity or less is probably grounded if resistance is below 1 million ohms On larger sized single phase compressors resistance to ground should not be less than 1000 ohms per volt of operating voltage Example 230 volts X 1000 ohms volt lt 230 000 ohms minimum E Short Circuit To determine if any wires within windings have broken through their insulation and made contact wi
23. wire such as cutting off strands so that the wire will fit a connector Proper size connectors should be used Check all factory and field electrical connections for tightness This should also be done after the unit has reached operating temperatures especially if aluminum conductors are used I CONTACTORS NOTE This section applies to single speed models only The contactor provides a means of applying power to unit using low voltage 24v from transformer in order to power the contactor coil See Fig 4 Depending on unit model you may encounter single double or triple pole contactors to break power One side of the line may be electrically energized so exercise extreme caution when troubleshooting The contactor coil for residential air conditioning units and heat pumps is powered by 24 vac If contactor does not operate 1 With power off check whether contacts are free to move Check for severe burning or arcing on contact points 2 With power off use ohmmeter to check for continuity of coil Disconnect leads before checking A low resistance reading is normal Do not look for a specific value as different part numbers have different resistance values A88413 Fig 3 Information Plate Removed Installed Below Control Box A88350 Fig 4 Contactor 3 Reconnect leads and apply Ow voltage power to contactor coil This may be done by leaving high voltage power to outdoor unit off
24. AINER RESTRICTED OUTDOOR COIL HEAVILY FROSTED DEFECTIVE WELDED CLOSED IN DEFROST RELAY REVERSING VALVE DID NOT SHIFT UNIT NOT PROPERLY CHARGED DEFROST THERMOSTAT DEFROST THERMOSTAT IN POOR PHYSICAL CONTACT WITH TUBE DEFECTIVE CIRCUIT BOARD BAD ELECTRICAL CONNECTION ANYWHERE IN DEFROST CIRCUIT Fig 43 Heat Pump Troubleshooting Chart Heating Cycle BROKEN HEATER ELEMENT OPEN KLIXON OVER TEMPERATURE THERMOSTAT DEFECTIVE ROOM THERMOSTAT 2ND STAGE A90206 1994 BDP Co P O Box 70 Indianapolis IN 46206 Printed in U S A 40 43005b Catalog No BDP 3356 115
25. ALVE ON TO OUTDOOR COIL OUTDOOR COIL TO ACCUMULATOR FROM COMPRESSOR DISCHARGE LINE A88342 Fig 36 Reversing Valve Cooling Mode or Defrost Mode Solenoid Energized VIII THERMOSTATIC EXPANSION VALVE BI FLOW TXV The standard thermostatic expansion valve is a metering device that is used in condensing and heat pump systems to adjust to changing load conditions by maintaining a pre set superheat temperature at the outlet of the evaporator coil The volume of refrigerant metered through the valve seat is dependent upon 1 Superheat temperature sensed by cap tube sensing bulb on suction tube at outlet of evaporator coil As long as this bulb and cap tube contains some liquid refrigerant this tempera ture is converted into suction pressure pushing downward on the diaphragm which tends to open the valve via the pushrods 29 INSULATE FOR FROM COMPRESSOR 3 PORT DESIGN A91457 FROM cc Wr o TO INDOOR COIL ACCUMULATOR OUTDOOR VIA SERVICE VALVE COIL ON OUTDOOR COIL INSULATE FOR TP 3 e ACCURATE READING ACCURATE READING DISCHARGE LINE ELECTRONIC THERMOMETER A88341 Fig 37 Reversing Valve Heating Mode Solenoid De Energized 2 The suction pressure at the outlet of the evaporator coil is transferred via the external equalizer tube to the underside of the diaphragm The needle valve on the pin carrier is spring loaded which also exerts pressure
26. AO1EBO23 4 5 32 LAO1ECO19 5 1 8 HC31GE230 231 LAO1EA026 4 5 8 LAO1RAO015 4 7 8 HC33GE208 LAO1EWO049 5 1 4 HC33GE232 LAO1RAO015 4 29 32 HC34GE231 HC34GE460 LAO1RAO015 5 5 32 HC35GE208 LA01EW048 4 15 16 HC35GE232 LAO1EA025 5 7 8 LAO1RA024 5 11 32 LAO1RAO026 5 9 16 HC37GE208 LAO1EA025 6 1 8 HC37GE230 LAO1EW042 6 5 32 HC38GE221 LAO1EA031 7 25 32 HC39GE232 LAO1ECO18 5 11 16 LAO1RAO026 5 1 2 LAO1EA036 5 9 16 HC39GE234 LAO1EA024 LAO1ECO18 5 3 32 5 1 2 HC39GE461 LAO1EA036 6 1 16 LAO1ECO18 6 1 4 LAO1RAO026 6 1 16 5 7 32 HC40GE230 LAO1EA024 5 9 32 5 11 32 HC40GE461 LAO1EA024 5 27 32 5 19 32 BASEPAN DIMENSIONS FOR STAR BURST TOP IN Small 22 1 2 x 26 3 16 Medium 30 x 33 Large 38 5 8 x 42 1 16 XI SERVICE ALARM CONTROL BOARD NOTE If the proper night setback thermostat is not used the service alarm control will work but there will be no light indication on thermostat The service alarm control provides immediate warning when outdoor heat pump reguires servicing It turns on indoor thermostat malfunction light if compressor does not operate for either heating or cooling This enables owner to obtain timely heat pump service during heating season reducing supplementary electric heat co
27. B products which started production March 1994 For 598A Series A and B and 698A Series A products refer to the Split System Service Manual dated 4 1 92 Catalog No BDP 3359 024 ll SYSTEM FUNCTIONS A Cooling Operation The 2 speed products utilize a 2 stage cooling indoor thermostat With a call for first stage cooling Yl the outdoor fan and low speed compressor are energized If low speed cannot satisfy the cooling demand high speed will be energized Y1 and Y2 by 19 LM1 DFT1DFT2 Ti T2 S2 S1 PW PW1 8 89989888 mE OFF ON FURN INT SPEED UP Sp 85 B3o sor cov ZONE STAGE2 DEFROST BALANCE LATCH TIME POINT A93568 Fig 23 Speed Up Terminals the second stage of the indoor thermostat The thermostat has a 2 differential between first and second stages After second stage is satisfied the unit returns to low speed operation until first stage is satisfied or until second stage is again required B Heating Operation Heat Pump Only The 2 speed products utilize a 2 stage heating indoor thermostat The first stage of heating is heat pump operation Y1 Auxiliary back up heat is controlled by second stage W2 There is a 2 differential between first and second stage The control board determines the compressor speed based on ambient temperature See Table 4 for ambient temperatures at wh
28. IG AT SERVICE FITTING 134 141 148 156 163 171 179 187 196 205 214 3 Evacuate recharge and operate unit through entire cycle E Final Check Out After the unit has been operating the following items should be checked 1 Check that unit operational noise is not excessive due to vibration of components tubing panels etc If present isolate problem and correct 2 Check to be sure caps are installed on service valves and that they are tight 3 Check to be sure tools loose parts and debris are removed from the unit 4 Check to be sure all panels and screws are in place and tight DESERT AND SEACOAST LOCATIONS Special consideration must be given to the installation and main tenance of condensing units and heat pumps installed in seacoast or desert locations This is because the salt and alkali content of the sand adheres to the aluminum fins of the coil and can cause premature coil failure due to corrosion from salt alkali and moisture Preventive measures can be taken during installations such as 1 Locating the unit on side of structure opposite the prevailing winds 2 Elevating the unit to height where drifting sand cannot pile up against coil Four in high mounting feet or an 18 in high mounting rack are available as accessories and can be used to elevate the unit 3 Addition of c
29. LURES The compressor mechanical pump is driven by an electric motor within its hermetic shell In electrical failures compressor does not run although external electrical and mechanical systems appear normal Compressor must be checked electrically for abnormali ties Before troubleshooting compressor motor review this description of compressor motor terminal identification A Single Phase Motors To identify terminals C S and R Turn off all unit power 2 Short the run and start capacitors to prevent shock 3 Remove all wires from motor terminals 4 Read resistance between all pairs of terminals using an ohmmeter on 0 10 ohm scale 5 Determine 2 terminals that provide greatest resistance reading i EXAMPLE TO DETERMINE INTERNAL CONNECTIONS OF SINGLE e PHASE MOTORS C S R EXCEPT SHADED POLE e POWER OFF DEDUCTION I 3 GREATEST RESISTANCE RUN WINDING R 5 80 OHM START WINDING S OHMMETER 2 3 SMALLEST RESISTANCE 2 IS COMMON C 0 109 SCALE 0 60 BY ELIMINATION REMAINING RESISTANCE 2 is COMMON 5 20 2 ace 5 20 THEREFORE 1 IS START WINDING S 8 IS RUN WINDING R A88344 Fig 19 Identifying Internal Connections Through elimination remaining terminal must be common C Greatest resistance between common C and another terminal indicates start winding because it has more turns This terminal is start S Remain
30. Motor Assembly section of this manual Be careful not to bend or dent fan blade Clean motor and blade with soft brush or cloth Be careful not to disturb balance weights on fan blade 3 Check fan blade setscrew for tightness Reinstall fan motor and blade to top cover and check for alignment 5 Reinstall top cover and position blade as per Fig 15 6 Electrical Controls and Wiring 1 2 34 Reconnect electrical power and check for proper operation Disconnect power to both the outdoor and indoor units Check all electrical connections for tightness Tighten all screws on electrical connections If any connections appear to be burned or smokey disassemble the connection clean all parts and stripped wires and reassemble Use a new connector if old one is burned or corroded and crimp tightly Reconnect electrical power to the indoor and outdoor units and observe unit through 1 complete operating cycle If there are any discrepancies in the operating cycle troubleshoot to find the cause and correct Refrigerant Circuit 1 Check the refrigerant charge using the superheat or sub cooling method whichever is applicable If low on charge check unit for leaks using an electronic leak detector If any leaks are found recover or isolate charge pump down if applicable and make necessary repairs TABLE 14 REQUIRED LIQUID LINE TEMPERATURE REQUIRED SUBCOOLING TEMPERATURE F PRESSURE PS
31. ONDITIONERS 591A 592A 593A 594A 598A 598A 691A 692A 693A 694A 698A Cooling Heating High Low High Low 698A A B A B A A 16 16 11 11 MODEL 561A 571A 661A 671A Series 014 018 024 030 036 042 048 060 5 Cleaning Outdoor Fan Motor and Blade 1 CAUTION Coil fin damage can result in higher oper ating costs or compressor damage Do not use flame high pressure water steam or volatile or corrosive clean ers on fins or tubing Clean coil using vacuum cleaner and its crevice tool Move crevice tool vertically close to area being cleaned making sure tool touches only the dirt on the fins and not the fins To prevent fin damage do not scrub fins with tool or move tool horizontally against fins If oil deposits are present spray coil with ordinary house hold detergent Wait 10 minutes and proceed to next step Using garden hose spray coil vertically downward with constant stream of water at moderate pressure Keep nozzle at a 15 to 20 angle about 3 in from coil face and 18 in from tube Spray so debris is washed out of coil and basepan Restore power to unit Remove fan motor and blade Refer to Remove Fan
32. OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT 36 COMPRESSOR RUNS BUT INSUFFICIENT COOLING LOW SUCTION PRESSURE DIRTY AIR FILTERS DUCT RESTRICTED DAMPERS PARTLY CLOSED INDOOR COIL FROSTED SLIGHTLY LOW ON REFRIGERANT LIQUID LINE SLIGHTLY RESTRICTED PISTON RESTRICTED INCORRECT SIZE PISTON INDOOR COIL STRAINER RESTRICTED INDOOR BLOWER MOTOR DEFECTIVE OR CYCLING ON OL Fig 41 Air Conditioner Troubleshooting Chart HIGH SUCTION LOW HEAD PRESSURE DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON A90208 HEAT PUMP TROUBLESHOOTING COOLING CYCLE NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN CONTACTOR OPEN POWER SUPPLY DEFECTIVE LOW VOLTAGE TRANSFORMER OPEN THERMOSTAT OPEN CONTROL CIRCUIT LOSS OF CHARGE CONTACTOR OR COIL DEFECTIVE LOOSE ELECTRICAL CONNECTION CONTACTOR CLOSED COMPRESSOR POWER SUPPLY OPEN LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH OPEN SHORTED OR GROUNDED COMPRESSOR MOTOR WINDINGS COMPRESSOR STUCK COMPRESSOR INTERNAL PROTECTION OPEN DEFECTIVE RUN CAPACITOR COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVER OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING DAMAGED OR S
33. Service Manual SPLIT SYSTEM RESIDENTIAL AIR CONDITIONER AND HEAT PUMP NOTE Read the entire instruction manual before starting the installation SAFETY CONSIDERATIONS Service and repair of these units should be attempted only by trained service technicians familiar with BDP standard service instructions and training material All equipment should be installed in accordance with accepted practices and unit Installation Instructions and in compliance with all national and local codes Power should be turned off when servicing or repairing electrical components Extreme caution should be observed when trouble shooting electrical components with power on Observe all warn ing notices posted on equipment Refrigeration system contains refrigerant under pressure Extreme caution should be observed when handling refrigerants Wear safety glasses and gloves to prevent personal injury During normal system operation some components are hot and can cause burns Rotating fan blades can cause personal injury Appropriate safety considerations are posted throughout this manual where potentially dangerous techniques are addressed WARNING Improper installation adjustment alter ation service maintenance or use can cause explosion fire electrical shock or other conditions which may A cause personal injury death or property damage Consult a qualified installer service agency or your distributor or branch for information or
34. TER JANUARY 1 1992 VI 1 Perform items 1 3 4 and 5 above Note item 2 is not reguired 2 Remove 4 screws holding wire basket to top cover i A88411 Fig 2 Information Plate I ALUMINUM WIRE CAUTION Aluminum wire may be used in the branch A circuit such as the circuit between the main and unit disconnect but only copper wire may be used between the unit disconnect and the unit on BDP systems Whenever aluminum wire is used in the branch circuit wiring with this unit adhere to the following recommendations Q A88412 Connections must be made in accordance with the National Electrical Code NEC using connectors approved for aluminum wire The connectors must be UL approved marked Al Cu with the UL symbol for the application and wire size The wire size selected must have a current capacity not less than that of the copper wire specified and must not create a voltage drop between the service panel and the unit in excess of 2 percent of the unit rated voltage To prepare the wire before installing the connector all aluminum wire must be brush scratched and coated with a corrosion inhibiter such as Pentrox A When it is suspected that the connection will be exposed to moisture it is very important to cover the entire connection completely to prevent an electrochemi cal action that will cause the connection to fail very quickly Do not reduce the effective size of
35. TUCK REVERSING VALVE RESTRICTED DISCHARGE TUBE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT LOAD LOOSE LEAD AT FAN MOTOR DEFROST RELAY N C CONTACTS OPEN MOTOR DEFECTIVE INCORRECT OFM CAPACITOR DEFECTIVE DEFROST THERMOSTAT COMPRESSOR RUNS BUT INSUFFICIENT COOLING LOW SUCTION PRESSURE DIRTY AIR FILTERS DUCT RESTRICTED DAMPERS PARTLY CLOSED INDOOR COIL FROSTED SLIGHTLY LOW ON REFRIGERANT LIQUID LINE SLIGHTLY RESTRICTED PISTON RESTRICTED INCORRECT SIZE PISTON INDOOR COIL STRAINER RESTRICTED INDOOR BLOWER MOTOR DEFECTIVE OR CYCLING ON OL HIGH SUCTION LOW HEAD PRESSURE REVERSING VALVE HUNG UP OR INTERNAL LEAK DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN Fig 42 Heat Pump Troubleshooting Chart Cooling Cycle I HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON A90207 HEAT PUMP TROUBLESHOOTING HEATING CYCLE NO HEATING OR INSUFFICIENT HEATING COMPRESSOR COMPRESSOR RUNS BUT RUNS CYCLES ON INSUFFICIENT INTERNAL HEATING OVERLOAD COMPRESSOR WILL NOT RUN CONTACT OPEN DEFECTIVE LOW VOLTAGE TRANSFORMER REMOTE CONTROL CENTER DEFECTIVE CONTACTOR COIL OPEN OR SHORTED OPEN INDOOR THERMOSTAT LIQ
36. UID LINE PRESSURE SWITCH OPEN LOSS OF CHARGE OPEN CONTROL CIRCUIT CONTACTOR CLOSED COMPRESSOR POWER SUPPLY LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH COMPRESSOR STUCK COMPRESSOR INTERNAL OVERLOAD OPEN OPEN SHORTED OR GROUNDED COMPRESSOR WINDINGS DEFECTIVE RUN CAPACITOR DIRTY FILTERS OR INDOOR COIL INDOOR FAN STOPPED OR CYCLING ON OVERLOAD DAMAGED REVERSING VALVE RESTRICTION IN DISCHARGE LINE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR 1 PH COMPRESSOR BEARINGS HIGH LOAD CONDITION REVERSING VALVE JAMMED IN MIDPOSITION HIGH SUPERHEAT DEFECTIVE FAN MOTOR CAPACITOR LOOSE LEADS AT FAN MOTOR FAN MOTOR BURNED OUT OUTDOOR FAN STOPPED LOOSE LEADS AT OUTDOOR FAN MOTOR INTERNAL FAN MOTOR KLIXON OPEN FAN MOTOR BURNED OUT DEFROST RELAY N C CONTACTS OPEN ON CIRCUIT BOARD FAN MOTOR CONTACTS OUTDOOR FAN RUNNING REVERSING VALVE STUCK RESTRICTED LIQUID LINE PISTON RESTRICTED OR IS CLOGGED UNDER CHARGED OUTDOOR COIL DIRTY STRIP HEATERS NOT OPERATING OUTDOOR THERMOSTAT DEFECTIVE ODT SETTING TOO LOW CAP TUBE PINCHED OR BULB NOT SENSING TRUE ODT STRIP HEATER RELAY OR CONTACTOR DEFECTIVE OPENING IN POWER CIRCUIT TO HEATER ELEMENTS BROKEN FUSE LINK STR
37. an now be operated Back seating service valves must be back seated turned counter clockwise until seated before the service port caps can be removed and hoses of gage manifold connected In this position refrigerant has access from and through outdoor and indoor unit The service valve stem cap is tightened to 20 2 ft lb torque and the service port caps to 9 2 ft lb torque The seating surface of the valve stem has a knife set edge against which the caps are tightened to attain a metal to metal seal If accessory pressure switches are used the service valve must be cracked Then the knife set stem cap becomes the primary seal The service valve cannot be field repaired therefore only a complete valve or valve stem and service port caps are available for replacement If the service valve is to be replaced a metal barrier must be inserted between the valve and the unit to prevent damaging the unit exterior from the heat of the brazing operations CAUTION Wear safety glasses and gloves when han dling refrigerants PUMPDOWN PROCEDURE Service valves provide a convenient shut off valve useful for certain refrigeration system repairs System may be pumped down to make repairs on low side without losing complete refrigerant charge 1 Attach pressure gage to suction service valve gage port 2 Front seat liquid line valve 3 Start unit in cooling mode Run until suction pressure reaches 5 psig 35kPa Do not allow comp
38. d and the triple evacuation method A Deep Vacuum Method The deep vacuum method reguires a vacuum pump capable of pulling a vacuum of 1000 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 liguid water B Triple Evacuation Method The triple evacuation method can be used where the vacuum pump is capable of pumping down to only 28 in of mercury vacuum and the system does not contain any liguid water The procedure is as follows 1 Pump the system down to 28 in of mercury vacuum and allow pump to continue to operate for additional 15 minutes 2 Close service valves and shut off vacuum pump 3 Connect a refrigerant cylinder to the system and open until system pressure is 2 psig 4 Close the service valve 5 Allow system to stand for 1 hr during which time the dry refrigerant will be able to diffuse throughout the system absorbing moisture This procedure is repeated 3 times after which the system will be free of any contaminants and water vapor XIII SYSTEM CHARGING For all approved combinations system must be charged correctly for normal system operation and reliable operation of components A CAUTION Always wear safety glasses and gloves when handling refrigerants If system has lost all charge weigh in charge using dial a charge or digital scale System charge should be fine tuned by using
39. defrost cycle in approximately 2 sec CAUTION Exercise extreme caution when shorting AN speed up pins If pins are accidentally shorted to other terminals damage to the control board will occur 10 Unit is now operating in defrost mode Check between C and W2 using voltmeter as shown in Fig 14 Reading on voltmeter should indicate 24v This step ensures defrost relay contacts have closed energizing supplemental heat W2 and reversing valve solenoid O 11 Unit should remain in defrost no longer than 10 minutes Actual time in defrost depends on how quickly speed up jumper is removed If it takes 2 sec to remove speed up jumper after unit has switched to defrost the unit will switch back to heat mode 12 After a few minutes in defrost cooling operation liquid line should be warm enough to have caused defrost ther mostat contacts to open Check resistance across defrost thermostat Ohmmeter should read infinite resistance indi cating defrost thermostat has opened at approximately 80 F 13 14 Shut off unit power and reconnect fan lead Remove jumper between DFT and R terminals Reconnect defrost thermostat leads Failure to remove jumper causes unit to switch to defrost every 30 50 or 90 minutes and remain in defrost for full 10 minutes 15 Replace control box cover Restore power to unit If defrost thermostat does not check out following above items or incorrect calibration is suspected check for a de
40. e bi flow TXV has an additional internal check valve and external tubing See Fig 39 These additions allow the refrigerant to bypass the TXV when refrigerant flow is reversed with only a 1 to 2 psig pressure drop through the device When the heat pump switches to the defrost mode the refrigerant flows through a completely open un throttled TXV and the bulb senses the residual heat of the outlet tube of the coil that had been operating in the heating mode about 85 F and 155 psig This temporary un throttled valve decreases the indoor pressure drop which in turn increases the refrigerant flow rate decreases overall defrost time and enhances defrost efficiency IX COIL REMOVAL Coils on this family of units are easy to remove if reguired for compressor removal or replacement coil A CAUTION Wear safety glasses and gloves when han dling refrigerants To remove or replace coil 1 Shut off all power to unit 2 Remove and recover refrigerant from system through ser vice valves 3 Remove top cover See Remove Top Cover section 4 Remove screws in base pan to coil grille 5 Remove coil grille from unit 6 Remove screws on corner post Reliant Endura service valve panel Cube unit holding coil tube sheet CAUTION Cut tubes to reduce the possibility of fire and personal injury 7 Use midget tubing cutter to cut liquid and vapor lines at both sides of coil Cut in convenient location for easy reassemb
41. e from system 2 Check valve design If valve is of the 3 port design and new replacement is of the 4 port design replacement of the solenoid coil and wire leads is necessary Valve bodies are interchangeable but solenoid and wires are not Three port reversing valve and solenoid coil with leads must be used together New solenoid coil cannot be used on a 3 port valve Four port reversing valve uses solenoid with quick connect terminals for leads connection Old solenoid coil cannot be used on 4 port reversing valve If for any reason a new wire cord is not available cut the leads on the old solenoid coil as close to the coil as possible Terminate the leads with 2 female 1 4 in quick connects Connect termi nals to new solenoid and tape connection to insulate and provide moisture barrier Replace these wires as soon as wire cord is available See RCD Replacement Component Catalog for proper cord part number 3 Remove solenoid coil from valve body Remove valve by cutting it from system with tubing cutter Repair person should cut in such a way that stubs can be easily rebrazed back into system Do not use hacksaw This introduces chips into system that cause failure After defective valve is removed wrap it in wet rag and carefully unbraze stubs Save stubs for future use Because defective valve is not overheated it can be analyzed for cause of failure when it is returned Braze new valve onto used stubs Keep stubs oriented cor
42. e remains 12 After a few minutes in defrost cooling operation liquid line should be warm enough to have caused defrost ther mostat contacts to open Check resistance across defrost thermostat Ohmmeter should read infinite resistance indi cating defrost thermostat has opened at approximately 80 F 13 Shut off unit power and reconnect fan lead 14 Remove jumper wire from speed up terminal and reinsert cover on speed up terminals Failure to remove jumper causes unit to speed up operating cycles continuously 15 Remove jumper between DFT and R terminals Reconnect defrost thermostat leads 16 Replace control box cover Restore power to unit If defrost thermostat does not check out following above items or incorrect calibration is suspected check for a defective thermostat as follows 1 Follow items 1 5 above 2 Using thermocouple temperature measuring device route sensor or probe underneath coil or other convenient loca tion Attach to liquid line near defrost thermostat Insulate for more accurate reading 3 Turn on power to outdoor unit 4 Restart unit in heating mode 5 Within a few minutes liquid line temperature drops within a range causing defrost thermostat contacts to close Tem perature range is from 33 F to 27 F Notice temperature at which ohmmeter reading goes from to zero ohms Thermostat contacts close at this point 6 Remove protective cover from TP1 and TP2 speed up terminals and
43. ed to pump into a vacuum The scroll compressor is capable of pumping into a vacuum very quickly which could cause fusite arcing and compressor failure See Section IV of Reciprocating Compressor section for removal and replacement HIGH VOLTAGE LOW VOLTAGE OBBE gg Ki K2 K3 Ka K5 Ke K7 2 DET1 DFT2 T o 8 888888887 18 FURN INT EIN OFF on ii BPA STAGE2 DEFROST BALANCE Q LATCH TIME POINT A93569 Fig 22 2 Speed Control Board TWO SPEED SYSTEM l CAUTIONS AND WARNINGS CAUTION For proper unit operation and reliability the 2 speed units must be installed with the factory supplied A balance port hard shut off TXV Do not install with indoor coils having piston or capillary tube metering devices CAUTION Do not install eguivalent interconnecting A tubing lengths greater than 100 ft Do not decrease or increase interconnecting tubing diameters CAUTION To avoid electrical shock bleed resistor A must be connected across run capacitor Replace if missing or damaged CAUTION Contactor is mechanically interlocked Do A not disable mechanical interlock Compressor damage may occur A WARNING Contactor control voltage is 240vac A WARNING Do not attempt to operate this eguipment below 55 F outdoor ambient temperature NOTE The sections that follow describe the 598A Series C and 698A Series
44. em charge so that pressure gages read 0 psi A CAUTION Wear safety glasses and gloves when work ing with refrigerants Apply heat with torch to solder joint and remove switch Wear safety glasses when using torch Have guenching cloth available Oil vapor in line may ignite when switch is removed Braze in 1 4 in flare fitting and screw on replacement pressure switch B High Pressure Switch Located on discharge line the high pressure switch protects against high discharge pressures caused by such events as over charge condenser fan motor failure system restriction etc It opens on pressure rise at about 435 psi If system pressures go above this setting during abnormal conditions the switch opens Do not attempt to simulate these system abnormalities as high pressures pose a serious safety hazard High pressure switch is also checked with an ohmmeter similar to checking low pressure switch If system pressure is below 435 psi the switch shows continuity It is replaced in the same manner as low pressure switch Observe all safety precautions C Liguid Line Pressure Switch Located on liguid line of heat pump only the liguid line pressure switch functions similar to conventional low pressure switch Because heat pumps experience very low suction pressures during normal system operation a conventional low pressure switch cannot be installed on suction line This switch is installed in liguid line instead and acts as loss of
45. ent and the other senses coil temperature heat pump only Refer to Fig 28 for resistance values versus temperature THERMISTOR CURVE 90 80 70 60 50 40 30 20 gt RESISTANCE KOHMS 10 0 20 40 60 80 TEMPERATURE DEG F 100 120 A91431 Fig 28 Resistance Values Versus Temperature If the outdoor ambient thermistor should fail a malfunction signal appears on the indoor thermostat and 2 speed control The control does not initiate second stage latching crankcase heater is turned on during all off cycles heating defaults to high speed and defrost initiates on demand from coil thermistor See Table 7 If the outdoor coil thermistor should fail a malfunction signal appears on the indoor thermostat and 2 speed control The control defrosts every 90 minutes of heating operation and terminates in 5 minutes See Table 7 V LED FUNCTION MALFUNCTION LIGHTS The 2 speed control is function malfunction light NOTE Only malfunction signal appears at thermostat Both function and malfunction signals appear at control board See Fig 22 for LED location Table 5 provides the function malfunction code location and definition VI TROUBLESHOOTING A Compressor Winding Check The 2 speed compressor is nothing more than 2 single phase motors within 1 compressor shell When the compressor fails to start or run there are 3 tests that can be made open ground or
46. er probe on terminals T1 T2 T3 T7 and T8 in sequence Note meter scale If any reading of zero or low resistance is obtained the motor is grounding Replace the compressor SHORT This is an extremely critical test and is not advised unless the following conditions are met The correct motor winding resistances must be known before testing See Table 8 for cold motor winding resistance The temperature of the windings must be specified 70 F 2 F The resistance measuring instrument must have an accurate ohmmeter such as a Wheatstone bridge or null balance type instrument The motor must be dry or free from direct contact with liquid refrigerant To determine if any wires have broken through their insulation and come in direct contact with each other thereby shorting all or part of the winding s 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals T1 T2 T3 T7 and T8 4 Subtract instrument probe and lead resistance from each reading If any reading is within 20 percent of the known resistance from Table 8 the motor probably does not have a short Usually a considerable difference will be noted if a turn to turn short is present B Control Board Failure The control board continuously monitors its own operation and the operation of the system The diagnostic feature allows easy troubleshooting of the control and system in the field If a failure occurs the LED light on the c
47. ervice port is not pressurized To pressurize the service port this valve must be moved off the back seating position This valve does not contain a Schrader fitting Both types of service valves are designed for sweat connection to the field tubing The service valves in the outdoor unit come from the factory front seated This means that the refrigerant charge is isolated from the line set connection ports Some heat pumps are shipped with sweat adapter tube This tube must be installed on the liquid service valve After connecting the sweat adapter to the liquid service valve of a heat pump the valves are ready for brazing The interconnecting tubing line set can be brazed to the service valves using either silver bearing or non silver bearing brazing material Consult local codes Before brazing the line set to the valves the belled ends of the sweat connections on the service valves must be cleaned so that no brass plating remains on either the inside or outside of the bell joint To prevent damage to the valve and or cap O ring use a wet cloth or other acceptable heat sinking material on the valve before brazing To prevent damage to the unit use a metal barrier between brazing area and unit After the brazing operation and the refrigerant tubing and evapo rator coil have been evacuated the valve stem can be turned counterclockwise until it opens or back seats which releases refrigerant into tubing and evaporator coil The system c
48. eter and a gage manifold Do not use mercury or small dial type thermometers as they are not adequate for this type of measurement Then use 1 of the following procedures A Superheat Charging Method 1 Operate a unit a minimum of 10 minutes before checking charge 2 Measure vapor pressure by attaching a gage to vapor valve service port 3 Measure vapor line temperature by attaching a service thermometer to unit vapor line near vapor valve On a heat pump attach to the suction tube between the accumulator and the compressor Insulate thermometer for accurate readings 4 Measure outdoor air dry bulb temperature with a second thermometer 5 Measure indoor air entering indoor coil wet bulb tempera ture with a sling psychrometer 6 Locate outdoor temperature and evaporator entering air wet bulb temperature in Table 11 At this intersection note the superheat 7 Locate superheat temperature located in previous step and vapor pressure in Table 12 At this intersection note vapor line temperature 8 If unit has a higher vapor line temperature than charted temperature add refrigerant until charted temperature is reached 9 If unit has a lower vapor line temperature than charted temperature bleed refrigerant until charted temperature is reached If outdoor air temperature or pressure at vapor valve changes charge to new vapor line temperature indicated on chart This procedure is valid independent of indoor air quanti
49. fe with control power 24v on and high voltage power off With high voltage power off attach voltmeter leads across T1 and T3 and set thermostat so that Y terminal is energized Make sure all protective devices in series with Y terminal are closed Voltmeter should read 24v across T1 and T3 With 24v still applied move voltmeter lead from T1 terminal to T2 terminal across T2 and T3 After 5 2 minutes voltmeter should read 24v indicating control is functioning normally If no time delay is encountered or device never times out change control T3 Ti T2 HN67ZA002 A91438 T1YEL T2 VIO xu Ma T2 T3 HN67ZA003 HN67PA025 A91439 A91440 Fig 8 Cycle Protector Device OPERATING OPERATING 5 TIME PEST UNS S TIME se je BLK DENOTES CLOSED CONTACTS BLK DENOTES CLOSED CONTACTS HN67ZA002 HN67PA025 HN67ZA003 HN67ZA008 A91436 A91437 Fig 9 Cycle Protector Seguence On units that have a single pole contactor the crankcase heater is wired parallel with the contactor contacts and in series with the compressor See Fig 11 When the contacts are open a circuit is V CRANKCASE HEATER Crankcase heater is a device for keeping compressor oil warm By keeping oil warm refrigerant does not migrate to and condense in compressor shell when the comp
50. fective thermostat as follows 1 Follow items 1 5 above TABLE 1 DEFROST CONTROL SPEED UP TIMING SEQUENCE FOR CES0110063 CES0130024 SPEED UP PARAMETER MINIMUM MAXIMUM NOMINAL 30 minute cycle 50 minute cycle 90 minute cycle 10 minute cycle 5 minutes O OF1 ga AR J OOOOOO e n ninin OOOOOO O R T2 Y TI a Tete nee eg A o PHE o ajojojajaja ka Fa Y EEA m CESO01 10063 HK32FA003 HK32FA006 CES0130024 5 A88404 A91444 Fig 13 Inserting Jumper Wire O co O AR Jejs a oon n n n n n gz O R T2 Y TI DFT C TEST30 50 90 E h y Es z 1511 l i z wi is capes o R y c CES0110063 HK32FA003 HK32FA006 CES0130024 A88403 A91443 Fig 14 Checking Between C and W2 2 Route sensor or probe underneath coil or other convenient 5 Within a few minutes liquid line temperature drops within location using thermocouple temperature measuring de a range causing defrost thermostat contacts to close Tem vice Attach to liquid line near defrost thermostat Insulate perature range is from 33 F to 27
51. g liquid line temperature at defrost thermostat should drop below closing set point of defrost thermostat of approximately 30 F Using ohmmeter check resistance across defrost thermostat leads Resistance of zero indicates defrost thermostat is closed and operating properly 9 Remove protective cover from TP1 and TP2 speed up terminals Install jumper wire on speed up terminals This reduces the timing sequence to 1 60 of original time See Fig 13 Since Fig 13 shows timing cycle set at 30 minutes unit initiates defrost within approximately 30 sec if setting is at 50 minutes within 50 sec 90 minutes within 90 sec When you hear the reversing valve change position remove protective cover jumper Otherwise control will terminate normal 10 minute defrost cycle in approximately 10 sec CAUTION Exercise extreme caution when shorting A speed up pins If pins are accidentally grounded damage to the control board will occur 10 Unit is now operating in defrost mode Using voltmeter check between C and W2 as shown in Fig 14 Reading on voltmeter should indicate 24v This step ensures defrost relay contacts have closed energizing supplemental heat W2 and reversing valve solenoid O 11 Unit should remain in defrost no longer than 10 minutes Actual time in defrost depends on how quickly speed up jumper is removed If it takes 3 sec to remove speed up jumper after unit has switched to defrost only 7 minutes of defrost cycl
52. g defrost control involves a series of simple steps that indicate whether or not board is defective NOTE This procedure allows the service technician to check control board and defrost thermostat for defects First troubleshoot to make sure unit operates properly in heating and cooling modes This ensures operational problems are not attributed to the defrost control board A HK32FA003 006 Defrost Control This control board utilizes screw terminals for the low voltage field wiring The board has a feature that allows the heat pump to restart in defrost if room thermostat is satisfied during defrost To troubleshoot the board perform the following items 1 Turn thermostat to OFF Shut off all power to outdoor unit 2 Remove control box cover for access to electrical compo nents and defrost control board 3 Disconnect defrost thermostat leads from control board and connect to ohmmeter Thermostat leads are the black insulated wires connected to DFT and R terminals on control board Resistance reading may be zero indicating closed defrost thermostat or infinity co for open thermo stat depending on outdoor temperature 4 Jumper between DFT and R terminals on control board as shown in Fig 12 5 Disconnect outdoor fan motor lead from OF2 Tape lead to prevent grounding Ec 6 Turn on power to outdoor unit 7 Restart unit in heating allowing frost to accumulate on outdoor coil 8 After a few minutes in heatin
53. glasses and gloves when han dling refrigerants and when using brazing torch 1 Shut off all power to unit 2 Remove and recover all refrigerant from system until pressure gages read zero psi Use all service ports 3 Disconnect electrical leads from compressor Disconnect or remove crankcase heater and remove compressor holddown bolts 4 Cut compressor from system with tubing cutters Do not use brazing torch for compressor removal Oil vapor may ignite when compressor is disconnected 5 Scratch matching marks on stubs in old compressor Make corresponding marks on replacement compressor 6 Use torch to remove stubs from old compressor and to reinstall them in replacement compressor 7 Use copper couplings to tie compressor back into system 8 Evacuate system recharge and check for normal system operation 9 Copeland CR 6 and scroll compressors have copper plated steel suction ports Excess heat during brazing will burn off copper plating See Brazing section for additional informa tion COPELAND SCROLL COMPRESSOR I FEATURES The scroll compressor pumps refrigerant through the system by the interaction of a stationary and an orbiting scroll See Fig 20 The scroll compressor has no dynamic suction or discharge valves and itis more tolerant of stresses caused by debris liquid slugging and flooded starts Due to the design of the scroll compressor the internal compression components unload equalize pressure
54. he fixed delay of 90 20 sec is completed the fan relay is de energized and fan motor stops If the wall thermostat closes during this delay the TDR is reset and the fan relay remains energized The TDR is a 24 v device that operates within a range of 15 to 30v and draws about 0 5 amps If the blower runs continuously instead of cycling off when the fan switch is set on AUTO the TDR is probably defective and must be replaced Vil PRESSURE SWITCHES Pressure switches are protective devices wired into control circuit low voltage They shut off compressor if abnormally high or low pressures are present in the refrigeration circuit Depending on unit model you may find a low and or high pressure switch in system A Low Pressure Switch Located on suction line of condensing unit only the low pressure switch protects against low suction pressures caused by such events as loss of charge low airflow across indoor coil dirty filters etc It opens on a pressure drop at about 27 psi If system pressure is above this switch should be closed To check switch turn off all power to unit disconnect leads on switch and apply ohmmeter leads across switch You should have continuity on a good switch Because these switches are attached to refrigeration system under pressure it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists If switch must be removed remove and recover all syst
55. heck for wiring errors or replace the service alarm To check for correct operation shut off circuit breaker or discon nect switch to outdoor unit while it is running Signal light on thermostat should light If this does not occur check for wiring errors or replace the service alarm XII OUTDOOR THERMOSTAT S The outdoor thermostat s is are installed in the control box The sensing bulb s remain in the control box Outdoor thermostat brings on stages of electric heat as outdoor temperature and heat pump output drops Setting at which thermostat closes is variable depending on design of system It is set at time of installation and should not be changed without good reason Up to 2 outdoor thermostats may be installed Some systems may not have any thermostat An outdoor thermostat can also be used to lock out compressor operation at low ambients in condensing unit not eguipped with low ambient control Although these devices are installed in control circuit 24v turn off all power to unit before attempting to troubleshoot thermostat Use a standard ohmmeter to check for continuity through thermo stat If you suspect thermostat is out of calibration use calibrated electronic thermometer to determine correct outdoor temperature Turn thermostat dial knob until switch closes Observe this using ohmmeter across switch Read temperature setting when switch closes It should be close to reading observed using electronic thermometer Any se
56. huts off the unit until the resistance range is acceptable See Table 6 for compressor PTC ranges TABLE 6 COMPRESSOR PTC RANGES COMPRESSOR INTERNAL PTC RESISTANCE Safe Range 77 F 1 5k to 7 8k ohms 26k to 34k ohms 8 4k to 10k ohms To trip To reset When the control turns off the outdoor unit due to out of range PTC s the unit remains off for 15 minutes with the outdoor fan running After 15 minutes the control checks the resistance every 5 minutes until it reaches the reset range During this time a malfunction signal appears on the control board If this happens remove the wires on control board at S1 and S2 and measure the resistance across the leads When the resistance reaches 8 400 to 10 000 ohms system operation may be resumed If the resistance remains outside this range a quick check of the leads at the compressor should be made Loose connections can cause inaccu rate readings If a PTC trip occurs 3 times the control will lock out the outdoor unit operation and provide malfunction signals at both the control and indoor thermostat U Pressure Switch Protection The outdoor unit is equipped with high and low pressure switches wired in series If a pressure switch opens the control provides a 5 minute time delay in outdoor unit operation with the outdoor fan running A malfunction signal appears on the control when a pressure switch opens If the switch remains open for 1 hr or longer a malfunc
57. ich speed changes occur When high speed heat pump heating is required the control provides a Y2 24 vac signal back to the thermostat to energize high speed indicator LED TABLE 4 AMBIENT TEMPERATURE FOR HIGH AND LOW SPEED OPERATION AMBIENT TEMPERATURE F High Speed Low Speed 30 or less 31 or greater 33 or less 34 or greater 40 or less 41 or greater C LED Function Lights When using the factory authorized indoor thermostats with the 2 speed outdoor units there are 2 locations where system function LED indicator lights are available The indoor thermostat provides indicator lights for high and low speed operation system mal function and auxiliary heat for heat pumps The 2 speed control board has an LED which provides signals for several system operations See Table 5 for LED functions indicator locations and definitions Table 5 also provides the order of signal importance if more than 1 signal should occur The signal to the indoor thermostat is supplied by the low voltage L lead D Three Sec Time Delay Any time the control receives a 24 v input such as Y1 or Y2 there is a 3 sec time delay before the control function is initiated This helps prevent nuisance trips and thermostat jiggling E One Minute Speed Change Time Delay When the compressor changes speeds from high to low or low to high there is a 1 minute time delay before the compressor restarts The outdoor fan motor remains running
58. indered in the other direction If indoor metering device is metering refrigerant the outdoor device by passes refrigerant and vice versa This allows both coils to serve a dual function ll LEAK DETECTION A CAUTION Always wear safety glasses and gloves when handling refrigerants New installations should be checked for leaks prior to complete charging TABLE 9 24 V PIN CONNECTION TROUBLESHOOTING TERMINAL LOCATION ON MODE OF OPERATION 18 PIN CONNECTOR DESIGNATION CONTROL BOARD VOLTAGE PATH VOLTAGE REQUIRED All R C POSSIBLE SOURCE OF PROBLEM Check transformer secondary Low speed Cooling Y1 0 C Check thermostat High speed Cooling Y1 Y2 0 C Low speed Heating Y1 C Input Check thermostat Check thermostat Y1 C Input Check thermostat High speed Heating Y2 C Output Outdoor temperature below speed change temperature Y1 C Input Check thermostat Defrost Y2 W2 0 C Output Outdoor temperature below 50 F Coil temperature less than 30 F Y1 W2 C Second Stage of Input Check thermostat Auxiliary Heat W3 Y2 C Output Check balance point setting Cooling Second stage Latching Yh Ya Oe Input 24 Ambient thermistor failure Check second stage POT T SCHEMATIC DIAGRAM HE LADDER FORM ei hi LS A VU 13
59. ing terminal will be run winding R See Fig 19 NOTE If compressor is hot allow time to cool and internal line break to reset There is an internal line break protector which must be closed B Three Phase Motors Resistance readings between all 3 sets of windings should be the same All compressors are equipped with internal motor protection If motor becomes hot for any reason protector opens Compressor should always be allowed to cool and protector to close before troubleshooting Always turn off all power to unit and disconnect leads at compressor terminals before taking readings Most common motor failures are due to either an open grounded or short circuit Directions below are specifically for single phase units however they also apply to 3 phase compressors When a single phase compressor fails to start or run 3 tests can help determine the problem First all possible external causes should be eliminated such as overloads improper voltage pressure equal ization defective capacitor s relays wiring etc Compressor has internal line break overload so be certain it is closed C Open Circuit To determine if any winding has a break in the internal wires and current is unable to pass through 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals C S and R 4 Check resistance from C R C S and R S using an ohmme ter on 0 1000 ohm scale Because winding resistances are
60. ischarge valves and 18 PLASTIC CAP BLUE SEALANT PRONG GROMMET THERMAL GREASE THERMOSTAT A90196 Fig 21 Location of Discharge Thermostat it is more tolerant of stresses caused by debris liguid slugging and flooded starts The Millennium scroll varies from the Copeland scroll in that the Millennium has a shutdown flapper valve located between the scroll plates and the discharge head whereas the Copeland has a check device at the discharge connection after the discharge head The Copeland discharge head unloads when the compressor shuts down The scroll plate actually runs backwards while it unloads A 1 to 3 second unloading of refrigerant occurs The Millennium flapper valve eliminates the refrigerant unloading by not allowing the discharge head to run backwards because of its location The Millennium scroll compressor uses Zerol 150 oil with 3 percent Syn 0 Ad and is the only oil recommended for oil recharge See Table 3 for recharge requirements I COMPRESSOR PROTECTION Millennium scroll compressors are protected by an internal line break mounted on the motor windings Internal protectors respond to overcurrent and high temperature These protectors are auto matic reset devices containing a snap action bimetal switch Ill TROUBLESHOOTING Troubleshooting mechanical and electrical problems in a scroll compressor is similar to a reciprocating compressor except that a scroll compressor should never be allow
61. ity loss must be eliminated before condemning compressor E Noisy Compressor Noise may be caused by a variety of internal problems such as loosened hardware broken mounting springs etc System prob lems such as overcharged compressor especially at start up or too much oil in compressor may also cause excessive noise Excess oil in compressor is normally encountered only after a replacement compressor has been added without purging oil from previous compressor As new compressor pumps excess oil in system returns and adds to volume already present causing noise F Compressor Leaks A CAUTION Use safety glasses and gloves when han dling refrigerants Sometimes a leak is detected at weld seam around girth of compressor or a fitting that joins compressor shell Many of these leaks can be repaired and the compressor saved if correct proce dure is followed 1 Turn off all power to unit 2 Remove and recover all refrigerant from system so that gage pressures are 0 psi 3 Clean area around leak to bare metal 4 Apply flux and repair joint with silver solder Do not use low temperature solder such as 50 50 5 Clean off excess flux check for leaks and apply paint over repaired area to prevent corrosion Do not use this method to repair a compressor leak due to severe corrosion Never attempt to repair a compressor leaking at electric terminals This type of failure reguires compressor replacement II ELECTRICAL FAI
62. ly with copper slip couplings 8 Lift coil vertically from basepan Place aside carefully 9 Reverse procedure to reinstall coil X LIQUID LINE STRAINER HEAT PUMPS ONLY The liquid line strainer is upstream of the heating piston The strainer catches debris in the liquid line during heating mode If it becomes plugged system operation and pressure become abnor mal and the compressor may become hot and cycle off on the overloads or pressure relief If the strainer must be replaced shut off all power to the unit See Fig 34 for strainer location XI ACCUMULATOR The accumulator is a device always found in heat pumps and found in some condensing unit models Under some light load conditions on indoor coils and on outdoor coil with heat pump in heating mode some liquid refrigerant is present in suction gas returning to compressor The accumulator stores liquid and allows it to boil off into a vapor so it can be safely returned to compressor Since a compressor is designed to pump refrigerant in its gaseous state introduction of liquid into it could cause severe damage or total failure of compressor The accumulator is a passive device which seldom needs replac ing Occasionally its internal oil return orifice or bleed hole may become plugged Some oil is contained in refrigerant returning to compressor It cannot boil off in accumulator with liquid refriger ant The bleed hole allows a small amount of oil and refrigerant to ente
63. mp Position 4 Model Letter New models are introduced with the letter A and subsequent major model changes are identified by changing to the next letter B then C etc Position 5 Electrical Characteristics Example J 208 230 1 Phase 60 Hertz N 208 230 208 240 1 Phase 60 Hertz P 208 230 208 240 3 Phase 60 Hertz E 460 3 Phase 60 Hertz Q 220 3 Phase 50 Hertz S 220 240 1 Phase 50 Hertz Z 380 415 3 Phase 50 Hertz Position 6 Fuel and Controls Not applicable on condensing units or heat pumps so the letter X is used to signify none Positions 7 8 and 9 Nominal Cooling Capacity in thousands Btuh Example 036 lt 36 000 Btuh or 3 ton capacity Positions 10 11 and 12 Heating Capacity Not applicable on condensing units or heat pumps so the number Zero is used to signify none Position 13 Brand Name Example A Common unit B D or P logo M BDP labeled J Common unit 50 cycle export products Position 14 Unit Series New units are introduced with the letter A and subsequent major component variations such as in compressor fan motor coil circuitor size etc are identified by changing to the next letter B then C etc Positions 15 and 16 Product Variations Example AA Standard unit Other letters For product variations from standard II SERIAL NUMBER IDENTIFICATION The unit serial number has 10 positions containing groups of numbers and a letter
64. nect capacitor from circuit Put ohmmeter on R X 10k scale Using ohmmeter check each terminal to ground use capacitor case Discard any capacitor which measures 1 2 scale deflection or less Place ohmmeter leads across capacitor and place on R X 10k scale Meter should jump to a low resistance value and slowly climb to higher value Failure of meter to do this indicates an open capacitor If resistance stays at zero or a low value capacitor is inter nally shorted A91455 Fig 5 Capacitors 2 Capacitance testers are available which read value of capacitor If value is not within 10 percent value stated on capacitor it should be changed If capacitor is not open or shorted the capacitance value is calculated by measuring voltage across capacitor and current it draws WARNING Exercise extreme caution when taking readings while power is on Electrical shock can cause personal injury or death Use following formula to calculate capacitance amps volts 3 Remove any capacitor that shows signs of bulging dents or leaking Do not apply power to a defective capacitor as it may explode A Start Capacitors and PTC Devices Sometimes under adverse conditions a standard run capacitor in a system is inadequate to start compressor In these instances a start assist device is used to provide an extra starting boost to compres sor motor The first device is called a positive temperature coefficient PTC or thermistor
65. ng pumped there is no return gas to cool compressor motor It eventually overheats and shuts off on its internal protection C Runs Does Not Pump High to Low Side Leak In this type of failure compressor motor runs and turns compres sor and compressor is pumping Usually an internal problem such as blown head gasket or broken internal discharge line causes compressor to pump hot discharge gas back into its own shell rather than through system Using pressure gages on service valves shows high suction and low discharge pressure readings Motor currents are lower than normal Because hot gas is being discharged into shell the shell becomes hot The hot gas causes compressor motor to cycle off on its internal protection D Runs and Pumps Low Capacity This failure type is difficult to pinpoint because extent of damage varies Compressor is a pump with internal valves that enable compressor to pump properly The cylinder has a set of suction and discharge valves Any of these parts may become damaged or broken causing loss in pumping capacity Severity of damage determines amount of capacity loss Use pressure gages to find any abnormal system pressures if system charge and other conditions are normal An owner may complain that a unit is not handling the building s heating or cooling load The compressor current draw may be abnormally low or high Although this type of failure does occur all other possible causes of capac
66. oastal filter see pre sale literature for acces sory listing Special maintenance requirements are as follows 1 Frequent inspection of coil and base pan especially after storms and or high winds 2 Cleaning coil by flushing out sand from between coil fins and out of base pan as frequently as inspection determines necessary 3 Protecting the unit in off season with cover that allows air to circulate through but prevents sand from sifting in such as canvas material Do not use plastic as plastic will hold moisture AIR CONDITIONER TROUBLESHOOTING CHART NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN CONTACTOR OPEN POWER SUPPLY DEFECTIVE LOW VOLTAGE TRANSFORMER OPEN THERMOSTAT OPEN CONTROL CIRCUIT LOSS OF CHARGE CONTACTOR OR COIL DEFECTIVE LOOSE ELECTRICAL CONNECTION CONTACTOR CLOSED COMPRESSOR POWER SUPPLY OPEN LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH OPEN SHORTED OR GROUNDED COMPRESSOR MOTOR WINDINGS COMPRESSOR STUCK COMPRESSOR INTERNAL PROTECTION OPEN DEFECTIVE RUN CAPACITOR COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD LOOSE LEAD AT FAN MOTOR OUTDOOR A RESTRICTED MOTOR RECIRCULATI DEFECTIVE RESTRICTED INCORRECT DISCHARGE OFM TUBE CAPACITOR OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH
67. of less than 14 amps will require 2 passes through the metallic loop Refer to Fig 16 or 17 for wiring connections for service alarm or service alarm with solid state cycle protector accessories when used NOTE The wire from the X terminal on the service alarm to L on the outdoor terminal board indoor terminal board and thermostat subbase is field supplied and wired when using defrost controls HK32FA003 or HK32FA006 When defrost control CES0110063 or CES0130024 is used field supplied wire from X terminal on service alarm to L on indoor thermostat subbase is required Service alarm requires 2 inputs It must sense a 24 v input from thermostat As thermostat calls for heating or cooling it supplies 24v to service alarm device 2 A current transformer or induction loop similar to a clamp on ammeter senses current draw in the compressor lead Induction loop must sense a minimum current draw when thermostat is calling for heating or cooling NOTE On a single phase compressor induction loop senses current in common leg On a 3 phase compressor induction loop senses current in any 1 of the phases ije WARNING If service alarm needs replacing shut off A all power to unit before attempting removal Electrical shock can cause personal injury or death Troubleshooting service alarm device is easy With thermostat calling for heating or cooling and compressor running indoor thermostat light should be off If on c
68. on Furnace interface Electric heat staging B Header Pin Housing The header pin housing is the plastic assembly which holds the stripped lead ends for field connections The 2 speed control receives the 24 vac low voltage control system inputs through the housing pins The housing also contains jumpers which the control uses for system configuration such as heat pump versus air conditioner See Fig 26 for header pin housing configurations C TRANSFORMER COMMON R TRANSFORMER LINE W2 FIRST STAGE AUXILIARY HEAT O REVERSING VALVE Y2 SECOND STAGE COOLING HEAT PUMP Y1 FIRST STAGE COOLING HEAT PUMP 9 W3 SECOND STAGE AUXILIARY HEAT oN o 0 fF WO MN 10 L MALFUNCTION LIGHT 11 4 TON 12 i IF NO JUMPER IS INSTALLED s ron DEFAULT IS 3 TON 14 15 16 17 JUMPER FOR 18 HEAT PUMP ONLY A93577 Fig 26 Header Pin Housing C Two Speed Compressor The 2 speed compressor contains motor windings that provide low speed 4 pole 1750 rpm and high speed 2 pole 3500 rpm operation Refer to Fig 27 to determine which windings are energized at each speed Refer to Compressor Winding Check section under Troubleshooting and Table 8 for appropriate
69. on the underside of the diaphragm via the pushrods which tends to close the valve Therefore bulb pressure equals evaporator pressure at outlet of coil plus spring pressure If the load increases the temperature increases at the bulb which increases the pressure on the topside of the diaphragm which pushes the pin carrier away from the seat opening the valve and increasing the flow of refrigerant The increased refrigerant flow causes increased leaving evaporator pressure which is transferred via the TABLE 10 TXV SUPERHEAT SETTING AT OUTLET OF EVAPORATOR COIL INSTALLATION Field Accessory TXV TYPE RPB HSO PRODUCT USAGE Air Conditioner Indoor Unit SUPERHEAT SETTING RPB HSO Field Accessory Heat Pump Indoor Unit Field Accessory Factory Installed HSO Indoor Fan Coil Unit Factory Installed HSO 2 Speed Heat Pump Outdoor Unit Factory Shipped Field Installed HSO 2 Speed Indoor Unit egualizer tube to the underside of the diaphragm This tends to cause the pin carrier spring pressure to close the valve The refrigerant flow is effectively stabilized to the load demand with negligible change in superheat The bi flow thermostatic expansion valve is used on split system heat pumps In the cooling mode the TXV operates the same as the standard TXV previously explained See Fig 38 However when the system is switched to the heating mode of operation the refrigerant flow is reversed Th
70. ontrol logic for the defrost function is the standard time and temperature initiated time or temperature terminated Defrost occurs only at outdoor temperatures less than 50 F The control initiates defrost when the outdoor coil thermistor is 30 F 2 or less and the selected defrost time interval has been accumulated during unit operation Termination occurs when the coil thermistor reaches 80 F 5 or the defrost period reaches a maximum of 10 minutes Defrost always occurs in high speed unless the stage 2 latch POT is set at ZONE During defrost the unit operates in high speed energizes the reversing valve O and auxiliary heat W2 and de energizes the outdoor fan Upon termination there is a 20 sec delay in the outdoor fan being energized If the stage 2 latch POT is set to ZONE and the heat pump is in low speed it defrosts in low speed N Field Initiated Forced Defrost By placing a jumper across the speed up terminals for a minimum of 5 sec and then removing it the unit initiates a defrost cycle See Fig 23 The cycle occurs only if the outdoor ambient is less than 50 F regardless of outdoor coil temperature The cycle terminates when the coil thermistor reaches 80 F 5 or the defrost period reaches a maximum of 10 minutes O Furnace Interface This feature provides a heat pump lock out upon a demand for auxiliary heat W2 and must be used when interfacing a heat pump with a gas oil furnace Field selection of
71. ontrol will flash a failure code If the failure is internal to the control board the light will stay on continuously no flash Before replacing control board reset the 24 v power If the fault clears check to ensure the indoor and outdoor unit and electrical service are properly grounded If the entire system is grounded the control board should be replaced as the control is not field reparable If the control board light is flashing see LED and Table 5 for function malfunction definition Cycling 24 vac to control board resets previous error messages and any lockouts which have occurred See Table 9 for more informa tion regarding control board operation C Control Board Power Inputs and Outputs See Fig 22 and 26 for inputs and outputs D Bleed Resistor The bleed resistor is a 150k 2 watt resistor across the compressor run capacitor to protect service technician from injury by electrical shock Capacitor will bleed off approximately 1 minute after power to outdoor unit is turned off If run capacitor is changed out be sure to place bleed resistor on new capacitor If bleed resistor is damaged replace resistor E Start Capacitor and Relay The 2 speed system has a second start relay in the control box One start relay is for low speed start and the second is for high speed start Both start relays use a common start capacitor When servicing this equipment be certain system starts in both low and high speed operation L1
72. ot have This thermostat is mounted in a well in the top of the compressor shell to sense if the discharge temperature reaches 290 F and shuts down the compressor to prevent damage to the compressor When the temperature of the TABLE 3 COMPRESSOR OIL RECHARGE RECHARGE FL OZ COMPRESSOR MODEL OIL TYPE Carlyle J Type SUNISO 3GS Copeland CRG3 CRH3 CRJ3 CRK3 CRL3 CRN5 CRP5 CRT5 CTH1 CTL1 CTM1 CRC4 CRZ4 CR16K6 THROUGH CR42K6 ZR18K1 ZR23K1 ZR28K1 ZR34K1 ZR40K1 ZR49K1 PFV ZR49K2 TF5 ZR49K2 TFD ZR61K2 PFV ZR61K2 TF5 ZR61K2 TFD Tecumseh AV AW AG Millennium SUNISO 3GS SUNISO 3GS sc Zerol 150 w 3 percent SR Syn 0 Ad Copeland scrolls are charged initially with Sontex 200LT white oil Since this oil is not commercially available use 3GS thermostat reaches 140 F power is restored to the compressor To determine if the thermostat is operating properly attach the thermocouple of an electronic thermometer to the dome of the compressor near the thermostat or remove the thermostat and place the thermocouple inside the well The electronic thermom eter must be capable of reading at least 300 F Start the unit and let it run for at least 15 minutes to obtain normal operating conditions Watch the thermometer to see if it is approaching 270 F If your thermocouple is located on the dome near the discharge thermo stat there could be a
73. oting this device with power on The easiest method of troubleshooting is to apply voltmeter across crankcase heater leads to see if heater has power Do not touch heater Carefully feel area around crankcase heater If warm crankcase heater is probably functioning Do not rely on this method as absolute evidence heater is functioning If compressor has been running the area will still be warm With power off and heater leads disconnected check across leads with ohmmeter Do not look for a specific resistance reading Check for resistance or an open circuit Change heater if an open circuit is detected Some crankcase heaters in this series of units are equipped with a crankcase heater switch installed in series with heater This energy saving device shuts off power to heater when temperatures are high enough that heater is not needed Be sure this switch is functioning normally before condemning crankcase heater VI TIME DELAY RELAY The time delay relay TDR is a solid state controlled recycle delay timer which keeps the indoor blower operating for 90 sec after thermostat is satisfied This delay enables the blower to remove residual cooling in the coil after compression shutdown thereby improving the efficiency of the system The sequence of uM operation is that on closure of the wall thermostat and at the end of a fixed on delay of 1 sec the fan relay is energized When the thermostat is satisfied an off delay is initiated When t
74. r the return line where velocity of refrigerant returns it to compressor If bleed hole plugs oil is trapped in accumulator and compressor will eventually fail from lack of lubrication If bleed hole is plugged accumulator must be changed Bleed hole is so tiny that cleaning efforts are usually not successful The accumu lator has a fusible element located in the bottom end bell See Fig 40 This fusible element melts at 430 F and vents the refrigerant if this temperature is reached either internal or external to the system If fuse melts the accumulator must be replaced es 430 FUSE ELEMENT A88410 Fig 40 Accumulator To change accumulator 1 Shut off all power to unit 2 Remove and reclaim all refrigerant from system NOTE Coil may be removed for access to accumulator Refer to appropriate sections of service manual for instructions CAPILLARY TUBE A DIAPHRAGM BYPASS TXV x PUSHRODS zz FEEDER TUBES Sed a INLET 1 KA gt OUTLET gt Ne COIL i IW NEEDLE VALVE l SPRING Wi a Nes Mm BULB i CHECK VALVE CLOSED Pes BYPASS TUBE EXTERNAL EQUALIZER TUBE A88406 Fig 38 TXV in Cooling Mode CAPILLARY TUBE A
75. re is higher than indicated or remove refrigerant if necessary but clean at least once each heating heat pump temperature is lower Allow a tolerance of 3 F only and cooling season XV CARE AND MAINTENANCE 2 Check fan motor and blade for cleanliness each heating and To assure high performance and minimize possible equipment cooling season and clean as necessary malfunction it is essential that maintenance be performed periodi cally on this equipment The frequency with which maintenance is performed is dependent on such factors as hours of operation geographic location and local environmental conditions 3 Check electrical connections for tightness and controls for proper operation each heating heat pump only or cooling season and service as necessary WARNING Disconnect all electrical power to unit before performing any maintenance or service on outdoor unit Remember to disconnect power supply to air handler as this unit supplies low voltage power to the outdoor unit Electric shock can cause personal injury or death The minimum maintenance that should be performed on this equipment is as follows CAUTION Because of possible damage to the equip ment or personal injury maintenance should be per formed by qualified personnel only A Coil Cleaning 1 Remove top cover See Remove Top Cover section TABLE 13 SUBCOOLING AT LIGUID SERVICE VALVE FOR UNITS PRODUCED THROUGH DECEMBER 1992 RELIANT ENDURA AIR C
76. rectly Scratch corresponding matching marks on old valve and stubs and on new valve body to aid in lining up new valve properly When brazing stubs into valve protect valve body with wet rag to prevent overheating 5 Use slip couplings to install new valve with stubs back into system Even if stubs are long wrap valve with a wet rag to prevent overheating 6 After valve is brazed in check for leaks Evacuate and charge system Operate system in both modes several times to be sure valve functions properly Vil THERMOSTATIC EXPANSION VALVES TXV The types of thermostatic expansion valves used in condensing unit and heat pump systems are as follows Rapid Pressure Balance RPB Has a special bleed port that allows rapid bleed through of pressure after system shutdown until pressure equalization occurs within approximately 1 to 2 minutes Hard Shut off HSO Has no bleed port and allows no bleed through after system shutdown No pressure equalization occurs Because of unequalized system pressures a start capacitor and relay must be installed on single phase reciprocating compressors to start the compressor See Table 10 for thermostatic expansion valve superheat settings These settings are factory set and are not field adjustable Table 10 settings are for BDP approved accessories and factory installed TXV s only NEW SOLENOID COIL 4 PORT DESIGN A91456 Fig 35 Reversing Valve FROM INDOOR COIL VIA SERVICE V
77. removed X FAN MOTORS Fan motor rotates the fan blade that either draws or blows air through outdoor coil to perform heat exchange Motors are totally enclosed to increase reliability This also eliminates need for rain shield For the correct position of the fan blade assembly see Fig 15 and Table 2 WARNING Turn off all power to unit before servicing AJ replacing fan motor Be sure unit main power switch is turned off Failure to do so may result in electric shock death or injury from rotating fan blade The bearings are permanently lubricated therefore no oil ports are provided For suspected electrical failures check for loose or faulty electrical connections or defective fan motor capacitor Fan motor is equipped with thermal overload device in motor windings which may open under adverse operating conditions Allow time for motor to cool so device can reset Further checking of motor can be done with an ohmmeter Set scale on R X 1 position check for continuity between 3 leads Replace motors that show an open circuit in any of the windings Place 1 lead of ohmmeter on each motor lead At same time place other ohmmeter lead on motor case ground Replace any motor that shows resistance to ground signs of arcing burning or overheating BASKET TOP TABLE 2 FAN POSITION Fan Motor Part No Fan Blade Part No A91428 BASKET TOP Dimension A In Brookside Revcor HC29GE208 L
78. ressor is off This prevents completed from the line side of the contactor through the flooded starts which can damage compressor crankcase heater through the run windings of the compressor and Crankcase heaters come in 2 basic types wraparound bellyband to the other side of the line When the contacts are closed there is type that is wrapped externally around compressor shell and no circuit through the crankcase heater because both leads are insertion type that is inserted into compressor oil well in shell of connected to the same side of the line This allows the heater to compressor Both types are used in outdoor units operate when the system is not calling for heating cooling The cp CUT YELLOW WIRE BETWEEN CONTACTOR AND LOW PRESSURE SWITCH ERAS SAFETY vc __ VEL GonTRoLJ YEL TERMINAL YEL BOARD CONNECTION LOGIC DU LA vu XeX BRN 4C VI TERMINAL 8 BOARD CONNECTION T3 BLK T2 A88415 Fig 10 Cycle Protector Wiring heater does not operate when the system is calling for heating cooling On units with 2 or 3 pole contactors the crank case heater is connected to the line side of the contactor and is not controlled by the contactor contacts DSV A CH 99 23 1 21 A91426 Fig 11 Wiring for Single Pole Contactor The crankcase heater is powered by high voltage power of unit Use extreme caution troublesho
79. ressor manufac turer Connect wires with insulated probes to each terminal Touch probes to each side of run capacitor 4 Energize and start compressor then pull probes away after 3 sec 5 Discharge start capacitor 6 Run compressor 10 minutes Stop and allow to sit idle for 5 minutes 7 Check system pressure equalization 8 Attempt to restart without capacitance boost If compressor does not start after several attempts add proper auxiliary start capacitor and relay If PTC thermistor device is inadequate as start device a start capacitor and relay may be added to system to ensure positive start Capacitor is wired in parallel with run capacitor through normally closed set of contacts on a device called start relay The relay coil EN 220 V FROM UNIT CONTACTOR START BOOST CAPACITOR A88349 Fig 7 Capacitance Boosting is wired across start and common terminals of compressor The added capacitance gets the compressor started As compressor comes up to speed voltage across start and common terminals increases to a value high enough to cause start relay to energize This opens normally closed contacts and removes start capacitor from circuit In actual practice this occurs in a fraction of a sec NOTE If bleed resistor is wired across start capacitor it must be disconnected to avoid erroneous readings when ohmmeter is applied across capacitor To check start relay and capacitor 1 Turn off all power
80. ressor to pump to a vacuum 4 Shut unit off Front seat suction valve NOTE All outdoor unit coils will hold only factory supplied amount of refrigerant Excess refrigerant such as in long line applications may cause unit to relieve pressure through internal pressure relief valve indicated by sudden rise of suction pressure before suction pressure reaches 5 psig 35kPa If this occurs shut off unit immediately front seat suction valve and recover remain ing pressure SERVICE PORT W SCHRADER CORE STEM SEAT FORGED FRONT SEATING VALVE A91448 FIELD STAINLESS STEEL NU STEM d SERVICE PORT ENTRANCE BACK SEAT A FRONT SEAT POSITION FIELD SIDE FORGED BACK SEATING VALVE A91435 STEM SERVICE PORT W SCHRADER CORE BAR STOCK FRONT SEATING VALVE A91447 Fig 33 Service Valves V CHECK FLO RATER BYPASS TYPE HEAT PUMPS ONLY Check Flo Rater piston has a refrigerant metering hole through it The retainer forms a stop for piston in refrigerant bypass mode and a sealing surface for liguid line flare connection See Fig 34 To check clean or replace piston A Reliant Endura Products Except 1992 Production 1 Shut off power to unit 2 Pump unit down using pumpdown procedure described in this service manual
81. roup as shown in Fig 18 You will notice that for the Carlyle and Bristol compressors in Fig 18 the triangle formed by the fusite terminals points down and the plug is likewise oriented The fusite terminals and plug terminal orientation shown for the Tecumseh compressor is shown with the triangle formed by the terminals pointing toward the top The configuration around the fusite terminals is the outline of the terminal covers used on the specific compressors The slot through which the wires of the plug are routed is oriented on the bottom or slightly to the left or right The correct plug can be connected easily to the compressor terminals and plug wires routed easily through the slot in the terminal cover Therefore if a Carlyle or Bristol compressor is substituted for a Tecumseh compressor a new plug must be installed If the plug is not changed proper connection and routing of the plug wires through the terminal cover will be impossible XIV LOW VOLTAGE TERMINALS The low voltage terminal designations and their description function are used on all split system condensers and heat pumps G Energizes blower circuit from indoor thermostat E Energizes emergency heat relay W2 Energizes first stage supplemental heat through defrost relay wht L Energizes light on thermostat with service alarm W3 Energizes second or third stage supplemental heat R Energizes 24 v power from transformer red Y Energizes contac
82. short This compressor has no internal line break overload however it does have PTC motor protectors See Compressor PTC Overload Protection section for PTC overload information NOTE To ensure accurate ohm measurements place ohmmeter probes on flat surface of compressor terminal tabs not the brass mounting screw OPEN To determine if a winding has an actual break in the internal wires and current is unable to pass through equipped with an LED 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals Tl T2 T3 T7 and T8 4 Use an ohmmeter on 0 1000 ohm scale to check resistance See Fig 27 29 and 30 and Table 8 Because winding resistances are usually less than 10 ohm each reading will appear to be approximately zero ohm If during any check the resistance remains at 1000 ohm an open or break exists and the motor or compressor should be replaced GROUND To determine if any wire has broken and come in direct contact with the housing or shell causing a direct short to ground 1 Be sure all power is off 23 2 Discharge all capacitors Remove wires from T1 T2 T3 T7 and T8 Allow crankcase heater to remain on for several hours before checking motor to ensure that windings are not saturated with refrigerant AU 5 Using an ohmmeter on R X 10 000 ohm scale place 1 meter probe on ground motor or compressor frame Make a good metal to metal contact Place oth
83. stat leads are the black insulated wires connected to DFT and R terminals on control board Resistance reading may be zero indicating closed defrost thermostat or infinity co for open thermo stat depending on outdoor temperature Jumper between DFT and R terminals on control board as shown in Fig 12 5 Disconnect outdoor fan motor lead from OF2 Tape lead to prevent grounding 6 Turn on power to outdoor unit 7 Restart unit in heating mode allowing frost to accumulate on outdoor coil 8 After a few minutes in heating mode liquid line tempera ture at defrost thermostat should drop below closing set point of defrost thermostat of approximately 30 F Check resistance across defrost thermostat leads using ohmmeter Resistance of zero indicates defrost thermostat is closed and operating properly 10 O OF1 R T2 Y IDE LEA xa sal MI 2 m O ooo o R w2 Y c CES01 10063 CES0130024 A91442 9 Short between the speed up terminals using a thermostat screwdriver This reduces the timing sequence to 1 256 of original time See Fig 13 and Table 1 NOTE Since Fig 13 shows timing cycle set at 90 minutes unit initiates defrost within approximately 21 sec When you hear the reversing valve change position remove screwdriver immediately Otherwise control will terminate normal 10 minute
84. stributor branch Some compressor electrical failures can cause motor to overheat When this occurs byproducts which include sludge carbon and acids contaminate system If burnout is severe enough system must be cleaned before replacement compressor is installed The 2 types of motor burnout are classified as mild or severe In mild burnout there is little or no detectable odor Compressor oil is clear or slightly discolored An acid test of compressor oil will be negative This type of failure is treated the same as mechanical failure Liquid line strainer should be removed and liquid line filter drier installed In a severe burnout there is a strong pungent rotten egg odor Compressor oil is very dark Evidence of burning may be present in tubing connected to compressor An acid test of compressor oil will be positive Complete system must be reverse flushed with refrigerant Check Flo Rater or TXV must be cleaned or replaced In a heat pump accumulator and reversing valve are replaced These components are also removed and bypassed during reverse flushing procedure Remove and discard liquid line strainer After system is reassembled install liquid and suction line filter driers Run system for 2 hrs Discard both driers and install new liquid line drier only IV COMPRESSOR REMOVAL AND REPLACEMENT Once it is determined that compressor has failed and the reason established compressor must be replaced A CAUTION Wear safety
85. sts and during cooling season reducing period of heat discomfort HIGH AND OR LOW PRESSURE AND OR DISCHARGE TEMPERATURE SWITCH IF USED pare o DTS HPS LPS 9 ba BLU YEL YEL fT JA ORN YEL RED 24 VOLT WIRING BRN L BLK THERMOSTAT INDOOR OUTDOOR SUBBASE UNIT UNIT TERMINAL TERMINAL BOARD BOARD UNITS WITH NAMEPLATE PASS SUPPLY WIRE THROUGH METALLIC LOOP TWICE ON RLA OF 14 AMPS OR LESS METALLIC 4 X ONE FIELD LOOP ZO D 8 amp SERVICE ALARM Z E S LINE VOLTAGE SUPPLY WIRE A88340 Fig 16 Service Alarm Wiring Connections The service alarm is an accessory device Service alarm locks out compressor under certain adverse operating conditions System is manually reset by shutting it off at thermostat subbase then turning it back on If adverse condition is corrected system restarts One example of an adverse condition would be a system located in a desert climate where high operating temperatures may cause system to shut down on the high pressure switch or on the compressor internal overload Connect service alarm to outdoor unit control circuit terminal board See Fig 16 and wiring diagram on unit Connect all field line power wires to unit in usual manner Route field line power supply wire through metallic loop on bottom of service alarm then to normal unit connection Units with RLA
86. tages of indoor thermostat holding room temperature closer to set point To utilize this function the unit capacity should be plotted versus the heat gain of the structure which provides the system s balance point when the structure requires high speed capacity See Fig 24 20 HIGH SPEED BALANCE POINT CTURE NCE POINT BTU 1000 S LOW SPEED BALANCE POINT 50 60 70 80 90 100 110 120 TEMPERATURE F A91282 Fig 24 Typical Cooling Balance Points Second stage latching can be selected by rotating the potentiom eter POT to the desired outdoor second stage latching tempera ture See Fig 23 The temperatures that can be selected are 85 90 95 100 and 105 F The POT is factory set at 105 F K Zone Selection If the stage 2 latch POT is set to ZONE position the compressor operating speed in either heat or cool mode is determined by the Y1 and or Y2 inputs The system operates in low speed with a Y1 input and high speed with Y2 or Y1 and Y2 input This allows the multistage zoning system to determine what speed is needed regardless of outdoor temperature or switchover point L Defrost Time Selection The defrost interval can be field selected depending on local or geographic requirements It is factory set at 90 minutes and can be changed to either 30 or 50 minutes by rotating the defrost time POT See Fig 23 M Defrost The 2 speed c
87. th other wires thereby shorting all or part of the winding s be sure the following conditions are met 1 Correct motor winding resistances must be known before testing either from previous readings or from manufactur er s specifications 2 Temperature of windings must be as specified usually about 70 F 3 Resistance measuring instrument must have an accuracy within 5 10 percent This requires an accurate ohmmeter such as a Wheatstone bridge or null balance type instru ment 4 Motor must be dry or free from direct contact with liquid refrigerant F Make This Critical Test Not advisable unless above conditions are met 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals C S and R 4 Place instrument probes together and determine probe and lead wire resistance 5 Check resistance readings from C R C S and R S 6 Subtract instrument probe and lead resistance from each reading If any reading is within 20 percent of known resistance motor is probably normal Usually a considerable difference in reading is noted if a turn to turn short is present Ill SYSTEM CLEAN UP AFTER BURNOUT CAUTION Turn off all power to unit before proceed ing Wear safety glasses and gloves when handling refrigerants Acids formed as a result of motor burnout can cause burns NOTE To analyze level of suspected contamination from com pressor burnout use Total Test See your di
88. that indicate specific information about the unit Listed below is the breakdown of the 10 positions Positions 1 and 2 Week of Manufacture Example 01 First week of a year 52 Last week of a year Positions 3 and 4 Year of Manufacture Example 94 1994 Position 5 Manufacturing Site Example A Indianapolis E Collierville Positions 6 through 10 Serial Number CABINET Certain maintenance routines and repairs require removal of cabinet panels There are 4 basic cabinet designs for air condition ers and heat pumps See Fig 1 I REMOVE TOP COVER RELIANT ENDURA PRODUCTS PRIOR TO JANUARY 1992 1 Turn off all power to outdoor and indoor units 2 Remove screws holding top cover to coil grille and corner posts 3 Remove access panel 4 Remove information plate 5 Disconnect fan motor wires cut wire ties and remove wire ties from control box Refer to unit wiring label 6 Lift top cover from unit 7 Reverse sequence for reassembly Il REMOVE FAN MOTOR ASSEMBLY RELIANT ENDURA PRODUCTS PRIOR TO JANUARY 1992 Perform items 1 through 6 above Remove nuts holding fan motor top cover Remove motor and fan blade assembly Reverse sequence for reassembly nF v bp Prior to applying power check that fan rotates freely Ill INFORMATION PLATE RELIANT ENDURA PRODUCTS The information plate is secured to the front of the control box and provides a cover for it See Fig 2
89. the superheat or subcooling method whichever is appropriate These methods are covered in the Checking Charge section below NOTE Heat pump check charts are for checking charge and performance and for adding a small amount of charge During heating mode correct method of charging is the weight method In 32 heating mode check should be made approximately 15 minutes after a defrost with unit running with a clean coil In cooling cycle system should run at least 10 minutes for temperatures and pressures to stabilize All charts assume there are no system abnormalities and indoor coil airflows are correct If system abnormalities exist correct them before checking system charge XIV CHECKING CHARGE Superheat charging is the process of charging refrigerant into a system until the temperature superheat of the suction gas entering the compressor reaches a prescribed value Small variations of charge affect suction gas superheat temperatures greatly There fore this method of charging is very accurate This method can be used only on split system condensing units and heat pumps operating in the cooling mode with fixed restrictor type metering devices such as Check Flo Rater cap tube etc For units using a TXV the subcooling method must be used Heat pumps must be operating in the cooling mode To charge by superheat a service technician needs an accurate superheat thermocouple or thermistor type thermometer a sling psychrom
90. tion signal is provided at the L terminal of the indoor thermostat Ill FACTORY DEFAULTS Factory defaults have been provided in the event of failure of the ambient thermistor outdoor coil thermistor and or furnace inter face jumper Refer to Table 7 for default and function IV MAJOR COMPONENTS A Two Speed Control The 2 speed control board controls the following functions High and low compressor contactor operation Outdoor fan motor operation Crankcase heater operation Compressor protection Pressure switch monitoring e Second stage latching TABLE 7 FACTORY DEFAULTS FAILED COMPONENT FUNCTION Crankcase Heater DEFAULT Energized during any off cycle Second Stage Latching Does not function Furnace Interface Balance point does not function but interface still energizes furnace and locks out heat pump with a call for w2 Ambient Thermistor Heating Switchover Speed Point Unit only runs in high compressor speed Defrost Initiation Defrost is initiated based on coil tem perature only Outdoor Thermostat for Auxiliary Heat Anytime there is a call for W2 W3 is also energized Outdoor Coil Thermistor Defrost Initiation and Termination Defrost occurs at each time interval but terminates after 5 minutes Furnace Interface Jumper Time delays e 5 minute time delay speed up bypass Heat pumps Time temperature defrost Defrost interval selecti
91. to unit 2 Discharge start and run capacitors as outlined earlier 3 Most start capacitors will have a 15 000 ohm 2 watt bleed resistor Disconnect these devices from system Start capacitor can be inspected visually It is designed for short duration or intermittent duty If left in circuit for prolonged period start capacitor blows through a specially designed bleed hole If it appears blown check for welded contacts in start relay Start capacitor can be checked by ohmmeter method discussed earlier Start relay is checked with ohmmeter Check for continuity across coil of relay You should encounter a high resistance Since relay contacts are normally closed you should read low resistance across them Both PTC device and capacitor relay start system are standard eguipment on some of these units They are also available as accessories and may be field installed IV CYCLE PROTECTOR Solid state cycle protector device protects unit compressor by preventing short cycling After a system shutdown cycle protector provides for a 5 2 minute delay before compressor restarts On normal start up a 5 minute delay occurs before thermostat closes After thermostat closes cycle protector device provides a 3 sec delay on HN67PA025 HN67ZA003 and HN67ZA008 See Fig 8 9 and 10 Cycle protector device is simple to troubleshoot Only a voltmeter capable of reading 24v is needed Device is in control circuit therefore troubleshooting is sa
92. tor for first stage cooling or first stage heat ing for heat pumps yel O Energizes reversing valve on heat pumps orn C Common side of transformer blk RECIPROCATING COMPRESSOR The compressor is the heart of the refrigeration system It pumps refrigerant through the system If it malfunctions system capacity and efficiency could be negatively affected 14 CAUTION The compressor is an electrical as well as mechanical device Exercise extreme caution when working near compressors Power should be shut off if A possible for most troubleshooting technigues Refriger ants in system present other safety hazards Always wear safety glasses and gloves when handling refrigerants Compressor failures are classified in 2 broad failure categories mechanical and electrical Both types are discussed below l MECHANICAL FAILURES A compressor is a mechanical pump driven by an electric motor contained in a welded or hermetic shell In a mechanical failure motor or electrical circuit appears normal but compressor does not function normally CAUTION Exercise extreme caution when reading compressor currents when high voltage power is on Correct any of the problems described below before installing and running a replacement compressor Wear safety glasses and gloves when handling refrigerants A Locked Rotor In this type of failure compressor motor and all starting compo nents are normal When compressor
93. tting within 5 F is acceptable XIII COMPRESSOR PLUG The compressor electrical plug provides a quick tight connection to the compressor terminals The plug completely covers the compressor terminals and the mating female terminals are com pletely encapsulated in the plug Therefore the terminals are FIELD LINE VOLTAGE SUPPLY WIRE Le CYCLE PROTECTOR 19 2 03 YEL HIGH AND OR LOW PRESSURE AND OR DISCHARGE TEMPERATURE VIO BLK SWITCH IF USED e ORN L L ee lt 2 2 ZA D L DTS ee JO YEL OU YE c BU Z BLU L fo BK LPS HPS C BLK G BRN BRN A88339 THERMOSTAT INDOOR OUTDOOR SUBBASE UNIT __UNIT COMMON POTENTIAL TERMINAL TERMINAL FACTORY WIRING FIELD CONNECTED BOARD BOARD FIELD SUPPLIED WIRING C CONTACTOR A88339 Fig 17 Wiring Connections for Service Alarm and Cycle Protector isolated from any moisture so corrosion and resultant pitted or discolored terminals are reduced The plug is oriented to the relief slot in the terminal box so the cover cannot be secured if wires are not positioned in slot assuring correct electrical connection at the compressor The plug can be removed by simultaneously pulling while rocking the plug However these plugs are specialized and vary in terminal orientation in the plug Therefore plugs can be used on only the specific compressor or g
94. ty B Subcooling Charging Method 10 1 Operate unit a minimum of 15 minutes before checking charge 2 Measure liquid service valve pressure by attaching an accurate gage to the service port 3 Measure the liquid line temperature by attaching an accu rate thermistor type or electronic thermometer to the liquid line near the outdoor coil 4 Refer to unit rating plate to find required subcooling temperature for units produced during or after January 1993 For units produced through December 1992 refer to Table 13 Find the point at which the required subcooling temperature intersects the measured liquid service valve pressure on Table 14 TABLE 11 SUPERHEAT CHARGING TABLE INDOOR COIL ENTERING AIR TEMP F WET BULB OUTDOOR TEMP F 55 60 65 70 75 80 85 90 95 Where a dash appears do not attempt to charge system under these conditions or refrigerant slugging may occur TABLE 12 REQUIRED VAPOR TEMPERATURE F SUPERHEAT TEMP VAPOR PRESSURE AT SERVICE PORT PSIG F 5 To obtain the required subcooling temperature at a specific 1 Check outdoor coil for cleanliness each month during the liquid line pressure add refrigerant if liquid line tempera heating heat pump only or cooling season and clean as tu
95. ugh wire raceway to change motor check that fan rotates freely gt 7 Reverse sequence for reassembly 8 Prior to applying power 1992 Turn off all power to outdoor and indoor units V REMOVE TOP COVER ALL PRODUCTS AFTER JANUARY 1 ELECTRICAL 2 Remove 5 screws holding top cover to coil grille and coil tube sheet S o bb i Es o 2 S o Bl ce 3 S o 5 5 S 9 o E 9 B x o o A 5 p o x ID o Z z tc S 3 Remove 2 screws holding control box cover g oO 2 Nn gt n o 8 o o amp z v tem o k 3 E a 2 o E o amp g o o es o 2 BH o o S o gt ge v prior to troubleshooting Some troubleshooting tech nigues reguire power to remain on In these instances 4 Remove 2 screws holding information plate cut any wire ties and move 5 Disconnect fan motor wires exercise extreme caution to avoid danger of electrical shock ONLY TRAINED SERVICE PERSONNEL SHOULD PERFORM ELECTRICAL TROUBLE SHOOTING wires out of control box and through tube clamp on back of control box 6 Lift top cover from unit 7 Reverse sequence for reassembly Troubleshooting charts for air conditioning and heat pump units are provided in the back of this manual They enable the service technician to use a systematic approach to locating the cause of a problem and correcting system malfunctions REMOVE FAN MOTOR ASSEMBLY ALL PROD UCTS AF
96. ween heating and cooling modes is accomplished with a valve that reverses flow of refrigerant in system See Fig 35 This reversing valve device is easy to troubleshoot and replace The reversing valve solenoid can be checked with power off with an ohmmeter Check for continuity and shorting to ground With control circuit 24 v power on check for correct voltage at solenoid coil Check for overheated solenoid With unit operating other items can be checked such as frost or condensate water on refrigerant lines The sound made by a reversing valve as it begins or ends defrost is a whooshing sound as the valve reverses and pressures in system equalize An experienced service technician detects this sound and uses it as a valuable troubleshooting tool 28 Using a remote measuring device check inlet and outlet line temperatures DO NOT touch lines If reversing valve is operating normally inlet and outlet temperatures on appropriate lines should be close Any difference would be due to heat loss or gain across valve body Temperatures are best checked with a remote reading electronic type thermometer with multiple probes Route thermo couple leads to inside of coil area through service valve mounting plate area underneath coil Fig 36 and 37 show test points TP on reversing valve for recording temperatures Insulate points for more accurate reading If valve is defective 1 Shut off all power to unit and remove all charg
97. wind ing resistances The 2 speed compressor is also protected by an internal pressure relief IPR which relieves discharge gas into the compressor shell low side when the differential between suction and discharge pressures exceed 500 psi The compressor is also protected by 3 PTC devices attached to the motor windings The PTC s resistance is sensed by the 2 speed control board See Table 6 for resistance ranges Furnace Interface Does not function T3 T8 T7 T2 T1 EXTERNAL MAIN 0000 ra 0000 MAIN WINDING 0000 50000 0000 0000 4 POLE START 090 20 00 2 POLE START HIGH SPEED LOW SPEED L1 T1 T7 L1 T1 L2 T2 T3 L2 T7 4 T8 A92015 Fig 27 Energizing Windings TABLE 8 TWO SPEED COMPRESSOR WINDING RESISTANCE AT 70 F 2 WINDING D Mechanically Interlocked Contactors The 2 speed products are equipped with mechanically interlocked contactors Each contactor has interconnecting linkage providing independent interlocks The 2 speed control provides the electrical interlock The contac tors are supplied with 240 v coils which reduce the va require ments of the low voltage 24 vac control system E Temperature Thermistors Thermistors are electronic devices which sense temperature As the temperature increases the resistance decreases Two ther mistors are used to sense temperature one senses outdoor ambi
98. y Heat If the system is operating in low speed heating and there is a demand for auxiliary heat W2 the system changes to high speed operation W2 is energized unless the low voltage control wiring is configured as described in Fig 25 R Auxiliary Heat W2 Lockout In some areas it is necessary to disable the auxiliary heat except for defrost until the outdoor ambient is less than the structure s balance point This is accomplished by using the low voltage wiring as shown in Fig 25 Wire the 24 vac W2 signal from the indoor thermostat to W3 of the control and W2 of the control to W2 of the indoor unit When the outdoor ambient is less than the setting of the balance point POT the 24 vac signal energizes the auxiliary heat W2 of the indoor unit TWO SPEED FAN TWO SPEED THERMOSTAT COIL HEAT PUMP W2 V EE W2 T W3 J CONTROL T tocic W3 A93572 Fig 25 Low Voltage Control Wiring S Emergency Heat If the 2 speed control receives a call for auxiliary heat W2 without a heat pump heating Y1 call the second auxiliary stage W3 is energized This ensures all available heat is energized if the indoor thermostat is switched to emergency heat T Compressor PTC Overload Protection The control senses the resistance of the compressor internal positive temperature coefficient PTC overloads If the resistance of the PTC s is out of range the control s

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