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Application Guideline and Service Manual

1. HN67ZA008 A94005 Fig 15 Cycle Protector Device CUT YELLOW WIRE OPERATING TIME e oom LEMM BLK DENOTES CLOSED CONTACTS BETWEEN CONTACTOR AND LOW PRESSURE SWITCH SAFETY YEL CONTROL YEL TERMINAL BOARD CONNECTION u LOGIC AZ HN67ZA008 A94009 Fig 16 Cycle Protector Sequence La VIO TERMINAL BOARD CONNECTION T3 BLK T2 A88415 Fig 17 Cycle Protector Wiring The effect of outdoor fan cycling on the HSPF Heating Seasonal Performance Factor is minimal due to its occurance at outdoor ambients where building load is very low The exact ambient which the outdoor fan cycles depends on the indoor unit size indoor airflow including restricted filter and or coil refrigerant charge and AccuRater If PresureGuard cycles at unsatisfactory low outdoor ambients check each of the following items Ensure ARI approved indoor outdoor combination is used Check for proper airflow per the Product Data Sheets Airflow may be drastically affected by dirty filters dirty coils poor duct work and or poor duct design Check refrigerant charge If in doubt about the proper charge recharge the unit by the weigh in method if ambient temperature does not allow checking the charge by subcooling method in cooling mode Check to ensure the proper outdoor AccuRater i
2. A97641 Fig 21 Checking Between C and W2 Ohmmeter should read infinite resistance indicating defrost thermostat has opened at approximately 80 F 13 Shut off unit power and reconnect fan lead 14 Remove jumper between DFT and R terminals Reconnect defrost thermostat leads Failure to remove jumper causes unit to switch to defrost every 30 50 or 90 minutes and remain in defrost for full 10 minutes 15 Replace control box cover Restore power to unit If defrost thermostat does not check out following above items or incorrect calibration is suspected check for a defective thermostat as follows 1 Follow items 1 5 above 2 Route sensor or probe underneath coil or other convenient location 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 Tempera ture range is from 33 F to 27 F Notice temperature at which ohmmeter reading goes from to zero ohms Thermostat contacts close at this point 6 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
3. TO ACCUMULATOR FROM COMPRESSOR DISCHARGE LINE A88342 Fig 26 Reversing Valve Cooling Mode or Defrost Mode Solenoid Energized 21 Step 6 Liquid Line Filter Drier The filter drier is specifically designed to operate with Puron use only factory authorized components Filter drier must be replaced whenever the refrigerant system is opened When removing a filter drier use a tubing cutter to cut the drier from the system Do not unsweat a filter drier from the system Heat from unsweating will release moisture and contaminants from drier into system Step 7 Suction Line Filter Drier The suction line drier is specifically designed to operate with Puron 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 suction line filter drier in a system longer than 72 hours actual time Step 8 Accumulator The accumulator is specifically designed to operate with Puron 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 introducti
4. 5 Repeat procedure 3 times System will then be free of any contaminants and water vapor 22 um C A95422 Fig 35 Electronic Leak Detection LEAK DETECTOR SOLUTION A95423 Fig 36 Bubble Leak Detection 5000 4500 4000 3500 5 3000 amp 2500 2000 1500 1000 500 LEAK IN SYSTEM VACUUM TIGHT TOO WET TIGHT DRY SYSTEM 0 1 2 3 4 5 6 7 MINUTES A95424 Fig 37 Deep Vacuum Graph v BREAK VACUUM WITH DRY NITROGEN WAIT v v EVACUATE v BREAK VACUUM WITH DRY NITROGEN v v EVACUATE v CHECK FOR TIGHT DRY SYSTEM IF IT HOLDS DEEP VACUUM v CHARGE SYSTEM Fig 38 Triple Evacuation Method A95425 Step 6 Puron R 410A Refrigerant Charging Refer to unit information plate for superheat charging procedure R 410A refrigerant cylinders contain a dip tube which allows liquid refrigerant to flow from cylinder in upright position Charge Puron units with cylinder in upright position and a commercial type metering device in manifold hose Charge refrig erant into suction line For all approved combinations system must be charged correctly for normal system operation and reliable operation of components See Fig 39 If system has lost all charge weigh in charge using digital scales System charge should be fine tuned by using superheat method or subcooling method as defined by cooling mode metering device For charging during heatin
5. NN X Carrier ME ff HEATING amp COOLING Air Conditioners and Heat Pumps using Puron R 410A Refrigerant Visit www carrier com Application Guideline and Service Manual 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 CAUTION Puron 410 systems operate at higher pressures than standard R 22 systems Do not use R 22 service equipment or components on Puron R 410A equipment Ensure service equipment is rated for Puron 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 operation some components are hot and can cause burns Rotating fan blades can cause personal injury Appropriate safety considerations are posted throughout this manual where potentially dangerous techniques are addressed INTRO
6. a Joe A A 4 SUCTION TUBE 8 O CLOCK X 4 O CLOCK 78 IN OD amp SMALLER LARGER THAN 78 IN OD Fig 32 Position of Sensing Bulb A81032 You may use an electronic leak detector designed for HFCs to check for leaks See Fig 35 This unquestionably is the most efficient and easiest method for checking leaks There are various types of electronic leak detectors Electronic leak detectors must be suitable for R 410A HFC refrigerant 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 Step 2 Coil Removal Coils are easy to remove if required for compressor removal or to replace coil 24 Shut off all power to unit Recover refrigerant from system through service valves Break vacuum with nitrogen WO N e Remove top cover See Remove Top Cover in Cabinet section of the manual 2 Remove screws in base pan to coil grille 3 Remo
7. 364 110 0 466 128 7 596 148 4 60 8 6 162 57 0 264 87 4 366 110 4 468 129 0 600 149 0 62 10 0 164 57 7 266 87 9 368 110 8 470 129 3 604 149 5 64 11 3 166 58 4 268 88 4 370 111 2 472 129 7 608 150 1 66 12 6 168 59 0 270 88 9 372 111 6 474 130 0 612 150 6 68 13 8 170 59 8 272 89 4 374 112 0 476 130 3 616 151 2 70 15 1 172 60 5 274 89 9 376 112 4 478 130 7 620 151 7 72 16 3 174 61 1 276 90 4 378 112 6 480 131 0 624 152 3 74 17 5 176 61 8 278 90 9 380 113 1 482 131 3 628 152 8 76 18 7 178 62 5 280 91 4 382 113 5 484 131 6 632 153 4 78 19 8 180 63 1 282 91 9 384 113 9 486 132 0 636 153 9 80 21 0 182 63 8 284 92 4 386 114 3 488 132 3 640 154 5 82 22 1 184 64 5 286 92 8 388 114 7 490 132 6 644 155 0 84 23 2 186 65 1 288 93 3 390 115 0 492 132 9 648 155 5 86 24 3 188 65 8 290 93 8 392 115 5 494 133 3 652 156 1 88 25 4 190 66 4 292 94 3 394 115 8 496 133 6 656 156 6 90 26 4 192 67 0 294 94 8 396 116 2 498 133 9 660 157 1 92 27 4 194 67 7 296 95 2 398 116 6 500 134 0 664 157 7 94 28 5 196 68 3 298 95 7 400 117 0 502 134 5 668 158 2 96 29 5 198 68 9 300 96 2 402 117 3 504 134 8 672 158 7 98 30 5 200 69 5 302 96 6 404 117 7 506 135 2 676 159 2 100 31 2 202 70 1 304 97 1 406 118 1 508 135 5 680 159 8 102 32 2 204 70 7 306 97 5 408 118 5 510 135 8 684 160 3 104 33 2 206 71 4 308 98 0 410 118 8 512 136 1 688 160 8 106 34 1 208 72 0 310 98 4 412 119 2 514 136 4 692 161 3 108 35 1 210 72 6 312 98 9 414 119 6 516 136 7 696 161 8 110 35 5 212 73 2 314 99 3 416 119 9 51
8. LINE STRAINER APPROX 2 LONG STRAINER LABEL AFFIX TO LIQ LINE NEAR STRAINER LOCATION A98066 Fig 29 Air Condioner AccuRater Components SWEAT FLARE O ADAPTER 430 FUSE ELEMENT TEFLON A88410 SEAL Fig 28 Accumulator Step 9 AccuRater AccuRater piston has a refrigerant metering hole through it The retainer forms a sealing surface for liquid line flare connection m d Any R 22 piston must be replaced with factory approved piston for PISTON Puron If air conditioner is shipped with a piston ring located in E gt piston bag be sure it is installed per Fig 29 The piston ring will PISTON BODY ensure piston stays seated during all operating conditions For Heat Pumps piston ring not used at outdoor piston To check clean or replace piston follow these steps See Fig 30 1 Shut off power to unit LIQUID SERVICE VALVE 2 Pump unit down using pumpdown procedure described in this service manual 3 Loosen nut and remove liquid line flare connection from AccuRater A97556 4 Pull retainer out of body being careful not to scratch flare Fig 30 Heat Pump AccuRater Components sealing surface If retainer does not pull out easily carefully use locking pliers to remove it 22 A97109 Fig 31 Puron R 410A TXV Kit Components Step 10 Thermostatic Expansion Valve TXV The thermostatic expansion valve is specifically designed to operate with Puron use
9. TXV a compressor start capacitor and relay and a crankcase heater in long line installations Step 1 Interconnecting Tubing Table 3a lists the required interconnecting vapor line diameters for heat pumps Puron systems installed in long line applications must use only 3 8 in liquid lines Equivalent line lengths equal the linear length measured of the interconnecting vapor tubing plus losses due to elbows See Table 4 and Fig 3 Table 3B provides estimated percentage of nominal cooling capacity losses based on standard required vapor line size versus what is selected for long line application Refer to outdoor unit presale literature for the required vapor line diameter Calculate linear length of vapor tube required adding any losses for total number of elbows for application See Table 4 Using this equivalent length select desired vapor line size from Table 3B Subtract nominal percentage loss from outdoor unit presale literature Detailed Cooling Capacities for given indoor outdoor combination Reference all notes of Table 3B NOTE When specifying the vapor line insulation be aware of the following standard practice 1 4 x 3 g 5 56 x 9 53 SLOT A 4 REQ D eee 1 8 3 45 DIA HOLE A 2 REQD I J 515 14 5 56 DIA HOLE 2 REQ D PE e a b SUPPORT TYP MAT L 18 GA STEEL E c
10. 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 Step 3 Servicing Systems on Roofs With Synthetic Materials POE polyol ester compressor lubricants are known to cause long term damage to some synthetic roofing materials Exposure even if immediately cleaned up may cause embrittlement leading to cracking to occur in one year or more When performing any service which may risk exposure of compressor oil to the roof take appropriate precautions to protect roofing Procedures which risk oil leakage include but are not limited to compressor replacement repairing refrigerant leaks replacing refrigerant components such as filter drier pressure switch metering device coil accumulator or reversing valve SYNTHETIC ROOF PRECAUTIONARY PROCEDURE 1 Cover extended roof working area with an impermeable polyethelene plastic drop cloth or tarp Cover an approxi mate 10 x 10 ft area 2 Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run offs and protect drop cloth from tears caused by tools or components 3 Place terry cloth shop towel inside unit immediately under component s to be serviced and prevent lubricant run offs through the louvered openings in the base pan 4 Perform required service 5 Remove and dispose of any oil contaminated mater
11. accessory TXV refer to unit presale literature Heat pumps with equivalent lengths over 100 ft must increase outdoor piston one size No piston change is required for the allowable 30 ft vertical differential A liquid line solenoid must be used for all long line heat pump applications The solenoid valve has a flow arrow stamped in the valve body This flow arrow must point toward the outdoor unit Step 3 Tubing Configuration Fig 4 through 6 detail the proper installation of equipment and provide applications where accessories may be required Reference all notes of appropriate figure Step 4 Charging Information Use subcooling charging method The standard subcooling charg ing methods can be found in refrigerant system charging section of Service Manual Since total system charge is increased for long line application it is necessary to calculate additional refrig erant charge The rating plate charge of a given outdoor unit is for a standard application of 15 ft of interconnecting tubing For line lengths greater than 15 ft add 0 60 oz of refrigerant per foot of additional line length The rating plate charge can be found on outdoor unit rating plate or in the outdoor unit presale literature Long line applications do not require additional oil charge NOTE Avoid contact between tubing and structure OUTDOOR WALL INDOOR T LIQUID TUBE y INSULATION t VAPOR TUBE THROUGH THE WALL kac SIST CAULK
12. due to vibration of component tubing panels etc If present isolate problem and correct Check to be sure caps are installed on service valves and are tight Check to be sure tools loose parts and debris are removed from unit Check to be sure all panels and screws are in place and tight 27 Step 2 Desert and Seacoast Locations Special consideration must be given to installation and mainte nance of condensing units 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 from salt alkali and moisture Preventive measures can be taken during installations such as 1 Locate unit on side of structure opposite prevailing winds 2 Elevate unit to height where drifting sand cannot pile up against coil Four in high mounting feet are available as accessories and can be used to elevate unit 3 Addition of coastal filter See Product Data Sheet for acces sory listing 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 because plastic w
13. 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 stubs 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 Do not leave system open to atmosphere Product damage could occur Compressor oil is highly susceptible to moisture absorption Step 4 System Clean Up After Burnout Some compressor electrical failures can cause motor to burn When this occurs byproducts 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 com pressor is installed The 2 types of motor burnout are classified as mild or severe In mild burnout there is little or no detectable odor Compressor oil is clear or slightly discolored An acid test of compressor oil will be negative This type of failure is treated the same as mechanical failure Liquid line strainer should be
14. 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 requires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth The deep vacuum method is the most positive way of assuring a system is free of air and moisture See Fig 37 TRIPLE EVACUATION METHOD The triple evacuation method should be used only when vacuum pump is capable of pumping down to only 28 in of mercury vacuum and system does not contain any moisture The procedure is as follows See Fig 38 CAPILLARY TUBE im COIL m B BULB EXTERNAL EQUALIZER TUBE A94056 Fig 34 TXV Operation 1 Pump system down to 28 in of mercury vacuum and allow pump to continue to operate for additional 15 minutes 2 Close service valves and shut off vacuum pump 3 Connect a nitrogen cylinder and regulator to system and open until system pressure is 2 psig 4 Close service valve and allow system to stand for 1 hr during which time dry nitrogen will be able to diffuse throughout the system absorbing moisture
15. 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 replaced DIAPHRAGM PUSHRODS 222 FEEDER TUBES PZ D INLET T 2 gt OUTLET 3 IN NEEDLE VALVE SPRING DISTRIBUTOR ii 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 Puron R 410A filter driers NOTE On heat pumps install suction line drier between compresser 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 Step 5 Evacuation Proper evacuation of the system will remove
16. system repairs System may be pumped down to make repairs on low side without losing complete refrigerant charge 20 1 Attach pressure gage to suction service valve gage port 2 Front seat liquid line valve 3 Start unit in cooling mode Run until low pressure switch opens at 50 psig 350kPa or loss of charge switch opens at 23 psig Do not allow compressor to pump to a vacuum 4 Shut off unit Front seat suction valve 5 Recover remaining refrigerant NOTE All outdoor unit coils will hold only factory supplied amount of refrigerant Excess refrigerant such as in long line applications may cause unit to relieve pressure through internal pressure relief valve indicated by sudden rise of suction pressure before suction pressure reaches cut out pressure of vapor pressure switch If this occurs shut off unit immediately front seat suction valve and recover remaining refrigerant NEW SOLENOID COIL 4TH PORT 4 PORT DESIGN A91456 Fig 25 Reversing Valve Reversing Valve In heat pumps changeover between heating and cooling modes is accomplished with a valve that reverses flow of refrigerant in system See Fig 25 This reversing valve device is easy to troubleshoot and replace The reversing valve solenoid can be checked with power off with an ohmmeter Check for continuity and shorting to ground With control circuit 24 v power on check for correct voltage at solenoid coil Check for overheated solenoid
17. 4 HANGER STRAP AROUND VAPOR 0 TUBE ONLY INSULATION VAPOR TUBE O 6 mm 3 1 4 Y LIQUID TUBE SUSPENSION A94028 Fig 2 Tubing Support NOTE Excessive charge will increase risk of refrigerant migra tion and compressor damage Charging units with long refrigerant lines must be done carefully to avoid over charging Pressure and temperature changes are slower with long lines Adding or removing charge must be done slowly to allow time for system to stabilize Table 3b Estimated Percentage of Nominal Cooling Capacity Losses OMINA STANDARD PERCENTAGE OF COOLING CAPACITY LOSS BTU VERSUS EQUIVALENT LENGTH im Z ae 25 Ft 50 Ft 75 Ft 100 Ft 125 Ft 150 Ft 175 Ft 5 8 0 1 2 3 4 6 7 24 000 5 8 3 4 0 0 0 1 1 2 2 7 8 0 0 0 0 0 1 1 5 8 1 2 3 4 5 6 7 30 000 3 4 3 4 0 0 1 1 2 2 2 7 8 0 0 0 0 1 1 1 5 8 1 3 5 6 8 9 11 36 000 3 4 3 4 0 1 1 2 3 3 4 7 8 0 0 0 0 1 1 2 3 4 0 1 2 2 3 4 5 42 000 7 8 7 8 0 0 0 1 1 1 2 1 1 8 0 0 0 0 0 0 0 3 4 1 1 2 3 2 4 7 48 000 7 8 7 8 0 0 1 1 2 3 3 1 1 8 0 0 0 0 0 0 1 3 4 2 3 5 7 8 10 11 60 000 1 1 8 7 8 1 2 2 3 4 5 6 1 1 8 0 0 1 1 1 1 2 Vapor line diameter that may be selected for a long line application If smaller vapor lines are selected but not specified within the table large capacity losses will occur and defrost capacities will be red
18. 8 137 0 112 36 9 214 73 8 316 99 7 418 120 3 520 137 3 Based on ALLIED SIGNAL Data 29 A95505 REQUIRED LIQUID LINE TEMPERATURE LIQUID PRESSURE REQUIRED SUBCOOLING TEMPERATURE F AT SERVICE VALVE PSIG x30 Jo s 189 56 54 52 50 48 195 58 56 54 52 50 202 60 58 56 54 52 208 62 60 58 56 54 215 64 62 60 58 56 222 66 64 62 60 58 229 68 66 64 62 60 236 70 68 66 64 62 243 72 70 68 66 64 251 74 72 70 68 66 259 76 74 72 70 68 266 78 76 74 72 70 274 80 78 76 74 72 283 82 80 78 76 74 291 84 82 80 78 76 299 86 84 82 80 78 308 88 86 84 82 80 317 90 88 86 84 82 326 92 90 88 86 84 335 94 92 90 88 86 345 96 94 92 90 88 354 98 96 94 92 90 364 100 98 96 94 92 374 102 100 98 96 94 384 104 102 100 98 96 395 106 104 102 100 98 406 108 106 104 102 100 416 110 108 427 439 112 110 450 114 112 110 118 116 114 112 110 118 116 114 112 118 116 114 118 116 120 118 Subcooling Charging Table 30 A95617 AIR CONDITIONER AND HEAT PUMP WITH PURON R 410A QUICK REFERENCE GUIDE Puron R 410A refrigerant operates at 50 70 higher pressures than R 22 Be sure that servicing equipment and replacement compo nents are designed to operate with Puron R 410A Puron R 410A refrigerant cylinders are rose colored Puron R 410A refrigerant cylinders have a dip tube which allows liquid to flow out of cylinder in upright position Recovery cylinder service pressure
19. BURNED OUT 33 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 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 SHIFT UNIT NOT PROPERLY CHARGED 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 SET TOO STRIP HE RELAY CONTAC DEFECT BROKEN FUSE LINK BROKEN HEATER ELEMENT OPEN KLIXON OVER TEMPERATURE THERMOSTAT DEFECTIVE ROOM THERMOSTAT 2ND STAGE HEAT PUMP TROUBLESHOOTING COOLING CYCLE NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN CONTACTOR OPEN POWER SUPPLY DEFECTIVE LOW VOLTAGE TRANSFORMER OPEN THERMOSTAT CONTROL RCUIT CHARGE CONTACTOR OR COIL DEFECTIVE LOOSE ELECTRICAL CONNECTION CONTACTOR CLOSED COMPRESSOR POWER SUPPLY OPEN LOOSE LEADS AT COMPRESSOR FAULTY START
20. DUCTION Section 1 of this Application Guideline and Service Manual provides the required system information necessary to install Puron R 410A equipment in all applications Section 2 provides the necessary information to service repair and maintain the family of Puron R 410A air conditioners and heat pumps Section 3 of this manual is an appendix Use the Table of Contents to locate desired topics TABLE OF CONTENTS Page SECTION 1 APPLICATION GUIDELINE 2 10 INSTALLATION GUIDELINE eene 2 Residential New Construction Add On Replacement Retrofit Seacoast For Air Conditioners Only REQUIRED FIELD INSTALLED ACCESSORIES 2 3 e ACCESSORY DESCRIPTIONS 2 3 e LOW AMBIENT 3 e LONG LINE GUIDELINE eere 3 8 Interconnecting Tubing Metering Device Tubing Configuration Charging Information SECTION 2 SERVICE MANUAL 9 28 UNIT IDENTIFICATION 9 Model Number Nomenclature Serial Number Nomenclature CABINET ASSEMBLY 1 eerte nee 9 Remove Top Cover Remove Fan Motor Assembly Information Plate s ELECTRICAL de EE EE ER PENES 10 16 Aluminum Wire Contactor Capacitor PTC Devices Cycle Protector Crankcase Heater Time Delay Relay Pressure Switches Check Defrost Thermostat Defrost Thermostats Defrost Control Board CES0110063 Defrost Control Fan Motor Comp
21. GEAR 1 PH OPEN SHORTED OR GROUNDED COMPRESSOR MOTOR WINDINGS COMPRESSOR STUCK COMPRESSOR INTERNAL PROTECTION OPEN DEFECTIVE RUN CAPACITOR COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVER OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING DAMAGED OR STUCK REVERSING VALVE RESTRICTED DISCHARGE TUBE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT LOAD LOOSE LEAD AT FAN MOTOR DEFROST RELAY N C CONTACTS OPEN MOTOR DEFECTIVE INCORRECT OFM CAPACITOR DEFECTIVE DEFROST THERMOSTAT 34 COMPRESSOR RUNS BUT INSUFFICIENT COOLING LOW SUCTION PRESSURE DIRTY AIR FILTERS DUCT RESTRICTED DAMPERS PARTLY CLOSED INDOOR COIL FROSTED SLIGHTLY LOW ON REFRIGERANT LIQUID LINE SLIGHTLY RESTRICTED PISTON RESTRICTED INCORRECT SIZE PISTON INDOOR COIL STRAINER RESTRICTED INDOOR BLOWER MOTOR DEFECTIVE OR CYCLING ON OL HIGH SUCTION LOW HEAD PRESSURE REVERSING VALVE HUNG UP OR INTERNAL LEAK DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON 35 Copyright 1998 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 388sm Manufacturer reserves the right t
22. Horizontal Configuration o o 4 gt GROUND LEVEL A crankcase heater must be installed on compressor LSV HEAT PUMP ONLY A97638 An inverted vapor line trap must be installed at indoor unit The top peak of trap must be greater than height of indoor coil The above requirements provide protection against condensed refrigerant collecting in the vapor line Maximum elevation between units is 30 ft Maximum equivalent total line length is 175 ft Heat Pump Only Bi flow liquid line solenoid must be installed witihn 2 ft of outdoor unit with arrow pointing toward outdoor unit Fig 5 Application with Air Conditioner or Heat Pump Installed with Indoor Unit Above Outdoor Unit LSV HEAT PUMP ONLY 30 A97639 A crankcase heater must be installed on compressor The above requirements provide protection against refrigerant migration to compressor when outdoor temperature is lower than indoor temperature Maximum elevation between units is 30 ft Maximum equivalent total line length is 175 f
23. ICIENCY CAPACITY LOW SYSTEM CAPACITY POOR EFFICIENCY SLUDGE POOR EFFICIENCY CARBONIZATION SLUDGE CARBONIZATION Fig 39 Charging 3 Measure liquid line temperature by attaching an accurate thermistor type or electronic thermometer to liquid line near outdoor coil 4 Refer to unit information plate to find required subcooling temperature for unit Find point at which required subcooling temperature intersects measured liquid service valve pressure Add refrigerant if liquid line temperature is higher than indicated Remove refrigerant if temperature is lower Allow a tolerance of 3 F CARE AND MAINTENANCE To assure high performance and minimize possible equipment malfunction it is essential that maintenance be performed periodi cally on this equipment The frequency with which maintenance is performed is dependent on such factors as hours of operation geographic location and local environmental conditions A WARNING Disconnect all electrical power to unit before performing any maintenance or service on outdoor unit Remember to dis connect power supply to air handler as this unit supplies low voltage power to the outdoor unit Failure to follow this warning can cause a fire personal injury or death The minimum maintenance that should be performed on this equipment is as follows 1 Check outdoor coil for cleanliness each month during cooling season and clean as necessary Check fan motor and bl
24. IZE PISTON INDOOR COIL STRAINER RESTRICTED INDOOR BLOWER MOTOR DEFECTIVE OR CYCLING ON OL HIGH SUCTION LOW HEAD PRESSURE DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON A90208 HEAT PUMP TROUBLESHOOTING HEATING CYCLE NO HEATING OR INSUFFICIENT HEATING COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD COMPRESSOR RUNS INSUFFICIENT HEATING COMPRESSOR WILL NOT RUN CONTACT OPEN DEFECTIVE LOW VOLTAGE TRANSFORMER REMOTE CONTROL CENTER DEFECTIVE CONTACTOR COIL OPEN OR SHORTED OPEN INDOOR THERMOSTAT LIQUID LINE PRESSURE SWITCH OPEN CONTROL RCUIT CONTACT CLOSE COMPRESSOR POWER SUPPLY LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH COMPRESSOR STUCK COMPRESSOR INTERNAL OVERLOAD OPEN OPEN SHORTED OR GROUNDED COMPRESSOR WINDINGS DEFECTIVE RUN CAPACITOR DIRTY FILTERS OR INDOOR COIL INDOOR FAN STOPPED OR CYCLING ON OVERLOAD DAMAGED REVERSING VALVE RESTRICTION IN DISCHARGE LINE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR 1 PH COMPRESSOR BEARINGS HIGH LOAD CONDITION REVERSING VALVE JAMMED IN MIDPOSITION HIGH SUPERHEAT DEFECTIVE FAN MOTOR CAPACITOR LOOSE LEADS AT FAN MOTOR FAN MOTOR
25. M BEIGE COLOR A94007 Fig 14 PTC Device CAUTION Wear safety glasses and gloves when working with refriger ants To replace switch 1 Apply heat with torch to solder joint and remove switch 4 CAUTION Wear safety glasses when using torch Have quenching cloth available Oil vapor in line may ignite when switch is removed 2 Braze in 1 4 in flare fitting and screw on replacement pressure switch HIGH PRESSURE SWITCH The high pressure switch is located in liquid line and protects against excessive condenser coil pressure It opens at 610 psig High pressure may be caused by a dirty condenser coil failed fan motor or condenser air recirculation To check switch 1 Turn off all power to unit 2 Disconnect leads on switch 3 Apply ohmmeter leads across switch You should have con tinuity 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 gages read 0 psi Never open system without breaking vacuum with dry nitrogen A WARNING Wear safety glasses and gloves when working with refriger ants To replace switch 1 Apply heat with torch to solder joint and remove switch 4 CAUTION Wear safety glasses when using torch Have quenching cloth a
26. With unit operating other items can be checked such as frost or condensate water on refrigerant lines The sound made by a reversing valve as it begins or ends defrost is a whooshing sound as the valve reverses and pressures in system equalize An experienced service technician detects this sound and uses it as a valuable troubleshooting tool Using a remote measuring device check inlet and outlet line temperatures DO NOT touch lines If reversing valve is operating normally inlet and outlet temperatures on appropriate lines should be close Any difference would be due to heat loss or gain across valve body Temperatures are best checked with a remote reading electronic type thermometer with multiple probes Route thermo couple leads to inside of coil area through service valve mounting plate area underneath coil Fig 26 and Fig 27 show test points TP on reversing valve for recording temperatures Insulate points for more accurate reading If valve is defective 1 Shut off all power to unit and remove all charge from system 2 Check valve design If valve is of the 3 port design and new replacement is of the 4 port design replacement of the solenoid coil and wire leads is necessary valve bodies are interchangeable but solenoid and wires are not Three port reversing valve and solenoid coil with leads must be used together New solenoid coil cannot be used on a 3 port valve Four port reversing valve uses solenoid with quick co
27. ade for cleanliness each heating and cooling season and clean as necessary Check electrical connections for tightness and controls for proper operation each cooling season and service as necessary A CAUTION Because of possible damage to the equipment or personal injury maintenance should be performed by qualified person nel only Step 1 Cleaning CLEANING COIL 1 Remove top cover See Remove Top Cover in Cabinet section of this manual 4 CAUTION 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 tool or move tool horizontally against fins If oil deposits are present spray coil with ordinary household detergent Wait 10 minutes and proceed to next step Using garden hose spray coil vertically downward with constant stream of water at moderate pressure Keep nozzle at a 15 to 20 angle about 3 in from coil face and 18 in from tube Spray so debris is washed out of coil and basepan 5 Reinstall top cover and position blade 6 Reconnect electrical power and check for proper operation CLEANING OUTDOOR FAN MOTOR AND BLADE 1 Remove fan motor and blade Be carefu
28. ant Connections and Recommended Liquid and Vapor Tube Diameters Heat Pumps CONNECTION DIAMETER IN TUBE DIAMETER IN TUBE DIAMETER M ETERS NOT UNIT SIZE ALTERNATE IN PERMITTED IN Liquid Vapor Liquid Vapor Vapor Vapor 024 3 8 5 8 3 8 5 8 3 4 ACR 3 4 030 3 8 3 4 3 8 3 4 7 8 1 1 8 036 3 8 3 4 3 8 3 4 7 8 1 1 8 042 048 3 8 7 8 3 8 7 8 7 8 3 4 and 1 1 8 060 3 8 7 8 3 8 1 1 8 7 8 3 4 NOTE 1 Tube diameters are for lengths up to 50 ft For tubing lengths greater than 50 ft consult the Application Guideline and Service Manual for Residential Split System Air Conditioners and Heat Pumps Using R 410 A Refrigerant 2 Refrigerant tubes and indoor coils must be evacuated to 500 microns to minimize contamination and moisture in the system Tubing kits should meet the following recommendations to mini mize losses through insulation 5 8 in and 3 4 in tubing kits should be supplied with 3 8 in insulation 7 8 in and 1 1 8 in tubing kits should be supplied with 1 2 in insulation For minimal capacity loss in long line application 1 2 in insulation should be specified NOTE Special consideration must be given to isolating intercon necting tubing from building structure Isolate tubing so that vibration or noise is not transmitted into structure See Fig 2 Step 2 Metering Device Long Line Set A hard shutoff TXV must be used instead of a piston for an indoor metering device When sizing an
29. c Los Y lt bs 12 7 1 8 3 45 DIA HOLE 1 REQ D The J 11 6 Fak REQ D 6 i 38 9 6 152 4 6 3 1 lt _ L gt A 0 1 4 x 2 BAFFLE 5 56 x 50 8 SLOT MAT L 20 GA STEEL SCREW 10 REQ D SUPPORT 4 REQ D OUTDOOR eu BAFFLE UNIT 2 REQ D BAFFLE ASSEMBLY A95445 Dimensions In UNIT SIZE AA UNIT HEIGHT A B c D E F G H J K L 23 13 16 17 1 4 24 5 16 10 1 4 19 3 4 20 1 2 34 1 2 19 5 8 20 3 8 19 5 8 0 0 Small 26 3 16 27 13 16 17 1 4 24 5 16 10 1 4 23 3 4 24 1 2 34 1 2 23 5 8 24 3 8 23 5 8 0 11 7 8 33 13 16 17 1 4 24 5 16 10 1 4 29 3 4 30 1 2 34 1 2 29 5 8 30 3 8 29 5 8 0 14 7 8 27 13 16 21 30 5 8 10 1 4 23 3 4 24 1 2 42 23 5 8 Medium 33 33 13 16 21 30 5 8 10 1 4 29 3 4 30 1 2 42 29 5 8 39 13 16 21 30 5 8 10 1 4 35 3 4 36 1 2 42 35 5 8 24 3 8 23 5 8 17 1 8 11 7 8 30 3 8 29 5 8 17 1 8 14 7 8 36 3 8 35 5 8 17 18 17 7 8 33 13 16 25 5 16 39 3 4 10 1 4 29 3 4 30 1 2 50 9 16 29 5 8 39 13 16 25 5 16 39 3 4 10 1 4 35 3 4 36 1 2 50 9 16 35 5 8 Fig 1 Wind Baffle Construction Dimensions 30 3 8 29 5 8 21 11 16 14 7 8 4810 36 3 8 35 5 8 21 11 16 17 7 8 4 Table 3a Refriger
30. d 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 as shown in Fig 14 The cold resistance RT of any PTC device should be approxi mately 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 Step 5 Cycle Protector Solid state cycle protector protects unit compressor by preventing short cycling After a system shutdown cycle protector provides for a 5 2 minute delay before compressor restarts On normal start up a 5 minute delay occurs before thermostat closes After thermostat closes cycle protector device provides a 3 sec delay See Fig 15 16 and 17 Cycle protector is simple to troubleshoot Only a voltmeter capable of reading 24v is needed Device is in control circuit therefore troubleshooting is safe with control power 24v on and high voltage power off With high voltage power off attach voltmeter leads acr
31. e 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 11 A WARNING Exercise extreme caution when taking readings while power is on Electrical shock can cause personal injury or death Use following formula to calculate capacitance 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 Capacitance mfd Step 4 PTC Devices Sometimes under adverse conditions a standard run capacitor in a system is inadequate to start compressor In these instances a start assist device is used to provide an extra starting boost to compres sor motor This device is called a positive temperature coefficient PTC or thermistor See Fig 14 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 through itself to an extremely low value This in effect removes the PTC from the circuit After system shutdown resistor cools an
32. e metering hole sealing surface around piston cones or fluted portion of piston 3 Break vacuum with dry nitrogen Do not exceed 5 psig NOTE Coil may be removed for access to accumulator Refer to appropriate sections of Service Manual for instructions 6 Clean piston refrigerant metering hole 7 Install a new retainer O ring retainer assembly or teflon washer before reassembling AccuRater A WARNING Wear safety glasses and gloves when working on refrigerants and when using brazing torch Failure to follow this warning can cause a fire personal injury or death PISTON RETAINER 4 Remove accumulator from system with tubing cutter PISTON 5 Tape ends of open tubing PISTON RING 6 Scratch matching marks on tubing stubs and old accumulator PISTON KS Scratch matching marks on new accumulator Unbraze stubs BODY J from old accumulator and braze into new accumulator 7 Thoroughly rinse any flux residue from joints and paint with 7 corrosion resistant coating such as zinc rich paint P d 8 Install factory authorized accumulator into system with copper gt 22 slip couplings p di 9 Evacuate and charge system PA WV Pour and measure oil quantity if any from old accumulator If P FIELD more than 20 percent of oil charge is trapped in accumulator add s A CONNECTION new POE oil to compressor to make up for this loss See Table 6 i i STRAINER pa DO FLARE lt ADAPTOR LIQUID
33. e all warnings cautions and bold text All Puron R 410A heat pumps must have indoor R 410A TXV Do not leave Puron suction line driers in place for more than 72 hrs AIR CONDITIONER TROUBLESHOOTING CHART NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN CONTACTOR OPEN POWER SUPPLY DEFECTIVE LOW VOLTAGE TRANSFORMER OPEN THERMOSTAT OPEN CONTROL CIRCUIT LOSS OF CHARGE CONTACTOR OR COIL DEFECTIVE LOOSE ELECTRICAL CONNECTION CONTACTOR CLOSED COMPRESSOR POWER SUPPLY OPEN LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH OPEN SHORTED OR GROUNDED COMPRESSOR MOTOR WINDINGS COMPRESSOR STUCK COMPRESSOR INTERNAL PROTECTION OPEN DEFECTIVE RUN CAPACITOR COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD LOOSE LEAD AT FAN MOTOR OUTDOOR A RESTRICTED MOTOR RECIRCULATI DEFECTIVE RESTRICTED INCORRECT DISCHARGE OFM TUBE CAPACITOR OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT 32 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 S
34. e outdoor unit indoor unit refrigerant tubing sets metering device and filter drier listed in Product Data Sheet PDS DO NOT DEVIATE FROM PDS Consult unit Installation Instructions for detailed information Step 2 Add On Replacement Retrofit Specifications for this unit in the add on replacement retrofit market require change out of outdoor unit metering device and all capillary tube coils Change out of indoor coil is recommended There can be no deviation 1 If system is being replaced due to compressor electrical failure assume acid is in system If system is being replaced for any other reason use approved acid test kit to determine acid level If even low levels of acid are detected install factory approved 100 activated alumina suction line filter drier in addition to the factory supplied liquid line filter drier Remove the suction line filter drier as soon as possible with a maximum of 72 hrs 2 Drain oil from low points or traps in suction line and evaporator if they were not replaced 3 Change out indoor coil or verify existing coil is listed in the Product Data Sheets 4 Unless indoor unit is equipped with an Puron R 410A approved metering device change out metering device to factory supplied or field accessory device specifically de signed for Puron 410 5 Replace outdoor unit with Puron R 410A outdoor unit 6 Install factory supplied liquid line filter drier A WARNING Never instal
35. e than 90 When information plate is removed these tabs can be inserted into 2 mating slots in bottom front edge of control box and plate will hang down forming a lower front panel See Fig 11 This is convenient when access to controls is required while unit is operating The information plate on small size casing completely covers opening below the control box On larger models informa tion plate may not cover entire opening In this instance access panel can be removed and placed on its side to cover additional space 550A NX 024 000 AAAA 550A 13 SEER Air Conditioner 552A 12 SEER Air Conditioner 556A 14 SEER Air Conditioner 650A 13 SEER Heat Pump Electrical 208 230 1 Series Not Used Nominal Capacity 024 24 000 Btuh 030 30 000 Btuh 036 36 000 Btuh 042 42 000 Btuh 048 48 000 Btuh 060 60 000 Btuh Fig 8 Model Number Nomenclature 01 96 Week of Manufacture Year of Manufacture E 00001 Serial Number Manufacturing Site A95406 Fig 9 Serial Number Nomenclature ELECTRICAL A WARNING Exercise extreme caution when working on any electrical components Shut off all power to system prior to trouble shooting Some troubleshooting techniques require power to remain on In these instances exercise extreme caution to avoid danger of electrical shock ONLY TRAINED SER VICE PERSONNEL SHOULD PERFORM ELECTRICAL TROUBLESHOOTING Failure to follow this warni
36. ee if heater has power Do not touch heater Carefully feel area around crankcase heater If warm crankcase heater is probably functioning Do not rely on this method as absolute evidence heater is functioning If compressor has been running the area will still be warm With power off and heater leads disconnected check across leads with ohmmeter Do not look for a specific resistance reading Check for resistance or an open circuit Change heater if an open circuit is detected Step 7 Time Delay Relay The TDR is a solid state control recycle delay timer which keeps indoor blower operating for 90 sec after thermostat is satisfied This delay enables blower to remove residual cooling in coil after compression shutdown thereby improving efficiency of system The sequence of operation is that on closure of wall thermostat and at end of a fixed on delay of 1 sec fan relay is energized When thermostat is satisfied an off delay is initiated When fixed delay of 90 20 sec is completed fan relay is de energized and fan motor stops If wall thermostat closes during this delay TDR is reset and fan relay remains energized TDR is a 24 v device that operates within a range of 15v to 30v and draws about 0 5 amps A95507 Fig 11 Information Plate Removed Installed Below Control Box If the blower runs continuously instead of cycling off when the fan switch is set on AUTO the TDR is probably defective and must be re
37. efrigerant liquid flow in response to compressor operation Maintains a column of refrigerant liquid ready for action at next compressor operation cycle Requires Compressor Start Assist Capacitor and Relay Do not use with TXV Step 13 Thermostatic Expansion Valve A modulating flow control device which meters refrigerant flow rate into the evaporator in response to the superheat of the refrigerant gas leaving the evaporator Puron R 410A TXVs are hard shutoff only Only use factory specified TXV s Requires Compressor Start Assist Capacitor and Relay Do not use with Liquid Line Solenoid Valve LOW AMBIENT GUIDELINE The minimum operating temperature for these units in cooling mode is 55 F outdoor ambient without additional accessories This equipment may be operated in cooling mode at ambient tempera tures below 55 F when the accessories listed in Table 1 or 2 are installed Wind baffles are required when operating in cooling mode at ambients below 55 F Refer to Fig 1 for wind baffle construction details LONG LINE GUIDELINE This guideline provides the required system changes for the Puron R 410A air conditioner having piping requirements greater than 50 ft or installations where indoor unit is located above and or below outdoor unit by more than 20 ft This guide is intended to cover applications outside standard Installation Instructions All air conditioners and heat pumps require a hard shutoff
38. ensive than refrigerant Nitrogen also leaks faster than R 410A Nitrogen cannot however be detected by an electronic leak detector See Fig 35 A WARNING Due to the high pressure of nitrogen it should never be used without a pressure regulator on the tank Failure to follow this warning can cause a fire personal injury or death Assuming that a system is pressurized with either all refrigerant or a mixture of nitrogen and refrigerant leaks in the system can be found with an electronic leak detector that is capable of detecting HFC refrigerant 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 36 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 10 O CLOCK 2 O CLOCK f SENSING BULB SE
39. er 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 17 should be checked for abnormalities such as incorrect refrigerant charge restrictions insufficient airflow across indoor or outdoor Table 7 PressureGuard Heating Vapor Pres sure Switch STINE SIZE IN PART NUMBER psp 5 8 HK02ZB325 325 400 3 4 HK02ZB309 309 384 7 8 HK02ZB325 325 400 11 8 HK02ZB300 300 374 Use only factory approved Part Numbers coil etc which could be contributing to the failure Runs Does Not Pump In this type of failure compressor motor runs and turns compres sor 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 return 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 or external problems such as loosened hardware System problems such as an over charged co
40. erating range between 550 and 625 psi differential pressure The Copeland scroll compressor uses Mobil EAL ARTIC 22CC oil The is the only oil allowed for oil recharge See Table 6 Table 6 Oil Charging COMPRESSOR COLD RECHARGE PART NO OZ ZP23 26 38 ZP32 41 42 ZP54 53 Step 1 COMPRESSOR FAILURES Compressor failures are classified in 2 broad failure categories mechanical and electrical Both types are discussed below Step 2 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 A WARNING Do not supply power to unit with compressor terminal box cover removed Failure to follow this warning can cause a fire personal injury or death A WARNING Exercise extreme caution when reading compressor currents when high voltage power is on Correct any of the problems described below before installing and running a replacement compressor Wear safety glasses and gloves when handling refrigerants Failure to follow this warning can cause a fire personal injury or death Locked Rotor In this type of failure compressor motor and all starting compo nents 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 ammet
41. erature sensor It is designed to control condenser fan motor speed in response to the saturated condensing temperature during operation in cooling mode only For outdoor temperature down to 20 F it maintains condensing temperature at 100 F 10 F Requires a ball bearing fan motor Step 8 Low Ambient Pressure Switch A long life pressure switch which is mounted to outdoor unit service valve It is designed to cycle the outdoor fan motor in response to condenser pressure in cooling mode in order to maintain head pressure within normal operating limits approxi mately 200 psig to 365 psig The control will maintain working head pressure at low ambient temperatures down to 0 when properly installed Step 9 Wind Baffle A field fabricated sheet metal cover used to stop prevailing winds or where outdoor ambient temperature is less than 55 F during unit operation of cooling mode Step 10 Coastal Filter Air Conditioner Only A mesh screen inserted under top cover and inside base pan to protect condenser coil from salt damage without restricting air flow Step 11 Support Feet Four adhesive plastic feet which raise unit 4 in above mounting pad This allows sand dirt and other debris to be flushed from unit base minimizes corrosion Step 12 Liquid Line Solenoid Valve An electrically operated shutoff valve to be installed at outdoor or indoor unit depending on tubing configuration which stops and starts r
42. from 75 F to 85 F Resistance goes from zero to when contacts open 8 If either opening or closing temperature does not fall within above ranges or thermostat sticks in 1 position replace thermostat to ensure proper defrost operation Step 13 Fan Motor Fan motor rotates fan blade that draws air through outdoor coil to perform heat exchange Motors are totally enclosed to increase reliability This also eliminates need for rain shield For the correct 16 position of fan blade assembly the fan hub should be flush with the motor shaft Replacement motors and blades may vary slightly A WARNING Turn off all power to unit before servicing or replacing fan motor Be sure unit main power switch is turned off Failure to do so may result in electric shock death or injury from rotating fan blade The bearings are permanently lubricated therefore no oil ports are provided For suspected electrical failures check for loose or faulty electrical connections or defective fan motor capacitor Fan motor is equipped with thermal overload device in motor windings which may open under adverse operating conditions Allow time for motor to cool so device can reset Further checking of motor can be done with an ohmmeter Set scale on R X 1 position 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 ohmmete
43. g season charge must be weighed in accordance with unit rating plate 0 6 oz ft of 3 8 in liquid line above or below 15 ft respectively Step 7 Checking Charge SUPERHEAT CHARGING METHOD Superheat charging is the process of charging refrigerant in a system until the temperature superheat of suction gas entering compressor reaches a prescribed value Small variations of charge affect suction gas superheat temperatures greatly Therefore this method of charging is very accurate This method can be used with fixed restrictor type metering devices such as AccuRater For units using a TXV the subcooling method must be used To charge by superheat a service technician will need an accurate superheat thermocouple or thermistor type thermometer a sling psychrom eter and a gage manifold Do not use mercury or small dial type thermometers as they are not adequate for this type of measure ment Refer to unit information plate for superheat charging procedure SUBCOOLING CHARGING METHOD SEE CHARGING TABLE IN APPENDIX 1 Operate unit a minimum of 15 minutes before checking charge 2 Measure liquid service valve pressure by attaching an accurate gage to service port CHARGE ACCURATELY Undercharge Proper Charge Overcharge LOW LOW SIDE LONG LIFE HIGH HIGH SIDE PRESSURE PRESSURE SAFE HIGH OPERATION HIGH DISCHARGE SUPERHEAT DESIGN TEMPERATURE OVERHEATED CAPACITY FLOODBACK MOTOR 2 om PEAK LOW SYSTEM EFF
44. ge supplemental heat R Energizes 24 v power from transformer red Y Energizes contactor for first stage cooling or first stage heat ing for heat pumps yel O Energizes reversing valve on heat pumps orn C Common side of transformer blk COPELAND SCROLL COMPRESSOR PURON REFRIGERANT The compressor used in this product is specifically designed to operate with Puron R 410A refrigerant and cannot be inter changed 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 tech niques Refrigerants present additional safety hazards A WARNING Wear safety glasses and gloves when handling refrigerants Failure to follow this warning can cause a fire personal injury or death The scroll compressor pumps refrigerant through the system by the interaction of a stationary and an orbiting scroll See Fig 22 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 anti rotational device and an internal pressure relief port The anti rotational device prevents the scroll from turning backwards and replaces the need for a cycle protector The pressure relief port is a safety device designed to protect against extreme high pressure The relief port has an op
45. ial per local codes Step 4 Brazing When brazing is required in the refrigeration system certain basics should be remembered The following are a few of the basic rules 1 Clean joints make the best joints To clean 19 a Remove all oxidation from surfaces to a shiny finish before brazing b Remove all flux residue with brush and water while material is still hot 2 Use sil fos or phos copper for copper to copper only No flux is required 3 Silver solder is used on copper to brass copper to steel or copper to copper Flux is required when using silver solder Do not use low temperature solder 4 Fluxes should be used carefully Avoid excessive application and do not allow fluxes to enter into the system 5 Brazing temperature of copper is proper when it is heated to a dull red color 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 above are listed only as a reminder Step 5 Service Valves and Pumpdown Service valves provide a means for holding original factory charge in outdoor unit prior to hookup to indoor coil They also contain gage ports for measuring system pressures and provide shut off convenience for certain types of repairs See Fig 24 The service valve is a combination front seating back seating valve which has a metal to metal seat in both the open and closed position
46. ill hold mois ture 28 SECTION 3 APPENDIX Pressure vs Temperature Chart R 410A PSIG PSIG PSIG PSIG F PSIG PSIG 12 37 7 114 37 8 216 74 3 318 100 2 420 120 7 522 137 6 14 34 7 116 38 7 218 74 9 320 100 7 422 121 0 524 137 9 16 32 0 118 39 5 220 75 5 322 101 1 424 121 4 526 138 3 18 29 4 120 40 5 222 76 1 324 101 6 426 121 7 528 138 6 20 36 9 122 41 3 224 76 7 326 102 0 428 122 1 530 138 9 22 24 5 124 42 2 226 77 2 328 102 4 430 122 5 532 139 2 24 22 2 126 43 0 228 77 8 330 102 9 432 122 8 534 139 5 26 20 0 128 43 8 230 78 4 332 103 3 434 123 2 536 139 8 28 17 9 130 44 7 232 78 9 334 103 7 436 123 5 538 140 1 30 15 8 132 45 5 234 79 5 336 104 2 438 123 9 540 140 4 32 13 8 134 46 3 236 80 0 338 104 6 440 124 2 544 141 0 34 11 9 136 47 1 238 80 6 340 105 1 442 124 6 548 141 6 36 10 1 138 47 9 240 81 1 342 105 4 444 124 9 552 142 1 38 8 3 140 48 7 242 81 6 344 105 8 446 125 3 556 142 7 40 6 5 142 49 5 244 82 2 346 106 3 448 125 6 560 143 3 42 4 5 144 50 3 246 82 7 348 106 6 450 126 0 564 143 9 44 32 146 51 1 248 83 3 350 107 1 452 126 3 568 144 5 46 1 6 148 51 8 250 83 8 352 107 5 454 126 6 572 145 0 48 0 0 150 52 5 252 84 3 354 107 9 456 127 0 576 145 6 50 1 5 152 53 3 254 84 8 356 108 3 458 127 3 580 146 2 52 3 0 154 54 0 256 85 4 358 108 8 460 127 7 584 146 7 54 45 156 54 8 258 85 9 360 109 2 462 128 0 588 147 3 56 5 9 158 55 5 260 86 4 362 109 6 464 128 3 592 147 9 58 7 3 160 56 2 262 86 9
47. ind Baffle N A Yes No No Coastal Filter KAACF0201MED No No Yes Support Feet KSASF0101AAA Recommended No Recommended Puron R 410A Hard Shutoff TXV No Yes No Fan motor with ball bearings required Table 2 Required Field Installed Accessories for Puron R 410A Heat Pumps REQUIRED FOR REQUIRED FOR ORDERING LOW AMBIENT COOLING LONG LINE ACCESSORY NUMBER APPLICATIONS APPLICATIONS BELOW 55 F 50 175 FT Crankcase Heater KAACH1201AAA Yes Yes Evaporator Freeze Thermostat KAAFT0101AAA Yes No KSAHS1501AAA Compressor Start Assist Capacitor and Relay KSAHS1601AAA Yes Yes Puron R 410A Low Ambient Pressure Switch KSALA0301410 Yes No Wind Baffle Yes No Support Feet KSASF0101AAA Recommended No KSATX0201HSZ Puron R 410A Hard Shutoff TXV a i Yes Yes KSATX0501HSZ Puron R 410A Liquid Line Solenoid Valve for Heating KHALA0401AAA No Yes Required for all applications Step 6 Low Ambient Controller Low ambient controller is a cycle control device activated by a temperature sensor mounted on a header tube of the outdoor coil It is designed to cycle the outdoor fan motor in order to maintain condensing temperature within normal operating limits approxi mately 100 F high and 60 F low The control will maintain working head pressure at low ambient temperatures down to 0 F when properly installed Step 7 MotorMaster Control A fan speed control device activated by a temp
48. l a suction line filter drier in the liquid line of a Puron R 410A system Failure to follow this warning can cause a fire personal injury or death 7 If suction line filter drier was installed for system clean up 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 and evacuate when replacing filter driers 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 8 Charge system See unit information plate Step 3 Seacoast For Air Conditioners Only Installation of these units in seacoast locations requires the use of a coastal filter See section on cleaning ACCESSORY DESCRIPTIONS Refer to Table 1 for an Accessory Usage Guide for Puron R 410A Air Conditioners and Table 2 for Puron R 410A Heat Pumps Refer to the appropriate section below for a description of each accessory and its use Step 1 Compressor Crankcase Heater An electric heater which mounts to base of compressor to keep lubricant warm during off cycles Improves compressor lubrication on restart and minimizes chance of refrigerant slugging and oil pumpout The crankcase heater may or may not include a thermostat control F
49. l not to bend or dent fan blade Clean motor and blade with soft brush or cloth Be careful not to disturb balance weights on fan blade 3 Check fan blade setscrew for tightness 4 Reinstall fan motor and blade to top cover and check for alignment 5 6 ELECTRICAL CONTROLS AND WIRING 1 2 Reinstall top cover and position blade Reconnect electrical power and check for proper operation Disconnect power to both outdoor and indoor units Check all electrical connections for tightness Tighten all screws on electrical connections If any connections appear to be burned or smokey disassemble the connection clean all parts and stripped wires and reassemble Use a new connector if old one is burned or corroded and crimp tightly Reconnect electrical power to indoor and outdoor units and observe unit through 1 complete operating cycle If there are any discrepancies in operating cycle troubleshoot to find cause and correct REFRIGERANT CIRCUIT 1 Check refrigerant charge using the superheat method and if low on charge check unit for leaks using an electronic leak detector If any leaks are found remove and reclaim or isolate charge pumpdown if applicable Make necessary repairs Evacuate recharge and observe unit through 1 complete operating cycle FINAL CHECK OUT After the unit has been operating the following items should be checked 1 Check that unit operational noise is not excessive
50. loth or other acceptable heat sinking material on valve before braz ing To prevent damage to unit use a metal barrier between brazing area and unit After the brazing operation and the refrigerant tubing and evapo rator coil have been evacuated valve stem can be turned counter clockwise until it opens or back seats which releases refrigerant into tubing and evaporator coil The system can now be operated Back seating service valves must be back seated turned counter clockwise until seated before service port caps can be removed and hoses of gage manifold connected In this position refrigerant has access from and through outdoor and indoor unit The service valve stem cap is tightened to 20 ft lb torque and service port caps to 9 2 ft lb torque The seating surface of valve stem has a knife set edge against which caps are tightened to attain a metal to metal seal The service valve cannot be field repaired therefore only a complete valve or valve stem and service port caps are available for replacement If the service valve is to be replaced a metal barrier must be inserted between the valve and unit to prevent damaging unit exterior from heat of brazing operations A WARNING Wear safety glasses and gloves when handling refrigerants Failure to follow this warning can cause a fire personal injury or death Pumpdown Procedure Service valves provide a convenient shut off valve useful for certain refrigeration
51. mpressor especially at start up may also cause exces sive noise 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 abnormali ties 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 start winding because it has more turns This terminal is start S Remaining terminal will be run winding R See Fig 21 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 NOTE Ohm readings in Fig 23 are examples not actual mea surements 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 t
52. ng can cause a fire personal injury or death Step 1 Aluminum Wire CAUTION 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 percent of unit rated voltage To prepare wire before installing connector all aluminum wire must be brush scratched and coated with a corrosion inhibiter such as Pentrox A When it is suspected that connection will be exposed to moisture it is very important to cover entire connection 10 completely to prevent an electrochemical action that will cause connection 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 tempera
53. nnect terminals for leads connection Old solenoid coils cannot be used on 4 port reversing valves If for any reason a new wire cord is not available cut the leads ont the old solenoid coil as close to the coil as possible Terminate the leads with 2 female 1 4 in quick connects Connect terminals to new solenoid and tape co 3 Remove solenoid coil from valve body Remove valve by cutting it from system with tubing cutter Repair person should cut in such a way that stubs can be easily rebrazed back into system Do not use hacksaw This introduces chips into system that cause failure After defective valve is removed wrap it in wet rag and carefully unbraze stubs Save stubs for future use Because defective valve is not overheated it can be analyzed for cause of failure when it is returned 4 Braze new valve onto used stubs Keep stubs oriented cor rectly Scratch corresponding matching marks on old valve and stubs and on new valve body to aid in lining up new valve properly When brazing stubs into valve protect valve body with wet rag to prevent overheating 5 Use slip couplings to install new valve with stubs back into system Even if stubs are long wrap valve with a wet rag to prevent overheating 6 After valve is brazed in check for leaks Evacuate and charge system Operate system in both modes several times to be sure valve functions properly FROM INDOOR COIL VIA SERVICE VALVE ON OUTDOOR COIL TO OUTDOOR COIL
54. o close before troubleshooting Always turn off all power to unit and disconnect leads at compressor terminals before taking readings Most common motor failures are due to either an open grounded or short circuit 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 pres sure equalization defective capacitor s relays wiring etc Com pressor has internal line break overload so be certain it is closed 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 Ww Y m UNO 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 MNI NUN U Qi S M N Q MM WM 4 mmo 5 K Nimmo By the time the gas arrives at the center port discharge pressure has been reached Actually during operation all six gas passages are in various stages of compression at all times resulting in nearly con tinuous suction and discharge A90198 Fig 22 Scroll Compressor Refrigerant Flow Open Circuit 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 capacitor
55. o discontinue or change at any time specifications or designs without notice and without incurring obligations 1 1 2 101 Catalog No 533 824 Printed in U S A Form 38 8SM Pg 36 2 98 Replaces 38TXA 1SM Tab 3a 5
56. on of liquid into it could cause severe damage or total failure of compressor The accumulator is a passive device which seldom needs replac ing Occasionally its internal oil return orifice or bleed hole may become plugged Some oil is contained in refrigerant returning to compressor It cannot boil off in accumulator with liquid refriger ant The bleed hole allows a small amount of oil and refrigerant to 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 28 This fusible element will melt at 430 F 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 accumulator 1 Shut off all power to unit TO FROM TO INDOOR COIL OUTDOOR ea VIA SERVICE VALVE COIL ON OUTDOOR COIL INSULATE FOR e ACCURATE READING INSULATE FOR ACCURATE A READING FROM COMPRESSOR DISCHARGE LINE ELECTRONIC THERMOMETER A88341 Fig 27 Reversing Valve Heating Mode Solenoid De Energized 2 Recover all refrigerant from system 5 Slide piston and piston ring out by inserting a small soft wire with small kinks through metering hole Do not damag
57. only factory authorized TXV Do not use an R 22 TXV Step 11 Hard Shutoff HSO Has no bleed port and allows no bleed through after system shutdown No pressure equalization occurs 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 See Fig 34 1 Superheat temperature sensed by cap tube sensing bulb on suction tube at outlet of evaporator coil As long as this bulb and cap tube contains some liquid refrigerant this temperature is converted into suction pressure pushing downward on the diaphragm which tends to open 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 3 The needle valve on the pin carrier is spring loaded which exerts pressure on the underside of the diaphragm via the pushrods and tends to close the valve Therefore bulb pressure equals evaporator pressure at outlet of coil plus spring pressure If the load increases the temperature increases at the bulb which increases the pressure on the top side of the diaphragm which pushes the pin carrier away from the seat opening the valve and increasing the flow of refrigerant The 23 increased refrigeran
58. or units equipped with crankcase heaters apply power for 24 hrs before starting compressor Step 2 Evaporator Freeze Thermostat An SPST temperature activated switch stops unit operation when evaporator reaches freeze up conditions Step 3 Winter Start Control An SPST delay relay which bypasses the low pressure switch for approximately 3 minutes to permit start up for cooling operation under low load conditions Step 4 Compressor Start Assist PTC Solid state electrical device which gives a soft boost to the compressor at each start Step 5 Compressor Start Assist Capacitor Relay Start capacitor and start relay gives hard boost to compressor motor at each start Required with Liquid Line Solenoid or hard shutoff TXV for all Series A equipment Table 1 Required Field Installed Accessories for Puron R 410A Air Conditioners ORDERING REQUIRED FOR LOW AMBIENT PONE OR SEACOAST ACCESSORY APPLICATIONS NUMBER BELOW 55 F APPLICATIONS APPLICATIONS 50 175 FT WITHIN 2 MILES Crankcase Heater KAACH1201AAA Yes Yes No Evaporator Freeze Thermostat KAAFT0101AAA Yes No No Winter Start Control KAAWS0101AAA Yes No No Compressor Start Assist PTC KAACS0201PTC 2r Yes Yes No Compressor Start KSAHS1501AAA Assist Capacitor Relay KSAHS1601AAA Low Ambient Controller P251 0083 RCD or MotorMaster Control 32LT660004 RCD Yes No No or Low Ambient Pressure Switch KSALA0301410 W
59. oss T1 and T3 and set thermostat so that Y terminal is energized Make sure all protective devices in series with Y terminal are closed Voltmeter should read 24v across and T3 With 24v still applied move voltmeter leads to T2 and T3 After 5 2 minutes voltmeter should read 24v indicating control is functioning normally If no time delay is encountered or device never times out change control Step 6 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 crankcase heater is wired in parallel with contactor contacts and in series with compressor See Fig 18 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 The crankcase heater is powered by high voltage power of unit Use extreme caution troubleshooting this device with power on The easiest method of troubleshooting is to apply voltmeter across crankcase heater leads to s
60. placed Step 8 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 These pressure switches are specifically designed to operate with Puron R 410A systems R 22 pressure switches must not be used as replacements for the Puron R 410A air conditioner Puron pressure switches are identified by a pink stripe down each wire LOW PRESSURE SWITCH AIR CONDITIONER ONLY The low pressure switch is located on suction line and protects against low suction pressures caused by such events as loss of charge low airflow across indoor coil dirty filters etc It opens on a pressure drop at about 50 psig If system pressure is above this switch should be closed To check switch 1 Turn off all power to unit 2 Disconnect leads on switch 3 Apply ohmmeter leads across switch You should have con tinuity 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 gages read 0 psi Never open system without breaking vacuum with dry nitrogen A95508 A88350 A94006 Fig 13 Capacitor 12 5 22 5 OHMS 12 5 OH
61. r In an air conditioning and heat pump system refrigerant transfers heat from one place to another The condenser is the outdoor coil in the cooling mode and the evaporator is the indoor coil The condenser is the indoor coil in the heating mode and the evaporator is the outdoor coil 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 eo EXAMPLE e e POWER OFF DEDUCTION 2 OHMMETER TO DETERMINE INTERNAL CONNECTIONS OF SINGLE PHASE MOTORS C S R EXCEPT SHADED POLE GREATEST RESISTANCE 5 80 OHM SMALLEST RESISTANCE 0 60 REMAINING RESISTANCE 5 20 RUN WINDING R START WINDING S 2 Is COMMON C BY ELIMINATION 2 is COMMON THEREFORE IS START WINDING S 3 IS RUN WINDING R A88344 Fig 23 Identifying Internal Connections 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 a hot gas and cycle repeats Step 2 Compressor Oil CAUTION The compressor in this system uses a polyol ester POE oil Mobil EAL ARTIC 22CC This oil is extremely hygroscopic meaning it absorbs water readily POE oils can
62. r lead on motor case ground Replace any motor that shows resistance to ground arcing burning or overheating Step 14 Compressor Plug The compressor electrical plug provides a quick tight connection to compressor terminals The plug completely covers compressor terminals and mating female terminals are completely encapsu lated 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 How ever these plugs are specialized and vary in terminal orientation Therefore plugs can be used on only specific compressor The configuration around the fusite terminals is outline of 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 routed easily through slot in terminal cover Step 15 Low Voltage Terminals The low voltage terminal designations description function are used on all split system condensers their W Energizes first stage supplemental heat through defrost relay wht L Energizes light on thermostat with service alarm W3 Energizes second or third sta
63. rating must be 400 psig DOT 4BA400 or DOT BW400 Puron R 410A systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose Manifold sets should be 700 psig high side and 180 psig low side with 550 psig low side retard Use hoses with 700 psig service pressure rat ing Leak detectors should be designed to detect HFC refrigerant Puron R 410A as with other HFCs is only compatible with POE oils Vacuum pumps will not remove moisture from oil e Only use factory specified liquid line filter driers with rated working pressures less than 600 psig 31 Do not install a suction line filter drier in liquid line POE oils absorb moisture rapidly Do not expose oil to atmosphere POE oils may cause damage to certain plastics and roofing materials Wrap all filter driers and service valves with wet cloth when brazing A liquid line filter drier is required on every unit Do not use an R 22 TXV If indoor unit is equipped with a TXV it must be changed to a Puron R 410A TXV Never open system to atmosphere while it is under a vacuum When system must be opened for service break vacuum with dry nitrogen and replace filter driers Always replace filter drier after opening system for service Do not vent Puron R 410A into the atmo sphere Do not use capillary tube coils Observ
64. ressor Plug Low Voltage Terminals COPELAND SCROLL COMPRESSOR 16 18 Mechanical Failure Electrical Failure REFRIGERATION SYSTEM 18 23 Refrigerant Compressor Oil Servicing Systems on Roofs with Synthetic Materials Brazing Service Valves and Pumpdown Filter Driers Accumulator AccuRater Thermostatic Expansion Valve TXV Hard Shutoff HSO Replacing R 22 Expansion Device with Puron TXV e REFRIGERATION SYSTEM REPAITR 23 27 Leak Detection Coil Removal Compressor Removal and Replacement System Clean Up After Burnout Evacuation Puron R 410A Refrigerant Charging Checking Charge CARE AND MAINTENANCE cher 27 28 Cleaning Desert and Seacoast Locations SECTION 3 APPENDIX 1 29 36 PRESSURE vs TEMPERATURE CHART FOR PURON audi yc 29 SUBCOOLING CHARGING TABLE 30 QUICK REFERENCE GUIDE e 31 TROUBLESHOOTING CHARTS 32 36 Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 112 PC 101 Catalog No 533 824 Tab 5 1a Printed in U S A Form 38 8SM Pg 1 2 98 Replaces 38TXA 1SM SECTION 1 APPLICATION GUIDE LINE INSTALLATION GUIDELINE Step 1 Residential New Construction Specifications for this unit in the residential new construction market require th
65. s 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 each reading appears to be approximately 0 ohm If resistance remains at 1000 ohms an open or break exists and compressor should be replaced CAUTION 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 follow these steps 1 Allow crankcase heaters to remain on for several hr before checking motor to ensure windings are not saturated with refrigerant 2 Using an ohmmeter on R X 10 000 ohm scale or megohmme ter follow manufacturer s instructions 18 Be sure all power is off Discharge all capacitors Remove wires from terminals C S and R O u R w 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 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
66. s When it is fully back seated the service port is not pressurized To pressurize the service port this valve must be moved off the back seating position This valve does not contain a Schrader fitting The service valves are designed for sweat connection to the field tubing The service valves in outdoor unit come from factory front seated This means that refrigerant charge is isolated from line set connection ports Heat pumps are shipped with sweat adapter tube This tube must be installed on the liquid service valve When checking piston replace teflon washer Tighten nut finder tight and then with wrench an additional 1 2 turn 15 ft lb Do not overtighten After connecting the sweat adapter to the service valve of a heat pump the valves are ready for brazing The interconnecting tubing line set can be brazed to service valves using either silver bearing or non silver bearing brazing material Consult local codes Before brazing line set to valves belled ends of sweat connections on service valves must be cleaned so that no brass plating remains on either inside or outside of bell joint To STAINLESS STEEL NE STEM 11 SERVICE PORT ENTRANCE ga PT SEAT POSITION FIELD SIDE FRONT SEAT POSITION FORGED BACK SEATING VALVE A91435 Fig 24 Service Valve prevent damage to valve and or cap ring use wet c
67. s installed according to the rating plate or the Long Line Guideline NOTE Due to the presence of a vapor pressure switch in outdoor unit fan circuit and the possibility of fan cycling this unit may go into brief defrost at high ambient heating conditions Step 9 Check Defrost Thermosiat There is a liquid header with a brass distributer and feeder tube going into outdoor coil At the end of 1 of the feeder tubes there 14 is a 3 8 in OD stub tube approximately 3 in long See Fig 19 The defrost thermostat should be located on stub tube Note that there is only 1 stub tube used with liquid header and on most units it is the bottom circuit Step 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 closed at 30 3 F and open at 80 5 F NOTE The defrost thermostat must be located on the liquid side of the outdoor coil on the bottom circuit and as close to the coil as possible Step 11 Defrost Control Board Solid state defrost boards used on heat pumps replace electrome chanical timer and defrost relay found on older defrost systems The defrost control board can be field set to check need for defrost every 30 50 or 90 minutes of operating time by connecting the jumper labeled W1 on the circuit board
68. sec 50 minute cycle 45 55 12 sec 90 minute cycle 81 99 21 sec 10 minute cycle 9 11 2 sec 5 minutes 4 5 5 5 1 sec NOTE Since Fig 19 shows timing cycle set at 90 minutes unit initiates defrost within approximately 21 sec When you hear the reversing valve change position remove screwdriver immediately Otherwise control will terminate normal 10 minute defrost cycle in approximately 2 sec 4 CAUTION 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 as shown in Fig 21 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 O OF1 OR T2 Y T DET gt J CES0110063 c TEST 30 50 90 ua
69. st control board 3 Disconnect defrost thermostat leads from control board and connect to ohmmeter Thermostat leads are the black insu lated wires connected to DFT and R terminals on control board Resistance reading may be zero indicating closed defrost thermostat or infinity co for open thermostat de pending on outdoor temperature 4 Jumper between DFT and R terminals on control board as shown in Fig 20 5 Disconnect outdoor fan motor lead from OF2 Tape lead to prevent grounding 6 Turn on power to outdoor unit 7 Restart unit in heating mode allowing frost to accumulate on outdoor coil 8 After a few minutes in heating mode liquid line temperature at defrost thermostat should drop below closing set point of defrost thermostat of approximately 30 F Check resistance across defrost thermostat leads using ohmmeter Resistance of zero indicates defrost thermostat is closed and operating properly 15 9 Short between the speed up terminals using a thermostat screwdriver This reduces the timing sequence to 1 256 of original time See Fig 20 and Table 5 TEST 30 50 90 o pie M A97642 Fig 20 CES0110063 Defrost Control Table 5 Defrost Control Speed Up Timing Sequence MINIMUM MAXIMUM SPEED UP PARAMETER MINUTES MINUTES NOMINAL 30 minute cycle 27 33 7
70. t Heat Pump Only Bi flow liquid line solenoid must be installed witihn 2 ft of outdoor unit with arrow pointing toward outdoor unit Fig 6 Application with Air Conditioner or Heat Pump with Indoor Unit Below Outdoor Unit 8 SECTION 2 SERVICE MANUAL RATING PLATE service 2 PANEL GROMMET a 1 n LIQ TUBE a BASE PAN 00o SERVICE fa VALVE INFO TOP CAP CONTROL BOX INFO PLATE Y WARNING LABEL V ACCESS PANEL o A95411 A95411 Fig 7 Callouts for R 410A Air Conditioner and Heat Pump A WARNING Improper installation adjustment alteration service mainte nance or use can cause explosion fire electrical shock or other conditions which may cause personal injury death or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified installer or agency must use factory authorized kits accessories or replacement components when modifying this product Troubleshooting Charts for Puron R 410A Air Conditioners and Heat Pumps are provided in the appendix at back of this manual They enable the service technician to use a systematic approach to locating the cause of a problem and correcting system malfunc tions UNIT IDENTIFICATION This section e
71. t flow causes increased leaving evaporator pressure which is transferred via the equalizer tube to the underside of the diaphragm This tends to cause the pin carrier spring pressure to close the valve The refrigerant flow is effectively stabilized to the load demand with negligible change in superheat Step 12 Replacing R 22 Expansion Device with Puron R 410A TXV An existing R 22 TXV must be replaced with a factory approved TXV specifically designed for Puron R 410A NOTE All Puron R 410A Heat Pumps require a hard shutoff Puron R 410A TXV For existing R 22 TXV Fan Coils and Furnace Coils the TXV must be replaced with a factory approved TXV specifically designed for Puron R 410A Fan Coils with internal TXV s may have TXV directly replaced with TXV from kit Fan coils and furnace coils with pistons TXV must be located external to cabinet as shown in Fig 33 See Fig 32 for proper sensing bulb position and Fig 33 for proper sensing bulb location Follow instructions included with Puron R 410A TXV kit for specific details See Fig 31 REFRIGERATION SYSTEM REPAIR Step 1 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 psi minimum and 375 psi maximum This can be done by adding refrigerant using normal charging procedures or by pressurizing system with nitrogen less exp
72. tep 3 Capacitor A WARNING Capacitors can store electrical energy when power is off Electrical shock can result if you touch the capacitor termi nals 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 Failure to follow this warning can cause a fire personal injury or death NOTE If bleed resistor is wired across start capacitor it must be disconnected to avoid erroneous readings when ohmmeter is applied across capacitor See Fig 13 A WARNING 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 Failure to follow this warning can cause a fire personal injury or death 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 ohmmeter check each terminal to ground use capacitor case Discard any capacitor which measures 1 2 scale deflection or less Place ohmmeter leads across capacitor and place on R X 10k scale Meter should jump to a low resistance value and slowly climb to higher valu
73. to the terminal for the defrost time desired The board is set at factory for 90 minutes The defrost period is field selectable depending upon geographic areas and defrost demands Troubleshooting defrost control involves a series of simple steps that indicate whether or not board is defective TEMP SWITCH CRANKCASE HTR R NN BLK BLK BLK BLK XP E A97586 Fig 18 Wiring for Single Pole Contactor FEEDER TUBE STUB TUBE DEFROST THERMOSTAT Fig 19 Defrost Thermostat Location d 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 Step 12 CES0110063 Defrost Control All heat pumps in this line use the CES0110063 defrost control This control board has a connector plug with stripped wire leads It also contains a feature that allows the heat pump to restart in defrost if the room thermostat is satisfied during defrost The board also contains a 5 minute cycle protector that prevents the unit from short cycling after it cycles off or after a power interruption To troubleshoot the board perform the following items 1 Turn thermostat to OFF Shut off all power to outdoor unit 2 Remove control box cover for access to electrical components and defro
74. tures especially if aluminum conductors are used Step 2 Contactor The contactor provides a means of applying power to unit using low voltage 24v from transformer in order to power contactor coil See Fig 12 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 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 A95506 Fig 10 Information Plate S
75. uced If larger vapor lines are selected but not specified within the table refrigerant oil return will be impaired due to velocity losses Standard vapor line diameter required per outdoor unit presale literature t The estimated percentage of cooling capacity that must be subtracted from Detailed Cooling Capacities specified in outdoor unit presale literature for any given indoor outdoor combination Air Conditioners Only 90 STD 90 LONG RAD A92498 Fig 3 Tube Bend Losses Table 4 Fitting Losses in Equivalent Ft TUBE SIZE OD REFERENCE DIAGRAM IN FIG 3 IN A B C 5 8 1 6 1 0 0 8 3 4 1 8 1 2 0 9 7 8 2 0 1 4 1 0 1 1 8 2 6 1 7 1 3 A97637 A hard shutoff TXV must be installed at indoor unit A crankcase heater must be installed on compressor Vapor line should slope toward indoor unit The above requirements provide refrigerant migration protection during off cycle due to temperature or slight elevation differences between indoor and outdoor units Maximum equivalent line length is 175 ft between indoor and outdoor units Heat Pump Only Bi flow liquid line solenoid must be installed witihn 2 ft of outdoor unit with arrow pointing toward outdoor unit Fig 4 Application with Air Conditioner or Heat Pump Installed in a
76. vailable Oil vapor in line may ignite when switch is removed 2 Braze in 1 4 in flare fitting and replace pressure switch LOSS OF CHARGE SWITCH HEAT PUMP ONLY PRESSUREGUARD 13 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 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 23 psi Troubleshooting and removing this switch is identical to procedures used on other switches Observe same safety precautions HEATING VAPOR PRESSURE SWITCH This outdoor unit is equipped with a heating vapor pressure limiting device which cycles the outdoor fan at high ambient heating conditions Because Puron R 410A is a high pressure refrigerant this switch provides maximum flexibility and minimum cost for the installer owner by not requiring special thicker wall vapor tubing and indoor coils thus allowing limited retrofit The use of this switch also allows the maximum number of indoor coil choices at minimum cost for the installer owner since it can use standard refrigeration tubing
77. ve coil grille from unit 4 Remove screws on corner post holding coil tube sheet A WARNING Cut tubing to reduce possibility of fire and personal injury 5 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 SENSING BULB sp EQUALIZER TUBE KDE URS 1 EP THERMOSTATIC EXPANSION VALVE A95616 Fig 33 Typical TXV Installation 6 Lift coil vertically from basepan and carefully place aside 7 Reverse procedure to reinstall coil 8 Replace filter drier evacuate system recharge and check for normal system operation Step 3 Compressor Removal and Replacement Once it is determined that compressor has failed and the reason established compressor must be replaced A CAUTION 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 A WARNING Wear safety glasses and gloves when handling refrigerants and when using brazing torch Failure to follow this warning can cause a fire personal injury or death 1 Shut off all power to unit 2 Remove and recover all refrigerant from system until pressure gages read 0 psi 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
78. 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 3 Resistance measuring instrument must have an accuracy within 5 10 percent This requires an accurate ohmmeter such as a Wheatstone bridge or null balance type 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 u 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 REFRIGERATION SYSTEM Step 1 Refrigerant A CAUTION This system uses Puron R 410A refrigerant which has higher pressures than R 22 and other refrigerants No other refrigerant may be used in this system Gage set hoses and recovery system must be designed to handle Puron If you are unsure consult the equipment manufacture
79. xplains how to obtain the model and serial number from unit rating plate These numbers are needed to service and repair the Puron R 410A air conditioner or heat pump Step 1 Model Number Nomenclature Model number is found on unit rating plate See Fig 8 and 10 Step 2 Serial Number Nomenclature Serial number is found on unit rating plate See Fig 9 and 10 CABINET ASSEMBLY Certain maintenance routines and repairs require removal of cabinet panels Step 1 Remove Top Cover 1 Turn off all power to outdoor and indoor units 2 Remove access panel 3 Remove information plate 4 Disconnect fan motor wires and cut wire ties Remove wires from control box Refer to unit wiring label 5 Remove screws holding top cover to coil grille and corner posts 6 Lift top cover from unit 7 Reverse sequence for reassembly Step 2 Remove Fan Motor Assembly 1 Perform items 1 through 6 from above Remove nuts securing fan motor to top cover 2 3 Remove motor and fan blade assembly 4 Reverse sequence for reassembly 5 Prior to applying power check that fan rotates freely Step 3 Information Plate The information plate is secured to front of control box and provides the control box cover See Fig 10 This plate also provides a surface to attach the wiring schematic superheat charging tables with instructions and warning labels The plate has 2 tabs on top edge that are bent down at slightly mor

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