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1. 15 15 15 16 19 Compressor Failures Mechanical Electrical Failures RECIPROCATING COMPRESSOR 16 17 19 19 19 20 23 Mechanical Failures Electrical Failures FAN MOTOR bis A150067 060 14 SEER Heat Pump COMPRESSOR PLUG Fig 1 A C and Heat Pump LOW VOLTAGE 5 PAGE REFRIGERATION 24 2 PISTON BODY CLEANING REPLACEMENT 20 2 Reftigerant trios ase anaes 4 REFRIGERATION SYSTEM REPAIR 0 Compressor diocese oe a aes 24 Leak Detection 20 25 Coil Removal 22 22 22 Liquid Line Filter Drier 25 Compressor Removal and Replacement Suction Line Filter 25 System Clean Up After Burnout 26 2 23 Thermostatic Expansion Valve
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3. Fig 35 Typical Heat Pump Unit Connection Electrical Diagram 35 A14544 LADDER WIRING DIAGRAM L1 GRN USE COPPER CONDUCTORS ONLY BLK FIELD SUPPLY POWER L EQUIPMENT 208 230 VAC 60 HZ 1PH GROUND 12 a YEL c 21 USED 11 1 BLK BLK 23 GIy DR DB 1 210 BLK OF 4 2 1 GRD 5 rh BRN YEL 23 A BLK c R YEL 9 23 onp 110 BLK 6 12 YEL 3 23 GN GIy FM TI GND SEE NOTE 6 PRIMARY 230V COM 110 BLK YEL 23 TRAN ED RED 7 4 bans SEE NOTE 48 GND R pit 7 O ORN tO PL1 8 0 24 VOLT Y 0815 y THERMISTAT 1000 OHMS CONNECT IONS chi GRN 4 5 NOTE 5 BRN BLU LOW SPEED OH RED MED SPEEL GIy PL1 6 W2 BLK HI SPEED IFM ai WHT GN SEE NOTE 5 SEE NOTE 4 BRN PL2 4 77149 BLU BRN LPS scat ea 586 BRN O PL2 3 PL3 1 PNK PL3 2 DFT C PNK PL2 1 BLK BRN OJ PL2 2 1 1 DEFROST BOARD L DEFROST BOARD 50ZH500517 Fig 36 Typical Heat Pump Unit Ladder Electrical Diagram 36 A14545 CARE AND MAINTENANCE To assure hi
4. CHECK 26 TROUBLESHOOTING WITH SUPERHEAT 27 INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS 28 30 25 howd 28 Heating Check Charge Procedure 28 Sequence of Operation 30 ECM FAN MOTOR TROUBLESHOOTING 30 31 31 Pressure Switches 31 Accumulator Reversing Valve 5 31 Control BOX cee ok else hes ond poles 31 CARE AND MAINTENANCE 37 R 410A QUICK REFERENCE GUIDE 38 INDEX OF TABLES 43 SAFETY CONSIDERATIONS Installation service and repair of these units should be attempted only by trained service technicians familiar with standard service instruction 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 troubleshooting electrical components with power on Observe all warning notices posted on equipment and in instructions or manuals 4 WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in persona
5. 48 60 14 SEER 42 60 Ye PCRKHTROO4A HP 13 SEER 42 60 GRG 004A00 HP 14 SEER 42 60 HP 13 SEER 24 36 ZHP 14 SEER 24 36 Yes CPCRKHTROO8A00 ACCESSORY DESCRIPTIONS Refer to Table 1 for an Accessory Usage Guide for Air Conditioners and Heat Pumps Refer to the appropriate section below for a description of each accessory and its use 1 Crankcase Heater An electric resistance heater which mounts to the base of the compressor to keep the lubricant warm during off cycles Improves compressor lubrication on restart and minimizes the chance of liquid slugging Usage Guideline Required in low ambient cooling applications Suggested in all commercial applications 2 Evaporator Freeze Thermostat An SPST temperature actuated switch that stops unit operation when evaporator reaches freeze up conditions Usage Guideline Required when low ambient kit has been added 3 Isolation Relay An SPDT relay which switches the low ambient controller out of the outdoor fan motor circuit when the heat pump switches to heating mode Usage Guideline Required in all heat pumps where low ambient kit has been added 4 Outdoor Thermostat Kit Locks out the accessory electric heater until outdoor ambient conditions falls below the pre set temperature This kit will activate the electric heat when additional heat is required at lower ambient making it a more efficient system LOW AMBIENT COOLING GUIDE LINE The min
6. 339 6 12914 19661 097 61 990 15911 8 1 0 222 09 1 062 802 06 960 9S ESV 61 9S 15911 8 1 06 121 612 0 2 802 57000960 19661 71 15871 61 19661 71 15911 8 1 0 ELL 672 09 1 0 2 802 06 060 906 71 092 61 900 71 15911 8 1 06 672 0 2 802 WO000E0 19561 E87 61 1956191 15911 8 1 0 vor oez 09 1 0 2 802 06 20 LISE 1 61 19561 1 15911 8 1 06 801 09 1 0 lt 2 802 7000760 1 A X oY 581 5211518312 8 2 1 X y ou 7581 SJILSIYILIVYYHI NW NI 11147890 30 831130 1 913 LINN IM LINN 1 21812313 TWN ALIAYY9 30 8 2 LINN IM LINN 1 21812313 Y33S 17 5 335 Cl 9296010609 14536 t ine Small Medium Cab imensions Fig 3 Unit Base 3015 14918 4330 117211 NIVYG 11 5436100 ei 9NIN3d0 1204 157091 1971061 8 6 2 122061 8 1 2 76 vie 6 ONINIdO 1210 109061 04 30004 HOT 7 71 8 10 TINVd ONINAdO 1210 55322 830018 66 ZIL X 187921 901 LNOYS 834101 1101 30S 1351 834101 1115
7. 10 831130 LINN IW LINN 1721812313 THAT NIALIAWED 30 931939 ININA WINI LINN 1 19941 dund 609 61 09 1 61 900 vb 101011 8 1 27 99 09 1 062 802 0 9 LEOS 6 61 eer 61 900 101011 9 1 7 091 256 09 1 062 802 1 000090 eos 61 097 61 900 71 101011 91 2 ttt 09 1 0 2 802 06 870 19071 91 61 19561 01981 9 17 61 50 09 1 062 802 77000870 19071 91 18 61 90 1 71 11981 8 1 7 82 6 2 09 1 02 802 06 20 19071 91 61 1951 11981 871 7 Bel 0 09 1 02 802 17000270 1 A x 98 591 5211518312 8 2 LINQ 1 X OW 581 SIILSIYILIVYYHI ini WW NI ALIAYY9 30 8 32 1H9IJH_LINN IM LINA 1 21812313 TWA NI ALIAVED JO 831412 LINA LINN 7701912213 l 433S 1 5196401 10609 335 61 14537 ize t except 14 SEER Heat Pump 060 5 ine Medium Large Cab imensions Fig 4 Unit Base D 9010091709 Aq MIA 9 8 1 2 ONINIdO LONG 0 909 02 9 418340 LONG 19756561 1276761 1 8621 8 lt 6 WA NI Juv NI 58015843414 39NY4Y319 ON 9381003148 30701888 YO 32833 39YYH SIO 3 8000100 817 20 NOILYINOYIDJY 14343860 OL GINIVINIVW 38 190 532 8 312 310
8. FUSE 1 BRN HPS 5 2 BLK a R RED 5 C BRN 24 VOLT THERMISTAT YEL CONNECTIONS W2 WHT G GRN SEE NOTE 5 COLOR CODE BLK BLACK PNK aru GRN GREEN ACCESSORY w3 VIO ELECTRIC HEAT ORN ORANGE 24 VOLT W2 GRY t BRN RED RED FAN SEQUENCE THERMISTAT VIQ VIOLET CONNECTIONS YEL YELLOW ON OFF a Sn i a tn i a Sy 1 ISEE NOTE TE LEGEND BLOWER OFF DELAT ACCESSSORY ELECTRIC HEAT A CONTACTOR HEATER TERMINAL MARKED CAP CAPACITOR SPEED TAP MED LOW TERMINAL UNMARKED CC CONTACTOR COIL e SPLICE CCH CRANK CASE HEATER FACTORY WIRING COMP COMPRESSOR MOTOR FIELD CONTROL WIRING GROUND FIELD POWER WIRING ACCESSORY OR OPTIONAL LEM INDOOR FAN MOTOR WIRING HPS HIGH PRESSURE SWITCH UNIT COMPONENT ARRANGEMENT OFM OUTDOOR FAN MOTOR TRAN TRANSFORMER OUTDOOR FAN CONTROL BOX AREA SECTION OFM mage TRAN SIm BREE 1 IF ANY OF THE ORIGINAL WIRES FURNISHED ARE REPLACED MUST BE REPLACED WITH THE SAME DISCONNECT TYPE OF WIRE OR IT S EQUIVALEN PER NEC 2 SEE PRICE PAGES FOR THERMOSTAT 3 USE CONDUCTORS SUITABLE FOR AT LEAST 75 C 161 SUPPLIED FOR FIELD INSTALLATION 4 FACTORY WIRING FOR SPEED SELECTOR PLUG 5 CH
9. Wear safety glasses protective clothing and gloves when handling refrigerant 14 The scroll compressor pumps refrigerant through the system by the interaction of a stationary and an orbiting scroll See Fig 17 The scroll compressor has no dynamic suction or discharge valves and it is more tolerant of stresses caused by debris liquid slugging and flooded starts The compressor is equipped with an internal pressure relief port The pressure relief port is a safety device designed to protect against extreme high pressure The relief port has an operating range between 550 to 625 psig differential pressure Copeland and 550 to 650 psig differential pressure Danfoss for R 410A refrigerant Scrolls have a variety of shut down solutions depending on model to prevent backward rotation and eliminate the need for cycle protection Compressor Failures Compressor failures are classified in 2 broad failure categories mechanical and electrical Both types are discussed below 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 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Do not supply power to unit with compressor terminal box cover removed 4 WARNING ELECTRICAL SHOCK HAZ
10. Wheatstone bridge or null balance type instrument 4 Motor must be dry or free from direct contact with liquid refrigerant 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 System Clean Up After Burnout Turn off all power to unit before proceeding 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 compressor burnout use Total Test See your distributor 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 o
11. 1 Relieve pressure and recover all refrigerant before servicing existing equipment and before final unit disposal Use all service ports 2 Federal regulations require that you do not vent refrigerant into the atmosphere Recover during system repair or final unit disposal CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage Damage may occur to the scroll compressor if operated at a negative suction pressure during a system pumpdown 1 Recover refrigerant from tubing and coil through high flow service port on suction and discharge lines Disconnect refrigerant liquid tube from distributor body See Fig 24 2 Avoid damaging seal ring or machined surfaces on piston bore and retainer 3 Using small wire with a hook on end of it remove piston from body TEFLON SEAL PISTON PISTON DISTRIBUTOR RETAINER BODY BRASS HEX NUT A10176 Fig 24 Refrigerant Flow Control Device CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage When cleaning the piston orifice be careful not to scratch or enlarge the opening as this will affect operation Install new or cleaned piston into body Replace seal ring on retainer Reconnect refrigerant tube to piston body Pressurize tubing and coil then leak check amp Evacuate tubing and coil as necessary
12. 24 81 27 81 27 81 27 83 28 85 29 87 31 38 21 1 73 23 75 24 83 28 83 28 83 28 83 28 85 29 87 31 89 32 85 29 87 31 50ZH500518 REV 2 0 29 A10038 Table 7 14 SEER Required Subcooling Required Subcooling F C Required Liquid Line Temperature for a Specific Subcooling R 410A Outdoor Ambient Temperature F C Model Size 75 24 85 29 95 35 Pressure psig 105 41 115 46 060 14 7 7 14 7 7 14 7 7 13 7 3 13 7 3 048 12 6 7 12 6 7 11 5 6 4 11 3 6 3 11 6 1 HP 060 10 5 6 9 5 8 4 4 8 4 2 7 4 1 Charging Procedure 1 Measure Discharge line pressure by attaching a gauge to the service port 2 Measure the Liquid line temperature by attaching a temperature sensing device to it 3 Insulate the temperature sensing device so that the Outdoor Ambient doesn t affect the reading 4 Refer to the required Subcooling in the table based on the model size the Outdoor Ambient temperature 5 Interpolate if the Outdoor ambient temperature lies in between the table values 6 Find the Pressure Value in the table corresponding to the the measured Pressure of the Compressor Discharge line 7 Read across from the Pressure reading to obtain the Liquid line temperature for a required Subcooling 8 Add Charge if the measured temperature is h
13. GREEN YELLOW 2 AT THE SAME TIME DFT CLOSED JUMPER SPEED 1 PINS WITH SMALL SCREW DRIVER UNTIL DEFROST 15 RED RED INITIATED THEN REMOVE SCREW DRIVER 3 SHORTED SPEED UP PINS WILL SPEED UP TIMER DISCONNECT WHT WHITE DEFROST cnp NEC Ye YELLOW BY A FACTOR OF 256 BOARD 2 NOTES 1 IF ANY OF THE ORIGINAL WIRES FURNISHED ARE 1 SUPPLIED rene LEG END REPLACED IT MUST BE REPLACED WITH THE SAME OF WIRE OR IT S EQUIVALENT TERMINAL MARKED GAP con 2 SEE PRICE PAGES FOR THERMOSTAT SPLICE CCH CRANK CASE HEATER 3 USE CONDUCTORS SUITABLE FOR AT LEAST 75 C VHERMISTAT FACTORY WIRING COMP COMPRESSOR MOTOR 167 F FOR FIELD INSTALLATION HPS WIRES 08 DEFROST BOARD FIELD CONTROL WIRING PB DEFROST BOARD 4 FACTORY WIRING FOR SPEED SELECTOR PLUG FM FIELD POWER WIRING DR DEFROST RELAY 5 CHANGING OF SPEED TAPS MAY BE REQUIRED ACCESSORY OR OPTIONAL GND GROUND WHEN USING FIELD INSTALLED ELECTRIC HEATERS WIRING HR RELAY CONSULT INSTALLATION INSTRUCTIONS TO LPS coup teagan DETERMINE CORRECT SPEED TAP SETTING Rvs ips KON PRESSURE SWITCH DO NOT DISCONNECT PLUG UNDER LOAD DFT GFA PAN ROTOR 1 MULTI STAGE HEATER SHOWN SINGLE STAGE HEATERS HAVE WHITE AND BROWN WIRES ONLY Tan SOLENOID FUSE MANUFACTURED BY LITTELFUSE P N 257003 9 N E C CLASS 2 24 V
14. HEATING OPERATION With call for heating the compressor outdoor fan and indoor fan start immediately If Y cannot satisfy the heating demand the auxiliary or backup heat W2 energizes In case of staged heating W3 is energized if the demand is not met When heating demand is met W3 W2 and Y sequentially de energize shutting the compressor indoor fan and the outdoor fan CONTINUOUS FAN With the continuous indoor fan option selected on the thermostat G is continuously energized The continuous fan speed will be the same as the cooling fan speed DEFROST Defrost board DB is a time and temperature control which includes a field selectable time period between checks for defrost A150075 30 60 90 and 120 minutes The time period is factory set at 60 minutes and should only be adjusted by a trained service person Electronic timer and defrost cycle start only when contactor is energized and defrost thermostat DFT is closed Defrost mode is identical to Cooling mode The outdoor fan motor stops because of OF1 and 2 contacts opening on the defrost board a bank of optional electric heat turns on to warm air supplying the conditioned space ELECTRIC RESISTANCE HEATING If accessory electric heaters are installed on a call for Emergency Heat the thermostat energizes W which energizes the heater relay and in turn energizes the electric heaters The IFM is energized which starts the indoor fan
15. Winding Resistance ohm Start C R 1 43 0 98 0 82 0 67 464 534 499 avg 391 449 420 avg Winding Resistance ohm Start C S 2 38 1 73 1 63 1 46 753 867 810 avg 814 936 875 avg Winding Resistance ohm Start R S 3 81 2 71 2 45 2 13 1 31 1 30 Run Capacitor mfd volts 35 440 40 440 45 440 45 440 70 440 70 440 13 SEER Heat Pump Unit Size 024 030 036 042 048 060 Type Chassis Size Small Small Medium Large Large Large Compressor Copeland Scroll Copeland Scroll Copeland Scroll Copeland Scroll Copeland Scroll Copeland Scroll 3MAF Polyolester 3MAF Polyolester 3MAF Polyolester 3MAF Polyolester 3MAF Polyolester 3MAF Polyolester Manufacturer Oil Type Oil POE Oil POE Oil POE Oil POE Oil POE Oil POE Oil Charge fl oz intial recharge 25 19 25 21 25 19 25 19 42 34 42 34 Winding Resistance ohm Start 1 23 0 98 0 87 0 56 0 52 0 45 Winding Resistance ohm Start C S 1 47 1 78 1 47 1 25 0 82 0 79 Winding Resistance ohm Start R S 2 7 2 76 2 34 1 81 1 34 1 24 Run Capacitor mfd volts 40 440 40 440 45 440 45 440 70 440 70 440 14 SEER Heat Pump Unit Size 024 030 036 042 048 060 Type Chassis Size Small Medium Medium Large Large Large Compressor Copeland Scroll Copeland Scroll LG Scroll LG Scroll LG Scroll Copeland Scroll Polyolester 3MAF Polyolester RB32G Polyolester RB32G Polyolester RB32G Polyolester 3MAF Polyol
16. 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 0 or a low value capacitor is internally shorted 2 Capacitance testers are available which will read value of capacitor If value is not within 10 percent value stated on capacitor it should be replaced If capacitor is not open or shorted the capacitance value is calculated by measuring voltage across capacitor and current it draws 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Exercise extreme caution when taking readings while power is on Use following formula to calculate capacitance Capacitance mfd 2650 X 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 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 compressor motor This device is called a positive temperature coefficient PTCR or PTC or start thermistor It is a resistor wired in parallel with the run capacitor As current flows through the PTC at start up it heats up As PTC heats up its resistance increases greatly until it effectively lowers the current
17. 1 1 TRAN a Le ae SEE NOTE 4 1 2 3 45 4 4 SECONDARY ie ce ee iy RESISTOR SEE NOTE 84 L 1000 OHMS bie 1 Lig 327 27 1 1 USE BRN 222 5 amp 2 Zea HPS BLU oT Se BLK Se FROST BOARD a a DEFROST BO 2 a 0 DR R RED 0 ORN BRN 24 VOLT WHT BRN THERMISTAT BLK Rvs CONNECTIONS Y YEL ips BRN BlU o o 6 GRN L_ 30 60 90 PNK SEE NOTE 5 005 12 0909 OF W3 PNK 10 C0 DF ACCESSORY W3 VIO 0 121 ELECTRIC HEAT R P1 24 VOLT 2 GRY SPEED UP THERMISTAT w2 WHT CONNECTIONS BRN SEE NOTE 5 SEE NOTE 7 SEE NOTE 5 gt EFROST TIMING SELECTION Qe FAN SEQUENCE 0 90 1 aru BLOWER OFF DELAY 0 30 60 ACCESSSORY ELECTRIC HEAT BRN 1 SECONDS ELD SELECTABLE OPTIONS FOR TIME PERIOD 2A VOLT HEATER RELAY COMNECTIONS SPEED TAP HI MED LOW BETWEEN DEFROST CYCLES MINUTES ACTORY DEFROST SETTING IS 60 MIN BRN COLOR CODE JUMPERED SPEED UP PINS USE METAL OBJECT BLACK uP FIELD SPEED UP CYCLE UNIT COMPONENT ARRANGEMENT BRN BROWN 1 DFT MUST BE CLOSED TO INITIATE DEFROST CYCLE GRN GREEN IF NECESSARY REMOVE DFT CONNECTION BEFORE QUTDOOR FAN ory CONTROL BOX AREA GRY GREY PLACING JUMPER ACCROSS DFT PINS ren TRAN
18. 4 gt BRN HPS BRN 50ZP500775 B A14543 Fig 34 Typical Air Conditioning Single Phase Unit Ladder Electrical Diagram 34 6 1 USE COPPER CONDUCTORS ONLY ir nero FIELD SUPPLY POWER 10 208 230 VAC 60 HZ me BLK BLK DR DB UNIT ONLY J BLK BLK OF DHO 2 BLK MAXIMUM WIRE 3 OFM SIZE 2 AWG YEL 23 EL YEL GND EQUIPMENT OMPRESSOR PLUG GROUND BLK YEL COMP YEL BLK YEL gt lt SEE NOTE 6 FOR WIRING WITH ELECTRIC HEATERS Sir i 12 SEE SCHEMATIC a 6 7 GND GND ON HEATER ACCESSORY PRIMARY 11 1 1 om 30 9 GND COM IFM
19. 5 46 1 6 18 7 148 51 8 11 0 250 83 8 28 8 352 107 5 41 9 454 126 6 52 6 572 145 0 62 8 48 0 0 17 8 150 52 5 11 4 252 84 3 29 1 354 107 9 42 2 456 127 0 52 8 576 145 6 63 1 50 1 5 16 9 152 53 3 11 8 254 84 8 29 3 356 108 3 42 4 458 127 3 52 9 580 146 2 63 4 52 3 0 16 1 154 54 0 12 2 256 85 4 29 7 358 108 8 42 7 460 127 7 53 2 584 146 7 63 7 54 4 5 15 3 156 54 8 12 7 258 85 9 29 9 360 109 2 42 9 462 128 0 53 3 588 147 3 64 1 56 5 9 14 5 158 55 5 13 1 260 86 4 30 2 362 109 6 43 1 464 128 3 53 5 592 147 9 64 4 58 7 3 13 7 160 56 2 13 4 262 86 9 30 5 364 110 0 43 3 466 128 7 53 7 596 148 4 64 7 60 8 6 13 0 162 57 0 13 9 264 87 4 30 8 366 110 4 43 6 468 129 0 53 9 600 149 0 65 0 62 10 0 12 2 164 57 7 14 3 266 87 9 31 1 368 110 8 43 8 470 129 3 54 1 604 149 5 65 3 64 11 3 11 5 166 58 4 14 7 268 88 4 31 3 370 111 2 44 0 472 129 7 53 2 608 150 1 65 6 66 12 6 10 8 168 59 0 15 0 270 88 9 31 6 372 111 6 44 2 474 130 0 54 4 612 150 6 65 9 68 13 8 10 1 170 59 8 15 4 272 89 4 31 9 374 112 0 44 4 476 130 3 54 6 616 151 2 66 2 70 15 1 9 4 172 60 5 15 8 274 89 9 32 2 376 112 4 44 7 478 130 7 54 8 620 151 7 66 5 72 16 3 8 7 174 61 1 16 2 276 90 4 32 4 378 112 6 44 8 480 131 0 55 0 624 152 3 66 8 74 17 5 8 1 176 61 8 16 6 278 90 9 32 7 380 113 1 45 1 482 131 3 55 2 628 152 8 67 1 76 18 7 7 4 178 62 5 16 9 280 91 4 33 0 382 113 5 45 3 484 131 6 55 3 632 153 4 67 4 78 19 8 6 8 180 63 1 17 3 282 91 9 33 3 384 113 9 45 5 486 132 0 55 6 636 153 9 67 7 80 21 0 6
20. A150080 Fig 16 DFT Sensor Location 060 Troubleshooting If unit will not run 1 Does the Y input has 24 volts from thermostat If not check thermostat or wire If yes proceed to 2 2 The Y spade terminal on the circuit board should have 24 volts if Y input is energized This output goes through the pressure switches and to the contactor If 24 volts is present on the Y spade terminal and the contactor is not closed check voltage on contactor coil If no voltage is present check for opened pressure switch 3 If voltage is present and contactor is open contactor may be defective Replace contactor if necessary 4 If contactor is closed and unit will still not run check wiring capacitor and compressor Defrost Speedup To test the defrost function on these units speed up pins are provided on the circuit board To force a defrost cycle the defrost thermostat must be closed or the defrost thermostat pins must be jumpered Follow the steps below to force a defrost cycle 1 Jumper the DFT input 2 Short the speed up pins This speeds up the defrost timer by a factor of 256 The longer the defrost interval setting the longer the pins must be shorted to speed through the timing For example if interval is 90 min the speed up will take 90 256 min x 60seconds minute 21 seconds max This could be shorter depending on how much time has elapsed since the defrost thermostat closed 3 Remove the short immediately wh
21. C in the low voltage control box If there is not 24 volts at R and C check the inline 3 amp fuse If the fuse is blown check for shorted bare or chaffed wires before installing another fuse in the holder If the fuse is good make sure there is line voltage on the primary side of the transformer Then check the secondary side of the transformer If there is line voltage on the transformer primary and no voltage on the secondary replace the transformer e If there is 24volts between R jump R and G together in the low voltage control box Check to see if there is a 24 volt signal at pins 1 2 or 3 referenced to common ground at the motor s low voltage plug If there is no voltage between common and one of the pins trace the wires back to the low voltage control box e If there is power at the high voltage plug voltage at pins 1 2 or 3 on the low voltage plug the connections are good between the plugs and motor and the motor is not running replace the motor Two 24 volt signal wires will be connected from the thermostat to the low voltage control plug One wire signal will be for constant fan cooling speed and the other will be for electric heat If there is an intermittent motor operation issue check the 1000 ohm resistor between the green wire and the brown wire in the unit s wiring harness See unit s wiring diagram The resistor could be blown open This resistor is in line with the fan m
22. CONDITIONER TROUBLESHOOTING CHART NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD 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 DEFECTIVE START CAPACITOR OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING 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 DEFECTIVE START CAPACITOR LOOSE LEAD AT FAN MOTOR MOTOR DEFECTIVE INCORRECT OFM CAPACITOR 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 37 Air Condition
23. Find the Pressure Value in the table corresponding to the measured Pressure of the Compressor Discharge line 7 Read across from the Pressure reading to obtain the Liquid line temperature for a required Subcooling 8 Add Charge if the measured temperature is higher than the table value 9 Remove charge if the measured temperature is lower than the table value Heating Mode NOTE When charging is necessary during heating season charge must be weighed in accordance with unit rating plate 28 Table 5 Minimum Airflow for Safe Electric Heater Operation Air Conditioner Minimum Airflow Unit Size 5 kW 7 5 kW 10 kW 15 kw 20 kW 24 600 750 750 X X 30 600 750 750 X X 36 600 750 750 1050 X 42 600 750 750 1050 X 48 600 750 750 1050 1400 60 600 750 750 1050 1400 X Not Approved Combination Heat Pump HP Unit Minimum Airflow CFM Size 5kW 7 5 kW 10 kW 15 kW 20 kW 24 750 800 800 X X 30 750 800 800 X X 36 750 800 800 1200 X 42 750 800 800 1200 X 48 750 800 800 1200 1700 60 750 800 800 1200 1700 X Not Approved Combination Table 6 Superheat Charging SUPERHEAT CHARGING TABLE SUPERHEAT F C AT COMPRESSOR SUCTION SERVICE PORT OUTDOOR TEMP F 50 10 52 11 54 12 56 13 58 14 60 16 62 17 64 18 66 19 EVAPORATOR ENTERING AIR F C WB 76 2
24. WH NI 3 1 NI SNOISNINIQ LINA 30 01108 JINYYY 112 192181 ON 53810038 30 0108879 YO 32833 FISVAONIY Y 3840910 3000110 081 JO 11 10281238 1134384 OL QINIVINIYN 28 ISAW SIONVYVITD 3100 91 3 38 10038 JIN 803 1432 3 12911 0706 AYINI YINOd HLIM LINA 30 3015 12911 0206 5918340 1200 31150440 LINN 30 3015 LINN 30 401 SIHONI 5 2 12 0 41 03 2 SONIN3dO LONG HLIM LINN 40 3015 19011 02 5523015 AYINI 83404 9301809 030800849 83110 17 31382802 YO 32076 ANY LINN 114405 10167 0796 2221015 AYINI 83804 SIOYAYNS GIONNOYONN ANY LINN 119011 022 773019 AYINI YIMOd 51140 1334136 AD Sanat S3ONVUVATO 03 0038 IN LINN 40 WOLLOG 197621 15 19071 91 E8 61 19561 71 11981 8 1 061 582 09 1 0 2 802 0 9 0 907 91 Teer 61 11981 871 76 921 09 1 0 2 802 0 0 0 190p 91 19561 71 11981 8 1 7 lt 061 582 09 1 0 2 802 000990 81 TIGE VI 16911 870 SE 06 720 19561 eer 61 1956191 15911 8 1 06 ozi 707 09 1 062 902 77000090 9S 8 61 956171 15911 8 1 06 0 1 92 09 1 0 2 802 17000720 A 581 9010304440 110 1 A x 9y 581 211 518 3112 2 i NI 1114 890 40 831120 LINN IM LIN 0181031 THN NI 10 431839 THOTIH LINN LINA 12181323113 LIN 199
25. during normal system operation a conventional low pressure switch cannot be installed on suction line This switch is installed in liquid line instead and acts as loss of charge protector The liquid line is the low side of the system in heating mode It operates identically to low pressure switch except it opens at 20 5 psig and closes at 45 10 psig for R 410A Troubleshooting and removing this switch is identical to procedures used on other switches Observe same safety precautions 10 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 for 13 SEER closed at 32 3 F and open at 65 5 F For 14 SEER 33 3 F and open at 55 5 F Check Defrost Thermostat There is a liquid header with a brass distributor and feeder tubes going into outdoor coil At the end of 1 of the feeder tubes there is a 3 8 in OD stub tube approximately 3 in long See Fig 13 The defrost thermostat should be located on stub tube Note that there is only 1 stub tube used with a liquid header and on most units it is the bottom circuit See Fig 15 and Fig 16 for DFT Sensor Location FEEDER TUBE STUB TUBE EFROST THERMOSTAT A97517 Fig 13 Defrost Thermostat
26. leak detectors Check with manufacturer of equipment for suitability Generally speaking they are portable 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 the movement of a pointer on detector dial a buzzing sound or a light In all instances when a leak is found system charge must be recovered and leak repaired before final charging and operation After leak testing or leak is repaired replace liquid line filter drier evacuate system and recharge with correct refrigerant quantity Coil Removal Coils are easy to remove if required for compressor removal or to replace coil 1 Shut off all power to unit 2 Recover refrigerant from system through high flow service valves 3 Break vacuum with nitrogen 4 Remove top cover See Access Compressor or other internal cabinet component Fig 6 Fig 8 5 Remove screws in coil panels 4 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury or equipment damage Cut tubing to reduce possibility of personal injury and fire 6 Use midget tubing cutter to cut liquid and vapor lines at both sides of coil Cut in convenient location for easy reassembly with copper slip couplings 7 Lift coil vertically from basepan and carefully place aside 8 Reverse procedure to reinstall coil 9 Replace fi
27. power off and contacts pulled in check for continuity across contacts with ohmmeter A very low or 0 resistance should be read Higher readings could indicate burned or pitted contacts which may cause future failures Capacitor 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or equipment damage Capacitors can store electrical energy when power is off Electrical shock can result if you touch the capacitor terminals and discharge the stored energy 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 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or equipment damage Always check capacitors with power off Attempting to troubleshoot a capacitor with power on can 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 With power off discharge capacitors as outlined above Disconnect capacitor from circuit Put ohmmeter on R X 10k scale Using an analog ohmmeter check each terminal to ground use capacitor case Discard any capacitor which measures 1 2 scale deflection or less Place ohmmeter leads
28. service ports and open all flow control devices including solenoid valves Federal regulations require that you do not vent refrigerant to the atmosphere Recover during system repair or final unit disposal 1 Shut off all power to unit 2 Remove and recover all refrigerant from system until pressure gages read zero psig Use all service ports 3 Disconnect electrical plug from compressor Disconnect or remove crankcase heater if equipped and remove compressor holddown nuts and washers 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 Use copper couplings to tie compressor back into system 8 Evacuate system recharge and check for normal system operation N 18 9 Compressors have copper plated steel suction ports Excess heat during brazing will burn off copper plating See Brazing section for additional information Outdoor Fan Adjustment A CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in damage to unit components Keep the condenser fan free from all obstructions to ensure proper cooling operation Never place articles on top of unit 1 Shut off unit power supply an
29. to fail very quickly Do not reduce effective size of wire such as cutting off strands so that 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 unit has reached operating temperatures especially if aluminum conductors are used Contactor The contactor provides a means of applying power to unit using low voltage 24v from transformer in order to power contactor coil Depending on unit model you may encounter single or double pole contactors Exercise extreme caution when troubleshooting as 1 side of line may be electrically energized The contactor coil is powered by 24vac 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 will have different resistance values 3 Reconnect leads and apply low voltage power to contactor coil This may be done by leaving high voltage power to outdoor unit off and turning thermostat to cooling 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 replace contactor 4 With high voltage
30. tubes causing imbalance to the circuiting 27 e proceed to Step 20 20 Check that proper size valve is used per Product Literature e proceed to Step 21 21 Check airflow sensing bulb tightness orientation on vapor tube and ensure bulb is properly wrapped e proceed to Step 22 22 Check for even temperature distribution 5 difference at outlet of each circuit of evaporator and for even air distribution over all evaporator slabs e proceed to Step 23 23 Move sensing bulb further down suction line e If problem not corrected replace valve Indoor Airflow and Airflow Adjustments 4 WARNING UNIT OPERATION HAZARD Failure to follow this caution may result in equipment damage or improper operation For cooling operation the recommended airflow is 350 to 450 cfm for each 12 000 Btuh of rated cooling capacity NOTE Be sure that all supply and return air grilles are open free from obstructions and adjusted properly 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Disconnect electrical power to the unit and install lockout tag before changing blower speed Blower speed tap can be changed by replacing the factory installed blue low speed tap wire cooling with the unused black high speed wire in unit control box The red medium speed wire is factory installed to operate with a call for supplemental electric hea
31. wires from terminals C S and R 4 Check resistance from C R C S and R S using an ohmmeter on 0 1000 ohm scale Because winding resistances are 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 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Be sure internal line break overload is not temporarily open 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 WARNING FIRE EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death and or property damage Wear safety glasses and gloves when handling refrigerants Keep torches and other ignition sources away from refrigerants and oils The compressor is an electrical as well as mechanical device Exercise extreme caution when working near compressors Power should be shut off if possible for most troubleshooting techniques Refrigerants in system present other safety hazards Always wear safety glasses and gloves when handling refrigerants Compressor Failures Compressor failures are classified in 2 broad failure categories mechanical and electrical Both types are discussed below Mechanical Fail
32. 1 182 63 8 17 7 284 92 4 33 6 386 114 3 45 7 488 132 3 55 7 640 154 5 68 1 82 22 1 5 5 184 64 5 18 1 286 92 8 33 8 388 114 7 45 9 490 132 6 55 9 644 155 0 68 3 84 23 2 4 9 186 65 1 18 4 288 93 3 34 1 390 115 0 46 1 492 132 9 56 1 648 155 5 68 6 86 24 3 4 3 188 65 8 18 8 290 93 8 34 3 392 115 5 46 4 494 133 3 56 3 652 156 1 68 9 88 25 4 3 7 190 66 4 19 1 292 94 3 34 6 394 115 8 46 6 496 133 6 56 4 656 156 6 69 2 90 26 4 3 1 192 67 0 19 4 294 94 8 34 9 396 116 2 46 8 498 133 9 56 6 660 157 1 69 5 92 27 4 2 6 194 67 7 19 8 296 95 2 35 1 398 116 6 47 0 500 134 0 56 7 664 157 7 69 8 94 28 5 1 9 196 68 3 20 2 298 95 7 35 4 400 117 0 47 2 502 134 5 56 9 668 158 2 70 1 96 29 5 1 4 198 68 9 20 5 300 96 2 35 7 402 117 3 47 4 504 134 8 57 1 672 158 7 70 4 98 30 5 0 8 200 69 5 20 8 302 96 6 35 9 404 117 7 47 6 506 135 2 57 3 676 159 2 70 7 100 31 2 0 4 202 70 1 21 2 304 97 1 36 2 406 118 1 47 8 508 135 5 57 5 680 159 8 71 0 102 32 2 0 1 204 70 7 21 5 306 97 5 36 4 408 118 5 471 510 135 8 57 7 684 160 3 71 3 104 33 2 0 7 206 71 4 21 9 308 98 0 36 7 410 118 8 48 2 512 136 1 57 8 688 160 8 71 6 106 34 1 1 2 208 72 0 22 2 310 98 4 36 9 412 119 2 48 4 514 136 4 58 0 692 161 3 71 8 108 35 1 1 7 210 72 6 22 6 312 98 9 37 2 414 119 6 47 7 516 136 7 57 7 696 161 8 72 1 110 35 5 1 9 212 73 2 22 9 314 99 3 37 4 416 119 9 48 8 518 137 0 58 3 112 36 9 2 7 214 73 8 23 2 316 99 7 37 6 418 120 3 49 1 520 137 3 58 5 39 AIR
33. 2 Thermostatic Expansion Valve The five ton air conditioning and heat pump units have a factory installed thermostatic expansion valve The will be bi flow hard shutoff with an external equalizer and a balance port pin A hard shut off TXV does not have a bleed port Therefore minimal equalization takes place after shutdown TXVs are specifically designed to operate with R 410A refrigerant use only factory authorized TXV s Do not interchange R 410A and R 22 TXVs Operation The TXV is a metering device that is used in air conditioning and heat pump systems to adjust to changing load conditions by maintaining a preset superheat temperature at the outlet of the evaporator coil The volume of refrigerant metered through the valve seat is dependent upon the following 1 Superheat temperature is sensed by cap tube sensing bulb on suction tube at outlet of evaporator coil This temperature is converted into pressure by refrigerant in the bulb pushing downward on the diaphragm which opens the valve via the pushrods 2 The suction pressure at the outlet of the evaporator coil is transferred via the external equalizer tube to the underside of the diaphragm This is needed to account for the indoor coil pressure drop Coils typically have a high pressure drop which requires this valve feature 3 The pin is spring loaded which exerts pressure on the underside of the diaphragm Therefore the bulb pre
34. 4 05 7 5 61 0261 99 vt 101011 8 1 27 61 Ser 09 1 062 802 06 09028705 1 x Y ow 50 011918300 8780 CWA NI ALIAYY9 30 83113 1 911 LINN 1M LINN 1421812313 150071 Fig 5 14 SEER Heat Pump 060 Size Access Compressor Or Other Internal Cabinet Components NOTE Access to most of the components through the side panels of the unit The top will need to be removed to access the evaporator or condenser coil In some instances screws on the back of the unit duct side will need to be accessed If the unit is up against the structure the unit will have to be pulled away for servicing Follow the procedures below to access the different components 1 Access to control box compressor reversing valve metering device accumulator and liquid line drier a Removal of the right front panel opposite the duct flanges will give access to the component above See Fig 6 2 Access to the indoor fan motor and electric heater a Removal of the right side side with electric access right back panel to access components above See Fig 7 3 Access or removal of the condenser coil a Removal of the top the control compressor panel the front left side louver panel b Screws from the compressor compartment and either the side of the unit or below the condenser fan depending on the shape of coil will need to be removed to remove condenser coil See Fig 8 4 A
35. 4 55 12 7 9 5 0 12 6 7 14 7 8 17 9 4 20 11 23 13 26 14 29 16 32 18 10 5 6 12 6 7 15 8 3 18 10 21 12 24 13 27 15 68 20 70 21 72 22 74 23 35 19 37 21 40 22 42 23 70 21 1 7 3 9 10 5 6 13 7 2 16 8 9 75 23 9 6 3 3 9 5 0 19 11 21 12 24 13 15 8 3 30 17 33 18 36 20 38 21 27 15 30 17 33 18 36 20 21 12 25 14 85 29 4 2022 11 6 1 8 4 4 18 10 15 8 3 5 24 9 5 0 13 7 2 16 8 9 20 11 24 13 27 15 19 11 22 12 28 16 31 17 26 14 30 17 14 7 8 22 12 _ 21 100 37 7 8 4 4 12 6 7 15 8 3 20 11 23 13 SUCTIO 111 869 SUPERHEAT TEMP F C 107 840 N PRESS 116 900 120 931 105 40 6 5 2 8 110 43 3 REQUIRED SUCTION TUBE TEMPERATURE F MEASURED AT COMPRESSOR SUCTION SERVICE PORT URE AT SUCTION SERVICE PORT PSIG kPa 130 140 145 996 1064 1103 35 1 7 37 2 8 39 3 9 41 5 0 43 6 1 45 7 2 47 8 3 49 9 4 51 11 125 963 6 3 3 11 6 1 15 8 3 20 11 860 14 7 8 18 10 55 13 57 14 59 15 39 3 9 41 5 0
36. 43 6 1 45 7 2 47 8 3 49 9 4 51 11 4 2 2 39 3 9 41 5 0 43 6 1 45 7 2 47 8 3 49 9 4 51 11 53 12 55 13 6 3 3 41 5 0 43 6 1 45 7 2 47 8 3 49 9 4 51 11 53 12 55 13 57 14 8 4 4 43 6 1 45 7 2 47 8 3 49 9 4 51 11 53 12 55 13 57 14 59 15 10 5 6 45 7 2 47 8 3 49 9 4 51 11 53 12 55 13 57 14 59 15 61 16 49 9 4 51 11 53 12 55 13 57 14 59 15 61 16 63 17 14 7 8 49 9 4 51 11 53 12 55 13 57 14 59 15 61 16 63 17 65 18 53 12 55 13 57 14 59 15 61 16 63 17 65 18 67 19 69 21 20 11 1 55 13 57 14 61 16 59 15 63 17 61 16 65 18 63 17 65 18 67 19 69 21 71 22 59 15 61 16 63 17 65 18 67 19 69 21 71 22 73 23 26 14 4 61 16 63 17 28 156 65 18 67 19 69 21 71 22 73 23 75 24 75 24 77 25 65 18 67 19 69 21 71 22 40 22 2 67 19 69 21 71 22 73 23 75 24 77 25 79 26 81 27 32 17 8 67 19 69 21 71 22 73 23 75 24 77 25 79 26 81 27 83 28 34 18 9 69 21 71 22 73 23 75 24 79 26 79 26 81 27 83 28 85 29 36 20 0 71 22 73 23 75
37. ANGING OF SPEED TAPS MAY BE REQUIRED THERMISTA WHEN USING FIELD INSTALLED ELECTRIC HEATERS HPS WIRES CONSULT INSTALLATION INSTRUCTIONS TO DETERMINE CORRECT SPEED TAP SETTING 6 DO NOT DISCONNECT PLUG UNDER LOAD MULTI STAGE HEATER SHOWN SINGLE STAGE HEATERS HAVE WHITE AND BROWN WIRES ONLY 8 FUSE MANUFACTURED BY LITTELFUSE P N 257003 9 N E C CLASS 2 24 V A14542 Fig 33 Typical Air Conditioning Single Phase Unit Connection Electrical Diagram 33 LADDER WIRING DIAGRAM DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE L1 GRN USE COPPER CONDUCTORS ONLY BLK FIELD SUPPLY POWER L EQUIPMENT 208 230 VAC 60 HZ 1PH GROUND gt YEL 21 USED 11 1 BLK BLK 23 GIy 1 BLK GND 923 BLK YEL 523 116 BLK 1 12 YEL 23 GN GIy M 17 GND SEE NOTE 6 PRIMARY 230v 208v 110 BLK WES 5 TRAN RED 241 34 0 SEE NOTE 8 GND l RESISTOR R RED 1000 OHMS GRN 6 GRN NOTE 5 BRN 24 VOLT L BLU Low SPEED z THERMISTAT w2 WHT RED MED SPEEL CONNECTIONS 222 1 Y EL GND SEE NOTE 5 SEE NOTE
38. ARD Failure to follow this warning could result in personal injury or death 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 Locked Rotor In this type of failure compressor motor and all starting components are normal When compressor attempts to start it draws locked rotor current and cycles off on internal protection Locked rotor current is measured by applying a clamp on ammeter around common blk lead of compressor Current drawn when it attempts to start is then measured Locked rotor amp LRA 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 Runs Does Not Pump In this type of failure compressor motor runs and turns compressor but compressor does not pump refrigerant A clamp on ammeter on common leg shows a very low current draw much lower than rated load amp RLA value stamped on compressor nameplate Because no refrigerant is being pumped there is no ret
39. CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage Use a backup wrench and do not over tighten as deformation of the piston body will occur causing the piston to lodge in a partially open or closed position LIQUID TUBE STRAINER FILTER The TXV and refrigerant flow control device is protected by either a wire mesh strainer or filter drier REFRIGERATION SYSTEM REPAIR WARNING EXPLOSION HAZARD Failure to follow this warning could result in death serious personal injury and or property damage Never use air or gases containing oxygen for leak testing or operating refrigerant compressors Pressurized mixtures of air or gases containing oxygen can lead to an explosion Leak Detection New installations should be checked for leaks prior to complete charging If a system has lost all or most of its charge system must be pressurized again to approximately 150 psig minimum and 375 psig maximum This can be done by adding refrigerant using normal charging procedures or by pressurizing system with nitrogen less expensive than refrigerant Nitrogen also leaks faster than refrigerants Nitrogen cannot however be detected by an electronic leak detector See Fig 25 95422 Fig 25 Electronic Leak Detection WARNING PERSONAL INJURY AND UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury or death Due to the high pressure of nit
40. Charge See Charging Tables 6 and 7 Factory charge amount and desired subcooling are shown on unit rating plate Charging method is shown on information plate inside unit To properly check or adjust charge conditions must be favorable for subcooling charging Favorable conditions exist 26 when the outdoor temperature is between 70 F 100 F 21 11 C and 37 78 C and the indoor temperature is between 70 F and 80 F 21 11 C and 26 67 C Follow the procedure below To check charge allow system to operate in cooling mode at least 15 minutes If conditions are favorable check system charge by subcooling method If any adjustment is necessary adjust charge slowly and allow system to operate for 15 minutes to stabilize before declaring a properly charged system If the indoor temperature is above 80 F 26 67 C and outdoor temperature is in the favorable range adjust system charge and allow the indoor temperature to drop to 80 F 26 67 C before attempting to check system charge by subcooling method as described above If the indoor temperature is below 70 F 21 11 C or the outdoor temperature is not in the favorable range the charge level could then be checked at another time when the both indoor and outdoor temperatures are in a more favorable range Troubleshooting with SuperHeat This troubleshooting routine was developed to diagnose cooling problems using superheat in TXV systems It is effective on h
41. EADS FAN MOTOR FAN MOTOR BURNED OUT LOW SUCTION LOW HEAD 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 WELDED CLOSED IN DEFROST RELAY REVERSING VALVE DID NOT SHIFT UNIT NOT OUTDOOR FAN RUNNING REVERSING VALVE STUCK RESTRICTED LIQUID LINE PISTON RESTRICTED OR IS CLOGGED UNDER CHARGED OUTDOOR COIL DIRTY STRAINER RESTRICTED OUTDOOR COIL HEAVILY FROSTED PROPERLY CHARGED Fig 38 Heat Pump Troubleshooting Heating Cycle 41 DEFECTIVE DEFROST THERMOSTAT DEFROST THERMOSTAT IN POOR PHYSICAL CONTACT WITH TUBE DEFECTIVE CIRCUIT BOARD BAD ELECTRICAL CONNECTION ANYWHERE IN DEFROST CIRCUIT 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 BROKEN HEATER ELEMENT OPEN KLIXON OVER TEMPERATURE THERMOSTAT DEFECTIVE ROOM THERMOSTAT 2ND STAGE A90206 HEAT PUMP TROUBLESHOOTING COOLING CYCLE NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD CONTACTOR OPEN POWER SU
42. IG F c 12 37 7 38 7 114 37 8 3 2 216 74 3 23 5 318 100 2 37 9 420 120 7 49 3 522 137 6 58 7 14 34 7 37 0 116 38 7 3 7 218 74 9 23 8 320 100 7 38 2 422 121 0 49 4 524 137 9 58 8 16 32 0 35 6 118 39 5 4 2 220 75 5 24 2 322 101 1 37 4 424 121 4 47 7 526 138 3 59 1 18 29 4 34 1 120 40 5 4 7 222 76 1 24 5 324 101 6 37 8 426 121 7 49 8 528 138 6 59 2 20 26 9 32 7 122 41 3 5 2 224 76 7 24 8 326 102 0 38 9 428 122 1 50 1 530 138 9 59 4 22 24 5 31 3 124 42 2 5 7 226 77 2 25 1 328 102 4 39 1 430 122 5 50 3 532 139 2 59 6 24 22 2 30 1 126 43 0 6 1 228 77 8 25 4 330 102 9 39 4 432 122 8 50 4 534 139 5 59 7 26 20 0 28 9 128 43 8 6 6 230 78 4 25 6 332 103 3 39 6 434 123 2 50 7 536 139 8 59 9 28 17 9 28 7 130 44 7 7 1 232 78 9 26 1 334 103 7 39 8 436 123 5 50 8 538 140 1 60 1 30 15 8 26 6 132 45 5 7 5 234 79 5 26 4 336 104 2 40 1 438 123 9 51 1 540 140 4 60 2 32 13 8 25 4 134 46 3 7 9 236 80 0 26 7 338 104 6 40 3 440 124 2 51 2 544 141 0 60 6 34 11 9 24 4 136 471 8 4 238 80 6 27 0 340 105 1 40 6 442 124 6 51 4 548 141 6 60 9 36 10 1 23 4 138 47 9 8 8 240 81 1 27 3 342 105 4 40 8 444 124 9 51 6 552 142 1 61 2 38 8 3 22 4 140 48 7 93 242 81 6 27 6 344 105 8 41 0 446 125 3 51 8 556 142 7 61 5 40 6 5 21 4 142 49 5 9 7 244 82 2 27 9 346 106 3 41 3 448 125 6 52 0 560 143 3 61 8 42 4 5 20 3 144 50 3 10 2 246 82 7 28 2 348 106 6 41 4 450 126 0 52 2 564 143 9 62 2 44 3 2 19 6 146 51 1 10 6 248 83 3 28 5 350 107 1 41 7 452 126 3 52 4 568 144 5 62
43. ION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation The compressor in a R 410A system uses a polyolester POE or polyvinyl ether PVE oil This oil is extremely hygroscopic meaning it absorbs water readily POE PVE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precautions to avoid exposure of the oil to the atmosphere See Table 3 Brazing This section on 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 below are listed only as a reminder Definition The joining and sealing of metals using a nonferrous metal having a melting point over 800 F 426 6 C Flux A cleaning solution applied to tubing or wire before it is brazed Flux improves the strength of the brazed connection 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 Remove all oxidation from surfaces to a shiny finish before brazing Remove all flux residue with brush and water while material is still hot 2 Silver brazing alloy is used _ copper to brass copper to steel or copper to copper Flux is required when using silver brazing alloy Do not use low temperature solder 3 Fluxes shoul
44. Indianapolis 46231 Edition Date 04 15 Catalog SM10 05 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces 5 10 04 44
45. LVE HUNG UP OR INTERNAL LEAK DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON FAILED TXV A90207 INDEX OF TABLES DESCRIPTION ere sie rare Required Field Installed Accessories for Air Conditioners amp Heat Pumps 1 2 Defrost Control Speed Up Timing Sequence Table 21 7 2 14 Air Conditioner amp Heat Pump Compressor Information Table 0 0 0 cece ee eee ee eens 21 PistOnfEXV wus Sob 23 Minimum Airflow for Safe Electric Heater Operation 2 1 2 29 Superheat Charging Table Seed Saas See ea waa heal OOR mad seus Seale ead ea ea eeu Saeed 29 Required Subcoolinig Bet di See ook hal Po aa ee 30 Pressure vs Temperature Chart Table 22 20 bb bie Ee RG hi Bede Cea es 39 43 Copyright 2015 7310 W Morris St
46. Location 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 Defrost Control Board Troubleshooting 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 Defrost Control The defrost control is used in all R 410A Mobile Home series heat pump models Its features include selectable defrost intervals of 30 60 90 minutes and standard defrost speed up capability This section describes the sequence of operation and trouble shooting methods for this control Cooling Sequence of Operation On a call for cooling thermostat makes R O R Y and R G Circuit R O energizes reversing valve switching it to cooling position Circuit R Y sends low voltage through the safeties and energizes the contactor which starts the compressor and energizes the T1 terminal on the circuit board This will energize the OF2 fan relay which starts the outdoor fan motor When the cycle is complete R Y is turned off and compressor and outdoor fan should stop With corporate thermostats the O terminal remains energized in the cooling mode If the mode is
47. PPLY 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 DEFECTIVE START CAPACITOR OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING DAMAGED OR STUCK REVERSING VALVE RESTRICTED DISCHARGE TUBE OVERCHARGE OR NON CONDENSABLES SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT DEFECTIVE START CAPACITOR LOOSE LEAD AT FAN MOTOR DEFROST RELAY N C CONTACTS OPEN MOTOR DEFECTIVE INCORRECT OFM CAPACITOR DEFECTIVE DEFROST THERMOSTAT COMPRESSOR RUNS BUT INSUFFICIENT COOLING 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 39 Heat Pump Troubleshooting Cooling Cycle 42 HIGH SUCTION LOW HEAD PRESSURE REVERSING VA
48. R 410A heat pumps have a specifically designed reversing valve for R 410A application and an accumulator for storing excess liquid refrigerant during the heating mode to prevent damaging flood back i i 00 10170 Fig 29 ECM Motor POWER CONNECTOR SIGNAL CONNECTOR A10169 Fig 30 ECM Module Plug Control Box Contactor Capacitor and Board Removal of the front right compressor control panel will expose most of the unit s components Both the air conditioner and heat pump control boxes will be in the upper right corner of the unit There will be a contactor that cycles components off and on The capacitor will assist the outdoor fan and compressor to operate The heat pump models will have a circuit board to control the defrost cycle 31 Always replace these devices with the Factory Approved Components Incoming Power Incoming power is attached to the two power wire stripped leads A ground lug is also provided Unit should always be grounded through the ground lug to the unit disconnect and from the disconnect to the electrical fuse box Failure to do so can cause serious injury or death o Electric Heat Control Box shown uninstalled Electric Heat wiring interconnection electric for clarity heater controls removed A10030 Air Conditioning Control Box Wiring 32 sho
49. SLN3WJYINOJY JIN 1432 3 14011 070659757759 AMINA 83406 HLIM LINN 40 3015 12911 0706 72277 750 1 340 LONG 31150440 LINN 10 3015 1710 07967 17 veers TINA 30 401 WW SIHONI 6 804 J NYAYITO 0341 034 119011 0727 3015 AYINI 83404 532 3805 03080049 83410 STIVM 31342802 32018 ONY LINN 716 0 96 71015 AYINI YIMOd 532 3805 CIONNOYINN LINN L904 0 777 7 77 7 1015 48143 YJMOd SLINA 1334136 WW SIHONI 5300873133 03 81 0368 IN SONINSdO LONG 31150440 LINN 40 3015 SONINAdO LONG 8114 LINN 30 3015 Shit ate et LINN 40 101108 140 401 31815 02 OL 0341 034 WW S3HONT 709 B E 2 1971721 71 6 TANVd 554 4 8340 19 92 MIAA 32615 48143 83406 977 5 10 12796 9171 6 1079611 9 0 62 4330 117211 2 1 8 92 5071 11780 FLVSNIGNOD 48183 19 110 MOT 127221 BILD 176661 8 6 61 786811 7 1 9 48 13 83004 FLVNYSL TV 2 22 8 10 LINN 40 WO1108 1872181 180136 LINNA 40 WOLLOS 7 56211 51015 1113 TANVd 93007 1102 800481 ONY 08 1041802 80551844402 IS MAA 3015 1 31 51015 110
50. Using R 410A Refrigerant Air Conditioners and Heat Pumps 6 x ou 5 pz 9 Service Manual TABLE OF CONTENTS SAFETY CONSIDERATIONS INTRODUCTION cee cw eee ee INSTALLATION GUIDELINE ACCESSORY DESCRIPTIONS LOW AMBIENT COOLING GUIDELINE CABINET ASSEMBLY amp COMPONENTS 9 10 Aluminum Wire ELECTRICAL 55595 99 led ak CONTAGION Sodas dab Capacitor sc cea aie gee EE 10 10 10 10 CYCLE 024 048 Heat Pump 060 A C amp 13 SEER Heat Pump Crankcase Heater PRESSURE SWITCHES A10165 10 10 10 11 11 11 Low Pressure Switch High Pressure Switch AC amp Loss Of Charge Switch HP only DEFROST THERMOSTAT DEFROST CONTROL BOARD 11 Defrost Control COPELAND SCROLL DANFOSS SCROLL gt 14 15 LG SCROLL
51. aced 2 Drain any trapped oil from accumulator if used 3 Remove and discard liquid line strainer and filter drier 4 After system is reassembled install liquid and suction line R 410A filter driers NOTE On heat pumps install suction line drier between compressor and accumulator 5 Operate system for 10 hr Monitor pressure drop across drier If pressure drop exceeds 3 psig replace suction line and liquid line filter driers Be sure to purge system with dry nitrogen when replacing filter driers If suction line driers must be replaced retest pressure drop after additional 10 hours run time Continue to monitor pressure drop across suction line filter drier After 10 hr of run time remove suction line filter drier and replace liquid line filter drier Never leave suction line filter drier in system longer than 72 hr actual time 6 Charge system See unit information plate CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Only suction line filter driers should be used for refrigerant and oil clean up Use of non approved products could limit system life and void unit warranty Evacuation Proper evacuation of the system will remove non condensibles and assure a tight dry system before charging The 2 methods used to evacuate a system are the deep vacuum method and the triple evacuation method Deep Vacuum Method The deep vacuum method requ
52. ankcase heater is wired in parallel with contactor contacts and in series with compressor See Fig 12 When contacts open a circuit is completed from line side of contactor through crankcase heater through run windings of compressor and to other side of line When contacts are closed there is no circuit through crankcase heater because both leads are connected to same side of line This allows heater to operate when system is not calling for cooling The heater does not operate when system is calling for cooling CRANKCASE HTR BLK BLK 09 10 10174 Fig 12 Wiring for Single Pole Contactor 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 R 410A pressure switches are specifically designed to operate with R 410A systems R 22 pressure switches must not be used as replacements for the R 410A air conditioners or heat pumps R 410A pressure switches are identified by a pink stripe down each wire Low Pressure Switch Neither of the air conditioner or heat pump units have a low pressure switch The heat pump models have a loss of charge switch located downstream of the liquid line filter drier See loss of charge for more details High Pressure Switch AC amp HP The high pressure switch is located in the discharge line and protects against excessive con
53. apacitors 3 Remove wires from terminals C S and R 4 On hermetic compressors allow crankcase heaters to remain 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 megohmmeter may be used in place of ohmmeter Follow manufacturer 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 sequence 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 230 000 ohms minimum SHORT CIRCUIT To determine if any wires within windings have broken through their insulation and made contact with 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 manufacturer s specifications 2 Temperature of windings must be as specified usually about 70 F 21 1 C 3 Resistance measuring instrument must have an accuracy within 5 10 percent This requires an accurate ohmmeter such as
54. ccess or removal of the evaporator coil a 024 to 036 The indoor evaporator coil is held in place by screws located in the compressor compartment and behind the return air duct The 14 return collar must be removed to access these screws b 042 to 060 The indoor evaporator coil is held in place by screws located in the compressor compartment and on the rectangular duct flange The rectangular duct flange does not need to be removed but the left side screws will have to be removed See Fig 8 and 9 A10160 A10159 Fig 7 Removal of Right Side Back Panel 1355 61 DUCT OPENING EVAPORATOR CONDENSOR COILS 10161 Fig 8 Access of Condenser Coil 9 3 8 18 3 4 j 1238 11 1416 21 Dis 1355 61 DUCT OPENINGS REAR VIEW SMALL MEDIUM CHASSIS 3 4 1355 61 DUCT OPENING 14 173 01 MEDIUM LARGE CHASSIS A10173 Fig 9 Location of Screws Labeling The wiring schematic sub cooling charging tables with instructions and warning labels Refer to Fig 10 for label location FIELD CONNECTIONS BLOWER PANEL WIRING DIAGRAM ON BACKSIDE OF CONTROL FRONT OF CONTROL amp COMPRESSOR PANEL A10163 Fig 10 Label Location ELECTRICAL A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Exercise extreme caution when working on any electrical components Shut off all power to system pri
55. chrometer or electronic equivalent 6 Using Superheat Charging Table Table 6 find outdoor temperature and indoor air wet bulb temperature At this intersection note superheat Where a dash appears on table do not attempt to charge unit under these conditions or refrigerant slugging may occur In this situation refrigerant must be evacuated and weighed in See rating plate for charge quantity 7 Refer to Required Suction Tube Temp Table Table 6 Find superheat temperature located in Step 6 and suction pressure At this intersection note suction line temperature 8 If unit has a higher suction line temperature than charted temperature add refrigerant until charted temperature is reached 9 If unit has a lower suction line temperature than charted temperature reclaim refrigerant until charted temperature is reached 10 If outdoor air temperature or pressure at suction port changes charge to new suction line temperature indicated on chart 048 060 Units TXV 1 Measure Discharge line pressure by attaching a gauge to the service port 2 Measure the Liquid line temperature by attaching a tempera ture sensing device to it 3 Insulate the temperature sensing device so that the Outdoor Ambient doesn t affect the reading 4 Refer to the required Subcooling in Table 7 based on the model size and the Outdoor Ambient temperature 5 Interpolate if the Outdoor ambient temperature lies in be tween the table values 6
56. d be used carefully Avoid excessive application and do not allow fluxes to enter into the system 4 Brazing temperature of copper is proper when it is heated to a minimum temperature of 800 F 426 6 C and it is a dull red color in appearance Reversing Valve In heat pumps changeover between heating and cooling modes is accomplished with a valve that reverses flow of refrigerant in system 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 24v 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 tubes 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 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 to each other 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 20 Route thermocou
57. d install lockout tag 2 Remove outdoor fan assembly grille motor motor cover and fan by removing screws and flipping assembly onto unit top cover 3 Inspect the fan blades for cracks or bends 4 If fan needs to be removed loosen the setscrew and slide the fan off the motor shaft 5 When replacing fan blade position blade as shown in Fig 19 Tighten setscrews Fan Motor The fan motor rotates the fan blade that draws air through the outdoor coil to exchange heat between the refrigerant and the air Motors are totally enclosed to increase reliability This eliminates the need for a rain shield For the correct position of fan blade assembly the fan hub should be flush with the motor shaft Replacement motors and blades may vary slightly 13 amp 14 SEER AC UNIT A SIZE in mm 024 13 16 20 6 030 13 16 20 6 036 0 042 0 048 0 060 3 16 4 8 14540 13 SEER HP SIZE in mm 024 13 16 20 6 030 13 16 20 6 036 0 042 0 048 0 060 1 2 12 7 14 5 HP SIZE in mm 024 13 16 20 6 030 13 16 20 6 036 0 042 0 048 172 12 7 060 1 2 12 7 150078 Fig 19 Outdoor Fan Adjustment 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Turn off all power before servicing or replacing fan m
58. denser coil pressure It opens around 650 psig and closes at 420 25 psig for R 410A High pressure may be caused by a dirty condenser coil failed fan motor or condenser air re circulation To check switch 1 Turn off all power to unit 2 Disconnect leads on switch 3 Apply ohmmeter leads across switch You should have continuity on a good switch NOTE 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 system charge so that pressure gauges read 0 psig Never open system without breaking vacuum with dry nitrogen CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant 1 Apply heat with torch to solder joint and remove switch CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses when using torch Have quenching cloth available Oil vapor in line may ignite when switch is removed 2 Braze in a new pressure switch Loss of Charge Switch HP Only Located on liquid line of heat pump only the liquid line pressure switch functions similar to conventional low pressure switch Because heat pumps experience very low suction pressures
59. eat pumps in cooling mode as well as air conditioners The system must utilize a TXV as the expansion device in cooling mode Basic Diagnostics NOTE When checking refrigerant charge and troubleshooting operating systems the indoor airflow has significant effect on the determination If you are at this stage it is assumed you have already checked the subcooling once and believe the charge is correct From this point the airflow must be verified prior to proceeding hence step 1 below 1 Check or verify proper indoor airflow e 1101001 air filter e Duct dampers and supply registers are open e coil for debris 2 Check subcooling at OD coil and discharge high flow valve e Outdoor airflow debris coil etc e Set the subcooling at value listed on rating plate 3 Check superheat at suction high flow service valve e If low lt 2 F proceed to Low SuperHeat section e If between 2 and 20 F 6 7 C valve is probably operating properly e If operation erratic hunting proceed to Hunting Superheat F Superheat in repetition section NOTE Hunting is when the valve superheat swings more than 10 Low Superheat with Normal or Low Suction Pressure NOTE Normal or low suction pressure is considered for R 410A lt 135 psig 1 Re check airflow and then check sensing bulb tightness orientation on vapor tube and is properly wrapped Superheat with Normal or Low Suction Pressure If OK proceed to Step 2 2 Check super
60. emove jumper causes unit to switch to defrost every 30 60 or 90 minutes and remain in defrost for full 10 minutes 15 Replace access panel Restore power to unit If defrost thermostat does not check out following above items or incorrect calibration is suspected check for defective thermostat as follows 1 Follow items 1 5 above 2 Route sensor or probe using thermocouple temperature measuring device Attach to liquid line near defrost thermostat Insulate for more accurate reading 3 Turn on power to outdoor unit 4 Restart unit in heating 5 Within a few minutes liquid line temperature drops within a range causing defrost thermostat contacts to close Temperature range is from 36 F 2 2 C to 29 F 1 7 C Notice temperature at which ohmmeter reading goes from to zero ohms Thermostat contacts close at this point 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 50 F 10 C to 70 F 21 1 C Resistance goes from zero to when contacts are 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 NOTE With timing cycle set at 90 minutes unit initiates defrost within approximatel
61. en the unit shifts into defrost Failure to remove the short immediately will result in a very short forced defrost cycle the 10 minute timer will be sped through in 2 seconds 4 When defrost begins it will continue until the defrost thermostat opens or 10 minutes has elapsed NOTE The T1 terminal on the defrost board powers the defrost timing function This terminal must be energized before any defrost function will occur If defrost thermostat is stuck closed Whether the unit is in heating or cooling mode it will run a defrost cycle for 10 minutes each time the compressor has been energized for the selected time interval The board will terminate automatically after 10 minutes of defrost time regardless of defrost thermostat position If defrost thermostat is stuck open The unit will not defrost If unit will not defrost 1 Perform the speedup function as described above to test the defrost function of the circuit board 2 If the unit does not go into defrost after performing the speed up check for 24 volts on the T1 terminal This terminal powers the defrost circuit and must be energized before any defrost function can occur The 1 should be energized once the Y terminal is energized and the pressure switches are closed Ensure the T1 wire is connected at the contactor and that 24 volts is present on the T1 terminal 3 If all voltages are present and unit will still not run defrost remove thermostat pigtail harness
62. entify terminals C S and R 1 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 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 Remaining terminal will be run winding R See Fig 18 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 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 ohmmeter on 0 1000 ohm scale Because winding resistances are usually less than 10 ohms 17 each reading appears to be approximately ohm If resistance remains at 1000 ohms an open or break exists and compressor should be replaced Be sure internal line break overload is not temporarily open 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 2 Discharge all c
63. er Troubleshooting Chart 40 HIGH SUCTION LOW HEAD PRESSURE DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON FAILED TXV A90208 TROUBLESHOOTING HEATING CYCLE NO HEATING OR INSUFFICIENT HEATING COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD COMPRESSOR WILL NOT RUN COMPRESSOR RUNS INSUFFICIENT HEATING CONTACT OPEN DEFECTIVE LOW VOLTAGE TRANSFORMER REMOTE CONTROL CENTER DEFECTIVE CONTACTOR COIL OPEN OR SHORTED OPEN INDOOR THERMOSTAT LIQUID 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 DEFECTIVE START 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 START CAPACITOR DEFECTIVE FAN MOTOR CAPACITOR LOOSE L
64. ester Manufacturer Oil Charge fl oz intial recharge 21 17 25 21 25 19 43 35 43 35 42 1 36 1 212 1 394 949 1 091 Winding Resistance ohm Start 1303 avg 1 020 avg 0 90 0 67 0 70 0 45 1 523 1 753 1 772 2 038 Winding Resistance ohm Start 5 1 638 avg 1 905 avg 1 30 1 46 0 82 0 79 Winding Resistance ohm Start R S 2 94 2 93 2 20 2 13 1 50 1 24 Run Capacitor mfd volts 40 440 35 440 45 440 45 440 70 440 70 440 21 OUTDOOR COIL FROM INDOOR COIL TO ACCUMULATOR FROM COMPRESSOR DISCHARGE LINE A10189 Fig 20 Reversing Valve Cooling Mode or Defrost Mode Solenoid Energized Liquid Line Filter Drier Filter driers are specifically designed for R 410A refrigerant Only operate with the appropriate drier using factory authorized components There is a liquid line drier located inside the unit in the compressor section The liquid line drier also acts as a strainer Suction Line Filter Drier The suction line drier is specifically designed to operate with R 410A use only factory authorized components Suction line filter drier is used in cases where acid might occur such as burnout Heat pump units must have the drier installed between the compressor and accumulator only Remove after 10 hours of operation Never leave suctio
65. etal contact Place other probe on terminals C S and R in sequence 7 Note meter scale 8 If reading of 0 or low resistance is obtained motor is grounded Replace compressor Compressor resistance to ground should not be less than 1000 ohms per volt of operating voltage Example 230 volts X 1000 ohms volt 230 000 ohms minimum Short Circuit To determine if any wires within windings have broken through their insulation and made contact with 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 manufacturer s specifications 2 Temperature of windings must be as specified usually about 70 F 21 C 3 Resistance measuring instrument must have an accuracy within 5 10 percent This requires an accurate ohmmeter such as Wheatstone bridge or null balance type instrument 4 Motor must be dry or free from direct contact with liquid refrigerant Make This Critical Test Not advisable unless above conditions are met Be sure all power is off Recover all refrigerant charge Discharge all capacitors Remove wires from terminals C S and R WN Place instrument probes together and determine probe and lead wire resistance 6 Check resistance readings from C R C S and R S 7 Subtract instrument probe and lead resistance from each
66. from board and perform checks directly on input pins with jumper wires The pigtail may have a bad connection or be mis wired To fully troubleshoot defrost thermostat and control function 1 Turn thermostat to OFF Shut off all power to outdoor unit 2 Remove control box cover for access 10 electrical components and defrost control board 3 Disconnect defrost thermostat leads from control board and connect to ohmmeter Thermostat leads are black insulated wires connected to DFT and R terminals on control board Resistance reading may be zero indicating closed defrost thermostat or infinity for open thermostat depending on outdoor temperature 4 Jumper between DFT and R terminals on control board as shown in Fig 14 5 Disconnect outdoor fan motor lead from OF2 Tape lead to prevent grounding 13 6 Turn 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 temperature at defrost thermostat should drop below closing set point of defrost thermostat of approximately 32 F 0 C Check resistance across defrost thermostat leads using ohmmeter Resistance of zero indicates defrost thermostat is closed and operating properly 9 Short between the speed up terminals using a thermostat screwdriver This reduces the timing sequence to 1 256 of original time See Table 2 Table 2 Defrost Control Speed Up Tim
67. gh performance and minimize possible equipment malfunction it is essential that maintenance be performed periodically 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 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in equipment damage or death 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 Lock out and tag switch with suitable warning label The minimum maintenance that should be performed on this equipment is as follows 1 Check outdoor coil for cleanliness each heating and cooling season and clean as necessary 2 Check fan motor and blade for cleanliness each month during cooling season and clean as necessary 3 Check electrical connections for tightness and controls for proper operation each cooling season and service as necessary CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Because of possible damage to the equipment or personal injury maintenance should be performed by qualified personnel only Desert and Seacoast Locations Special consideration must be given to installation and maintenance of condensing unit
68. heat at suction high flow service valve and Pseudo Evaporator Superheat e If both are less than 2 likely not controlling properly i e stuck open gt REPLACE VALVE e If superheat is higher than 15 F proceed to Step 3 3 Perform function check e With system running place sensing bulb ice bath for 1 minute gt superheat should increase If response Replace Valve If OK proceed to Step 4 4 Check for even temperature distribution at outlet of each circuit of evaporator e If greater than 15 F between circuits distributor or coil has a restriction e proceed to Step 5 Low Superheat with High Suction Pressure NOTE High suction pressure is considered for R 410A gt 135 psig Component failure typically causes this condition 5 Check airflow sensing bulb tightness orientation on vapor tube and ensure bulb is properly wrapped e proceed to Step 6 6 Check that compressor is pumping properly NOTE Loose Rules of Thumb Is discharge saturated 20 F higher than ambient temperature Is discharge superheat between 15 and 50 e proceed to Step 7 7 Recheck Airflow and Subcooling e proceed to Replace Valve High Superheat with Normal or Low Pressure NOTE Normal or low suction pressure is considered R 410A lt 135 psig 8 Check for restriction in liquid line kinked line filter drier restricted etc e proceed to Step 9 9 Check for restriction in suc
69. igher than the table value 9 Remove charge if the measured temperature is lower than the table value DRAWING NUMBER 50ZH500700 A SHEET 1 1 Required Subcooling F Required Subcooling C Sequence of Operation FAN OPERATION The FAN switch on the thermostat controls indoor fan operation When the FAN switch is placed in the ON position the indoor evaporator fan motor IFM is energized through the G terminal on the thermostat The motor s internal logic then provides power to the indoor evaporator fan motor IFM The IFM will run continuously when the FAN switch is set to ON When the FAN switch is set to AUTO the thermostat deenergizes the IFM provided there is not a call for cooling The contacts open and the IFM is deenergized The IFM will be energized only when there is a call for cooling in heat pump heating mode or if the unit is equipped with accessory electric heat the indoor fan motor will also run while the accessory electric heat is energized NOTE Motors on this product are programmed for 60 second time delay on tap 1 and 30 second time delay on tap 2 There is no time delay on tap 3 The indoor fan will remain ON for the set time delay after G or W2 is de energized COOLING OPERATION With a call for cooling Y the compressor outdoor fan and indoor fan start immediately When the cooling demand is met Y de energizes shutting the compressor indoor fan and the outdoor fan
70. il 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 Metering device 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 Compressor Removal and Replacement Once it is determined that compressor has failed and the reason established compressor must be replaced 4 CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant and observe the following The high flow service valve is equipped with Schrader valves 4 WARNING PERSONAL INJURY AND ENVIRONMENTAL HAZARD Failure to follow this warning could result in personal injury or death Relieve pressure and recover all refrigerant before system repair or final unit disposal Use all
71. imum operating temperature for these units in cooling mode is 40 F 4 4 C outdoor ambient without additional accessories This equipment may be operated in cooling mode at ambient temperatures below 40 F 4 4 C when the accessories listed in Table 1 are installed 10165 CABINET ASSEMBLY Basic Cabinet Designs Certain maintenance routines and repairs require removal of the cabinet panels There are 3 cabinet sizes for the air conditioning and heat pump models However all of the units have similar panel construction other than their size The base footprint is the same on all three cabinet sizes REAR VIEW 10166 Small and Medium Cabinet A10167 Medium and Large Cabinet Rear View Fig 2 Cabinet Designs 59 1 340 LONG 1975561 091 8 lt 2 553277 830018 30S 1491 13 4 1971061 lt 61 4330 117211 2 1 X 187921 5071 11780 31 5820802 MIA 1062 127061 91 1 AYINI 39 110 MOT 127221 8 1 83 001 1104 660 8 6 61 1178611 395 1441 1103 2 911 17862 8 6 1279611 91 1 62 13 4 93007 1102 000 1 ONY 7081802 80553844902 1079511 9 11 62 MJA dOL
72. ing Sequence MINIMUM MAXIMUM SPEED UP PARAMETER MINUTES MINUTES NOMINAL 30 minute cycle 27 33 7 50 45 55 12 sec 90 minute cycle 81 99 21 sec 10 minute cycle 9 11 2 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Exercise extreme caution when shorting 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 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 thermostat contacts to open Check resistance across defrost thermostat Ohmmeter should read infinite resistance indicating defrost thermostat has opened at approximately 65 F 13 Shut off unit power and reconnect fan lead 14 Remove jumper between DFT and R terminals Reconnect defrost thermostat leads Failure to r
73. ires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gauge 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 moisture See Fig 27 5000 4500 4000 3500 5 3000 2500 2000 1500 1000 500 LEAK IN SYSTEM VACUUM TIGHT TOO WET TIGHT DRY SYSTEM 0 1 2 3 4 MINUTES 6 7 95424 Fig 27 Deep Vacuum Graph Triple Evacuation Method The triple evacuation method should be used when vacuum pump is only capable of pumping down to 28 in of mercury vacuum and system does not contain any liquid water Refer to Fig 28 and proceed as follows 1 Pump system down to 28 in of mercury and allow pump to continue operating for an additional 15 minutes 2 Shut off vacuum pump 3 Connect a nitrogen cylinder and regulator to system and open until system pressure is 2 psig 4 Allow system to stand for 1 hr During this time dry nitrogen will be able to diffuse throughout the system absorbing moisture 5 Repeat this procedure as indicated in Fig 28 System will then be free of any contaminants and water vapor EVACUATE BREAK VACUUM WITH DRY NITROGEN WAIT EVACUATE BREAK VACUUM WITH DRY NITROGEN WAIT EVACUATE CHECK FOR TIGHT DRY SYSTEM IF IT HOLDS DEEP VACUUM Yy 5 5 495425 Fig 28 Triple Evacuation Method Check
74. l injury or equipment damage R 410A systems operate at higher pressures than standard R 22 systems Do not use R 22 service equipment or components on these R 410A units Ensure service equipment is rated for R 410A Refrigeration systems contain refrigerant under pressure Extreme caution should be observed when handling refrigerants Wear safety glasses and gloves to prevent personal injury During normal system operations 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 Follow all safety codes Wear safety glasses protective clothing and work gloves Have a fire extinguisher available Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit Consult local building codes the current editions of the National Electrical Code NEC NFPA 70 and NFPA 90B Installation Warm Air Heating and A C Systems Residential In Canada refer to the current editions of the Canadian Electrical Code CSA C22 1 INTRODUCTION This document provides required system information necessary to install service repair or maintain the small package products SPP air conditioners and heat pumps using R 410A refrigerant Refer to the unit Product Data Technical specifications for rating information electrical data required clea
75. 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 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 capacity loss must be eliminated before condemning compressor Noisy Compressor Noise may be caused by a variety of internal problems such as loosened hardware broken mounting springs etc System problems 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 Compress
76. lter drier evacuate system recharge and check for normal systems operation Compressor Removal and Replacement Once it is determined that compressor has failed and the reason established compressor must be replaced A CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Turn off all power to unit before proceeding Lock out and tag switch with suitable warning label Wear safety glasses protective clothing and gloves when handling refrigerant Acids formed as a result of motor burnout can cause burns CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant and when using brazing torch 1 Shut off all power to unit 2 Remove and recover all refrigerant from system until pressure gauges read 0 psig Use all service ports Never open a system under a vacuum to atmosphere Break vacuum with dry nitrogen holding charge first Do not exceed 5 psig 3 Disconnect electrical leads from compressor Disconnect or remove crankcase heater and remove compressor hold down bolts 4 Cut compressor from system with tubing cutter 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 st
77. motor If the heaters are staged W2 is energized when the second stage of heating is required When the need for heating is satisfied the heater and IFM are de energized ECM Fan Motor Troubleshooting Caution Do not disconnect motor plugs under load e Check the high voltage supply to motor The ECM fan motor will always have high voltage to the motor even when the motor is off The 24 volt signal cycles the motor on and off The motor can accept more than one 24 volt control signal to the different motor taps without damaging it The motor will default to the highest speed tap that see a 24 volt signal 30 Fan won t run e Cycle power off to the unit Disconnect the two plugs going into the motor One plug is the high voltage supply and the other is the low voltage control e Cycle power back on and measure the high voltage supply plug to determine if there is voltage at plug If there is no voltage at plug determine if there is power to the unit The easiest place to measure the voltage is on the line side of the contactor If there is voltage at the contactor and no voltage at the plug cycle the power back off and inspect the wiring harness and plug for loose or broken connections Replace the wiring harness and plug if it is found to be defective there is power at the high voltage plug check the low voltage control signal e With the power on to the unit verify that there is 24volts between R and
78. n line filter drier in a system longer than 72 hours actual time Accumulator The accumulator is specifically designed to operate with R 410A pressures use only factory authorized components Under some light load conditions on indoor coils 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 replacing 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 refrigerant The bleed hole allows a small amount of oil and refrigerant to enter 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 The accumulator has a fusible element located in the bottom end bell See Fig 22 This fusible element will melt at 430 F 221 C and vent the refrigerant if this temperature is reached either internal or external to the system If fuse melts the accumulator must be replaced To change accumulato
79. ng because it has more turns This terminal is the start S The remaining terminal will be run winding R 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 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 15 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 When a 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 equalization defective capacitor s relays wiring etc Compressor has internal line break overload so be certain it is closed Open Circuit 4 WARNING UNIT PERSONAL INJURY HAZARD Failure to follow this warning could result in personal injury Use caution when working near compressor terminals Damaged terminals have the potential to cause personal injury Never put face or body directly in line with terminals To determine if any winding has a break in the internal wires and current is unable to pass through follow these steps 1 Be sure all power is off 2 Discharge all capacitors 3 Remove
80. nses coil temperature throughout the heating cycle When the coil temperature reaches the defrost thermostat setting it will close which energizes the DFT terminal and begins the defrost timing sequence When the DTF has been energized for the selected time the defrost cycle begins and the control shifts the reversing valve into cooling position and turns the outdoor fan off This shifts hot gas flow into the outdoor coil which melts the frost from the coil The defrost cycle is terminated when defrost thermostat opens or automatically after 10 minutes 11 DETAIL D B SEE DETAIL SEE DETAIL D 024 030 13 SEER 024 14 SEER 036 13 SEER 030 036 14 SEER DETAIL F DETAIL H SEE DETAIL F SEE DETAIL 042 13 amp 14 SEER Defrost thermostat can either be located on the bottom of tube as shown or on the top and must not interfere with any other tubing A14538 Fig 15 DFT Sensor Location 024 048 12 DETAIL L SEE DETAIL 060 13 SEER Defrost thermostat can either be located on the bottom of tube as shown or on the top and must not interfere with any other tubing A150079 DEFROST SWITCH LOCATION SEE NOTE SEE DETAIL M 2 Defrost switch can either be located on the bottom of tube as shown or on the top and must not interfere with any other tubing 060 14 SEER Heat Pump
81. ol or move tool horizontally against fins 3 If oil deposits are present spray coil with ordinary household detergent Wait 10 minutes and proceed to next step 4 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 5 Reinstall side panel 6 Reconnect electrical power and check for proper operation Cleaning Outdoor Fan Motor and Blade 1 Remove grille fan motor and blade Be careful not to bend or dent fan blade 2 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 4 Reinstall fan motor and blade to grille and check for alignment 5 Reinstall grille and position blade 6 Reconnect electrical power and check for proper operation Electrical Controls and Wiring 1 Disconnect power to unit 2 Check all electrical connections for tightness Tighten all screws on electrical connections If any connections appear to be burned or smoky 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 3 Reconnect electrical power to unit and observe unit through 1 complete operating cycle 4 If there are any discrepancies in operating cycle troubleshoo
82. oltage or amperage issue Verify adequate voltage and operational start components if installed If it is drawing excessive amperage and voltage doesn t appear to be the problem it may be assumed a locked condition Ensure refrigerant has had ample time to equalize and boil out of the compressor before condemning 7 When a heat pump switches into and out of defrost a swooshing noise is expected due to the rapid pressure change within the system Check that the defrost thermostat or thermistor is operating properly Insulating the defrost sensing device may also help Electrical Failures 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 abnormalities Before troubleshooting compressor motor review this description of compressor motor terminal identification Single Phase Motors To identify terminals C S and R 1 Turn off all unit power 2 Discharge 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 Through elimination remaining terminal must be common C Greatest resistance between common C and another terminal indicates the start windi
83. or Leaks 4 CAUTION UNIT DAMAGE AND OR PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury and or unit component damage High flow service valves are equipped with Schrader valves Wear safety glasses and gloves when handling refrigerant 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 procedure is followed 1 Turn off all power to unit 2 Remove and recover all refrigerant from system so that gage pressures are 0 psig 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 requires compressor replacement Electrical Failures 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 abnormalities Before troubleshooting compressor motor review this description of compressor motor terminal identification Single Phase Motors To id
84. or to troubleshooting Some troubleshooting techniques require power to remain on In these instances exercise extreme caution to avoid danger of electrical shock ONLY TRAINED SERVICE PERSONNEL SHOULD PERFORM ELECTRICAL TROUBLESHOOTING Aluminum Wire CAUTION UNIT OPERATION AND SAFETY HAZARD Failure to follow this caution may result in equipment damage or improper operation Aluminum wire may be used in the branch 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 Whenever aluminum wire is used in branch circuit wiring with this unit adhere to the following recommendations 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 service panel and unit in excess of 2 of unit rated voltage To prepare wire before installing connector all aluminum wire must be brush scratched and coated with a corrosion inhibitor such as Pentrox A When it is suspected that connection will be exposed to moisture it is very important to cover entire connection completely to prevent an electrochemical action that will cause connection
85. otor Be sure unit main power switch is turned off Lock out and tag with suitable warning label 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 and 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 arcing burning or overheating Compressor Plug The compressor electrical plug provides a quick tight connection to compressor terminals The plug completely covers the compressor terminals and the mating female terminals are completely encapsulated in plug Therefore terminals are isolated from any moisture so corrosion and resultant pitted or discolored terminals are reduced The plug is oriented to relief slot in terminal box so 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 plug However the
86. otor to provide a load for the thermostat s triacs or relay Time Delays The unit system time delays include e The air conditioning or heat pump units do not have any built in time delays to start the cooling or heating cycle Most residential thermostats have an electronic safety start feature built into the software to prevent compressor short cycling The indoor fan motor ECM has a built in fan off delays on the first two taps of the motor The third motor tap will shut off immediately after the 24v signal is gone See the following for details Tap 1 60 second off delay Tap 2 30 second off delay Tap 3 0 second off delay e The only other timing feature in the heat pump units built into the defrost board See defrost board sequence for more details on defrost time delays and setups Pressure Switches The R 410A air conditioner contains one pressure switch to prevent system operation of the pressures get excessively high The high pressure switch opens at 650 psig and closes at 420 psig The pressure switch setting is considerably higher than on comparably sized R 22 units The high pressure switch can be identified by their pink stripe on the switch s electrical wires The R 410A heat pump contains a loss of charge switch in the liquid line which opens at 20 psig and closes at 45 psig See troubleshooting section for sequence when a pressure switch trip occurs Accumulator Reversing Valve RVS The
87. ple leads to inside of coil area through service valve mounting plate area underneath coil Fig 20 and Fig 21 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 charge from system 2 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 re brazed 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 Because defective valve is not Save stubs for future use overheated it can be analyzed for cause of failure when it is returned 3 Braze new valve onto used stubs Keep stubs oriented correctly 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 4 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 5 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 Table 3 Compressor Information 13 SEER Air Conditioner Uni
88. r 1 Shut off all power to unit 2 Recover all refrigerant from system 3 Break vacuum with dry nitrogen Do not exceed 5 psig NOTE Refer to appropriate sections of Service Manual for instructions TO FROM OUTDOOR ACCUMULATOR COIL TO INDOOR COIL INSULATE FOR TP 4 3 ACCURATE READING INSULATE FOR ACCURATE 7 READING FROM COMPRESSOR DISCHARGE LINE ELECTRONIC THERMOMETER A10188 Fig 21 Reversing Valve Heating Mode Solenoid De Energized CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant 4 Remove accumulator from system with tubing cutter 5 Tape ends of open tubing 6 Scratch matching marks on tubing studs and old accumulator Scratch matching marks on new accumulator Unbraze stubs from old accumulator and braze into new accumulator 7 Thoroughly rinse any flux residue from joints and paint with corrosion resistant coating such as zinc rich paint 8 Install factory authorized accumulator into system with copper slip couplings 9 Evacuate and charge system Pour and measure oil quantity if any from old accumulator If more than 20 percent of oil charge is trapped in accumulator add new POE or PVE oil to compressor to make up for this loss See Table 3 430 FUSE ELEMENT A88410 Fig 22 Accumulator 2
89. rances additional component part numbers and related pre sale data Installation Instructions are also available per specific models Information in this document refers to units produced in 2010 to current INSTALLATION GUIDELINE Residential New Construction Specifications for these units in the residential new construction market require the unit to be installed outdoors and meet all local code and requirements Consult the Installation Instructions for any additional installation detail Add On Replacement Retrofit Specifications for these units in the add on replacement retrofit market require the unit to be installed outdoors and meet all local codes and requirements Clearances power supply system static needs to be check to ensure that the replacement unit can perform within the design parameter desired specified in the Product Data ACCESSORIES Table 1 Required Field Installed Accessories for Air Conditioners and Heat Pumps Required for low ambient cooling Accessory Part Accessory applications Number Below 40 F 4 4 C Motormaster Low Ambient Kit Yes CPLOWAMB001A00 Evaporator Freeze Thermostat Recommended KSAFT0101AAA Compressor Start Assist CTCR Yes CPHSTARTO002A00 Isolation Relay Required for Heat Yes HN 65KJ 016 Pumps Crankcase Heater See below AC 13 SEER 24 42 Ye 14 SEER 24 36 GRG 00400 13
90. 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 REFRIGERATION SYSTEM Refrigerant 4 WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in personal injury or equipment damage R 410A refrigerant which has higher pressures than R 22 and other refrigerants No other refrigerant may be used in this system Gauge set hoses and recovery system must be designed to handle R 410A If you are unsure consult the equipment manufacturer In an air conditioning and heat pump system refrigerant transfers heat from one replace to another The condenser is the outdoor coil in the cooling mode and the evaporator is the indoor coil In a heat pump the condenser is the indoor coil in the heating mode and the evaporator is the outdoor coil In the typical air conditioning mode compressed hot gas leaves the compressor and enters the condensing coil As gas passes through the condenser coil it rejects heat and condenses into liquid The liquid leaves condensing unit through liquid line and enters metering device at evaporator coil As it passes through metering device it becomes a gas liquid mixture As it passes through indoor coil it absorbs heat and the refrigerant moves to the compressor and is again compressed to hot gas and cycle repeats Compressor Oil CAUT
91. rogen it should never be used without a pressure regulator on the tank Assuming that a system is pressurized with either all refrigerant or a mixture of nitrogen and refrigerant leaks in the system can be 24 found with an electronic leak detector that is capable of detecting specific refrigerants If system has been operating for some time 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 See Fig 26 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 If the leak is very small several minutes may pass before a bubble will form Popular commercial leak detection solutions give better longer lasting bubbles and more accurate results than plain soapy water The bubble solution must be removed from the tubing and fittings after checking for leaks as some solutions may corrode the metal LEAK DETECTOR SOLUTION 95423 Fig 26 Bubble Leak Detection You may use an electronic leak detector designed for specific refrigerant to check for leaks See Fig 25 This unquestionably is the most efficient and easiest method for checking leaks There are various types of electronic
92. s Does Not Pump In this type of failure compressor motor runs and turns compressor but compressor does not pump the refrigerant A clamp on ammeter on common leg of a single phase compressor shows a very low current draw much lower than RLA rated load amps value stamped on compressor nameplate Because no refrigerant is being pumped there is no return gas to cool compressor motor It eventually overheats and shuts off on its internal protection 16 EXAMPLE 2 DETERMINE INTERNAL CONNECTIONS OF SINGLE e e PHASE MOTORS C S R EXCEPT SHADED POLE e POWER OFF DEDUCTION 2 17 3 GREATEST RESISTANCE RUN WINDING R 5 80 OHM START WINDING S OHMMETER 2 3 SMALLEST RESISTANCE 2 is COMMON 0 108 SCALE 0 62 BY ELIMINATION 9 G REMAINING RESISTANCE 2 IS COMMON 520 5 20 THEREFORE IS 580 2 5 9 START WINDING 6 8 IS RUN WINDING A88344 Fig 18 Identifying Compressor Terminals Runs Does Not Pump High To Low Side Leak In this type of failure compressor motor runs and turns compressor 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 high flow service valves shows high suction and low discharge pressure readings Motor currents are
93. s installed in coastal or desert locations This is because salt and alkali content of sand adheres to aluminum fins of coil and can cause premature coil failure due to corrosion Preventive measures can be taken during installations such as 1 Locate unit on side of structure opposite prevailing winds 2 Install unit where drifting sand cannot pile up against coil Maintenance in desert and seacoast locations 1 Frequent inspection of coil and basepan especially after storms and or high winds 2 Clean coil by flushing out sand from between coil fins and out of basepan as frequently as inspection determines necessary 3 In off season cover with covering 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 possibly causing corrosion Cleaning Coil 1 Remove side panel See Remove Side Panel in Cabinet section of this manual CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Coil fin damage can result in higher operating costs or compressor damage Do not use flame high pressure water steam volatile or corrosive cleaners on fins or tubing 2 Clean coil using vacuum cleaner and its crevice tool Move crevice tool vertically close to area being cleaned making sure tool touches only dirt on fins and not fins to prevent fin damage do not scrub fins with to
94. se plugs can be used only on specific compressors The configuration around the fusite terminals is outlined on the terminal covers The slot through which wires of plug are routed is oriented on the bottom and slightly to the left The correct plug can be connected easily to compressor terminals and plug wires can easily be routed through slot terminal cover It is strongly recommended to replace the compressor plug should a compressor fail due to a suspected electrical failure At a minimum inspect plug for proper connection and good condition on any compressor replacement Low Voltage Terminals The low voltage terminal designations and their description and function are used on all Small Packaged Products SPP condensers W Energizes first stage supplemental heat R Energizes 24 v power from transformer Y Energizes contactor for first stage cooling or first stage heating for heat pumps O Energizes reversing valve on heat pumps C Common side of transformer 116001 Fan Ground Circuit To determine if a wire has broken or come in direct contact with shell causing a direct short to ground follow these steps 1 Recover all refrigerant charge 2 Using an ohmmeter on R X 10 000 ohm scale or megohmmeter follow manufacturer s instructions 3 Be sure all power is off 4 Discharge all capacitors 5 Remove compressor plug 19 6 Place one meter probe on ground or on compressor shell Make a good metal to m
95. ssure works against the spring pressure and evaporator suction pressure to open the valve If the load increases the temperature increases at the bulb which increases the pressure on the top side of the diaphragm This opens the valve and increases the flow of refrigerant The increased refrigerant flow causes the leaving evaporator temperature to decrease This lowers the pressure on the diaphragm and closes the pin The refrigerant flow is effectively stabilized to the load demand with negligible change in superheat Table 4 Piston TXV Table Air Conditioner Outdoor Unit Size Indoor Cooling Piston Heating ton TXV Number Piston Number 13 SEER 24 59 24 59 30 59 36 67 42 73 48 82 60 TXV 14 SEER 24 57 30 63 36 67 42 76 3 48 80 60 TXV Heat Pump Outdoor Unit Size Indoor Cooling Piston Heating ton TXV Number Piston Number 13 SEER 24 59 49 30 59 49 36 70 57 42 73 61 48 82 70 60 TXV 73 14 SEER 24 59 TXV 30 59 49 36 67 57 42 76 59 48 TXV TXV 60 TXV 70 10 O CLOCK 2 O CLOCK SENSING BULB STRAP A TUBE Fig 23 Position of Sensing Bulb 08083 23 PISTON BODY CLEANING REPLACEMENT WARNING PERSONAL INJURY AND ENVIRONMENTAL HAZARD Failure to relieve system pressure could result in personal injury and or death
96. switched to heat or Off the valve is de energized There is no compressor delay built into this control OUTDOOR RELAY F2 DEFROST THERMOSTAT MUST BE CLOSED BEFORE DEFROST TIMER BEGINS T1 ENABLES DEFROST TIMER MUST BE ENERGIZED FOR DEFROST TIMER START COMMON Y OUTPUT TO PRESSURE SWITCHES AND CONTACTOR roel y corer cA Or ORWY SPEEDUP THERMOSTAT INPUTS REVERSING VALVE r A05332 Fig 14 Defrost Control Heating Sequence of Operation On a call for heating thermostat makes R Y and R G Circuit R Y sends low voltage through the safeties and energizes the contactor which starts the compressor and energizes the T1 terminal on the circuit board The T1 terminal energizes the defrost logic This will energize the OF2 fan relay start the outdoor motor The T1 terminal must be energized for defrost to function When the cycle is complete R Y is turned off and the compressor and outdoor fan should stop There is no compressor delay built into this control Defrost Sequence The defrost control is a time temperature control that has field selectable settings of 30 60 and 90 minutes These represent the amount of time that must pass after closure of the defrost thermostat before the defrost sequence begins The defrost thermostat se
97. t See unit wiring diagram Be sure new airflow meets the range noted above and minimum electric heat CFM if equipped Refer to Table 5 All model sizes are factory wired or rated airflow operation Refrigerant Charge Refrigerant Charge The refrigerant system is fully charged with R 410A refrigerant and is tested and factory sealed Amount of refrigerant charge is listed on unit s rating plate Unit must operate a minimum of 15 minutes before checking charge NOTE Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R 410A charge NOTE Unit sizes 024 048 have fixed orifice refrigerant metering devices the 060 size has a TXV There is a different charging procedure for both expansion devices Refer to the correct procedure for your unit NO CHARGE Use standard evacuating techniques After evacuating system weigh in the specified amount of refrigerant refer to unit s rating plate LOW CHARGE COOLING Fixed Metering Device 1 Operate unit a minimum of 10 minutes before checking charge 2 Measure suction pressure by attaching an accurate gauge to compressor suction side service port 3 Measure suction side temperature by attaching an accurate thermisitor type or electronic thermometer to suction line about 10 in from compressor 4 Measure outdoor air dry bulb temperature with thermo meter 5 Measure indoor air return air wet bulb temperature with a sling psy
98. t Size 024 030 036 042 048 060 Type Chassis Size Small Small Small Medium Medium Large Compressor Bristol Recip Bristol Recip Bristol Recip Bristol Recip Copeland Scroll Danfoss Scroll Manufacturer Oil Type Hatcol 32BCE Hatcol 32BCE Hatcol 32BCE Hatcol 32BCE 3MAF Polyolester Polyvinyl Ether Polyolester POE Polyolester POE Polyolester POE Polyolester POE Oil POE Oil PVE Oil Charge fl oz intial recharge 30 27 30 27 40 37 40 37 42 34 45 39 Winding Resistance ohm Start 1 43 0 98 0 63 0 52 0 52 0 43 Winding Resistance ohm Start C S 2 38 1 73 1 26 1 64 0 82 1 06 Winding Resistance ohm Start R S 3 81 2 71 1 89 2 16 1 34 1 5 Run Capacitor mfd volts 35 440 35 440 40 440 45 440 70 440 70 440 14 SEER Air Conditioner Unit Size 024 030 036 042 048 060 Type AC AC AC AC AC AC Chassis Size Small Small Small Medium Large Large Compressor Bristol Recip Bristol Recip Bristol Recip LG Scroll Copeland Scroll Copeland Scroll Manufacturer Oil Type Hatcol 32BCE Hatcol 32BCE Hatcol 32BCE RB32G Polyolester 3MAF Polyolester Oil 3MAF Polyolester Oil Polyolester POE Polyolester POE Polyolester POE POE POE POE Oil Charge fl oz intial recharge 30 27 30 27 30 27 43 35 42 36 42 36
99. t to find cause and correct 37 Refrigerant Circuit Final Check Out 1 Check refrigerant charge using the superheat method and if After the unit has been operating the following items should be low on charge check unit for leaks using an electronic leak checked detector 1 Check that unit operational noise is not excessive due to 2 If any leaks are found remove and reclaim or isolate charge vibration of component tubing panels etc If present pumpdown if applicable Make necessary repairs isolate problem and correct 3 Evacuate recharge and observe unit through 1 complete 2 Check to be sure caps are installed on high flow valves and operating cycle are tight 3 Check to be sure tools loose parts and debris are removed from unit 4 Check to be sure all panels and screws are in place and tight R 410A REFRIGERANT QUICK REFERENCE GUIDE e R 410A refrigerant operates at 50 70 percent higher pressures than R 22 Be sure that servicing equipment and replacement components are designed to operate with R 410A refrigerant e R 410A refrigerant cylinders are rose colored e Recovery cylinder service pressure rating must be 400 psig DOT 4BA400 or DOT BW400 e R 410A refrigerant systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose when charging into suction line with compressor operating e Manifold sets should be 700 psig high side and 180 psig low side with 550 psig lo
100. through itself to an extremely low value This in effect removes the PTC from the circuit After system shutdown resistor cools and resistance value returns to normal until next time system starts Thermistor device is adequate for most conditions however in systems where off cycle is short device cannot fully cool and becomes less effective as a start device It is an easy device to troubleshoot Shut off all power to system Check thermistor with ohmmeter as described below Shut off all power to unit Remove PTC from unit Wait at least 10 minutes for PTC to cool to ambient temperature Measure resistance of PTC with ohmmeter The cold resistance RT of any PTC device should be approximately 100 180 percent of device ohm rating 12 5 ohm PTC 12 5 22 5 ohm resistance beige color If PTC resistance is appreciably less than rating or more than 200 percent higher than rating device is defective A94006 Fig 11 Capacitors Cycle Protector Corporate thermostats have anti cycle protection built in to protect the compressor If cycle protection is needed consult factory authorized aftermarket offering 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 compressor is off This prevents flooded starts which can damage compressor On units that have a single pole contactor the cr
101. tion line kink restricted suction filter drier etc proceed to Step 10 10 Check power element cap tube is not broken proceed to Step 11 11 Check that equalizer tube is not kinked or plugged e If OK proceed to Step 12 12 Check that inlet screen is not restricted proceed to Step 13 13 Replace Valve High Superheat with Normal or High Suction Pressure NOTE Normal to High suction pressure is considered for R 410A gt 110 psig An application issue or other system component failure typically causes this condition 14 Check airflow sensing bulb tightness orientation on vapor tube and ensure bulb is properly wrapped e If OK proceed to Step 15 15 R 410A Systems Make sure proper valve is used Not R 22 proceed to Step 16 16 Check for even temperature distribution at outlet of each circuit of evaporator e proceed to Step 17 17 Check for high evaporator load Return Air Leaks high indoor wet bulb and or dry bulb temp undersized system etc e proceed to Step 18 18 Check that compressor is pumping properly e Loose Rule of Thumb Is discharge saturated 20 F higher than ambient temperature Is discharge superheat between 15 F 9 4 C and 50 F 10 C Hunting Superheat NOTE Hunting is when the valve superheat swings more than 10 F Superheat in repetition This is typically an application issue 19 Check for obvious kinked or pinched distributor capillary
102. ubs from old compressor and to reinstall them in replacement compressor 7 Use copper couplings to tie compressor back into system 8 Replace filter drier evacuate system recharge and check for normal system operation CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Do not leave system open to atmosphere Compressor oil is highly susceptible to moisture absorption System Clean Up After Burnout Some compressor electrical failures can cause motor to burn When this occurs by products of burn which include sludge carbon and acids contaminate system Test the oil for acidity using POE oil acid test to determine burnout severity 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 25 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 replaced 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 Follow these additional steps 1 TXV must be cleaned or repl
103. ures 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 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label Locked Rotor In this type of failure compressor motor and all starting components are normal When compressor 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 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 Run
104. urn gas to cool compressor motor It eventually overheats and shuts off on its internal protection Noisy Compressor Noise may be caused by a variety of internal and external factors Careful attention to the type of noise may help identify the source The following are some examples of abnormal conditions that may create objectionable noise 1 gurgling sound may indicate a liquid refrigerant floodback during operation This could be confirmed if there is no compressor superheat A compressor superheat of 0 degrees would indicate liquid refrigerant returning to the compressor Most common reasons for floodback are loss of evaporator blower dirty coils and improper airflow 2 A rattling noise may indicate loose hardware Inspect all unit hardware including the compressor grommets 3 internal thunking thumping grinding rattling noise could indicate compressor internal failures and may be verified by comparing the compressor amperage to what the compressor should be drawing according to a manufacturer s performance data 4 A whistling or squealing noise during operation may indicate a partial blockage of the refrigerant charge 5 A whistle on shut down could indicate a partial leak path as refrigerant is equalizing from high to low side On occasion an in line discharge check valve has prevented this sound 6 If a compressor hums but won t start it could indicate either a v
105. w side retard e Use hoses with 700 psig service pressure rating e Leak detectors should be designed to detect HFC refrigerant e R 410A refrigerant as with other HFCs is only compatible with POE or PVE oils e Vacuum pumps will not remove moisture from oil e Do not use liquid line filter driers with rated working pressures less than 600 psig e Do not leave R 410A refrigerant suction line filter driers in line longer than 72 hours e Do not install a suction line filter drier in liquid line e POE and PVE oils absorb moisture rapidly Do not expose oil to atmosphere e POE and PVE oils may cause damage to certain plastics and roofing materials e Wrap all filter driers with wet cloth when brazing A factory approved liquid line filter drier is required on every unit e Do NOT use an R 22 e Never open system to atmosphere while it is under a vacuum e When system must be opened for service recover refrigerant evacuate then break vacuum with dry nitrogen and replace filter driers Evacuate to 500 microns prior to recharging e Do not vent R 410A refrigerant into the atmosphere e Observe all warnings cautions and bold text 38 Table 8 Pressure vs Temperature Chart R 410A Refrigerant PSIG F c PSIG F c PSIG F c PSIG F c PSIG F c PS
106. wn uninstalled o Electric Heat Control Box Electric Heat wiring interconnection electric heater controls removed for clarity A10031 Heat Pump Control Box Wiring Fig 31 Control Box Wiring HIGH VOLTAGE POWER WIRING ENTRY HOLE LOW VOLTAGE WIRING ENTRY HOLE grommet hole A08407 Fig 32 Unit Electrical Connection CONNECTION WIRING DIAGRAM DANGER ELECTRICAL SHOCK HAZARD DISCONNECT POWER BEFORE SERVICING yr ans vhs 2087230 VAC 60 4 BLK BLR UNIT ONLY 7 OFM MAXIMUM WIRE SIE _ amp YEL 23 23 YEL YEL ii b GND EQUIPMENT OMPRESSOR PLUG GROUND F GRN BLK O YEL BLK BLU XD YEL E FOR WITH 1 lt NOTE 6 ELECTRIC HEATERS ry SEE SCHEMATIC Li 2 ia ON HEATER ACCESSORY s ry PRIMARY ak 9 GND 1 i TRAN a SEE NOTE 412345 tig SECONDARY 1 RESISTOR E 1 SEE NOTE 8 GIy 1000 5 2 i gt GAD ee
107. y 21 sec When you hear the reversing valve changing position remove screwdriver immediately Otherwise control will terminate normal 10 minute defrost cycle in approximately 2 sec COPELAND DANFOSS LG SCROLL COMPRESSOR Scroll Gas Flow Compression in the scroll is created by the interaction of an orbiting spiral anda stationary spiral Gas enters an outer opening as one of the spirals orbits 9 1 Q G 2 A 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 1 Ny Wy 6 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 90198 Fig 17 Scroll Compressor Refrigerant Flow The compressors used in these products are specifically designed to operate with designated refrigerant and cannot be interchanged The compressor is an electrical as well as mechanical device Exercise extreme caution when working near compressors Power should be shut off if possible for most troubleshooting techniques Refrigerants present additional safety hazards A CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury

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