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1. Air delivery values are based on operating voltage of 230v wet coil without filter or electric heater Deduct filter and electric heater pressure drops to obtain static pressure available for ducting NOTES 1 Do not operate the unit at a cooling airflow that is less than 350 cfm for each 12 000 Btuh of rated cooling capacity Evaporator coil frosting may occur at air flows below this point 2 Standard Cubic Feet per Minute Heat Pump VO HORIZONTAL D HARE SPEED TAR EXTERNAL STATIC PRESSURE W C s 94 95 o7 98 99 297 s s ex 800 _ su ws su 3 66 05 2 ver vr es 586 3 s 865 74 95 sm 875 555 2 na wor 7069 1006 94 52 3 Screw wes 1195 1005 958 85 88 _ 2 som ws 1364 1266 1203 1064 102 969 3 1090 oem 1499 144 1894 1549 1307 1273 1169 1108 1098 2 1185 3 1264 1340 2 7407 150 1870 180 1809 1775 1746 1685 1646 1445 2 o 1872 wes 1795 1717 1678 1629 1568 1525 3 1753 Air delivery values based on operating voltage of 230v wet coil without filter or electric heater Deduct filter and electric heater pressure drops to obtain static pressure available for ducting NOTES 1 Do not operate the uni
2. 01140 YO 14055323 03810038 38 03345 30 9NIOMWMO 1 1504430 30 H380d 07 ONIA 30123135 03345 404 ONTHIA 130123 Y IVISONDM 1508330 140 9NIWIA 100802 0131 1818 1013 LO EE 01914 80 YOLON 905538890 4802 1VISINAJHL 5 iO a 30121802 5 321146 01313 419140 30 ANY dT 1 sao 413931 c gen 035072 51 140 31 ATWNAON 31YNIMHJL 1118 1900130 0 8340 51 130 41 7236 0 NI TITA 1508330 wj 0300491 38 VIIN LYONS ININYNAJA E n Td QNID 1504330 432803 803 253138 23S 5 803 180 2 AID 1V130 440 WOSS3NdNOD ximo MD SSVdA OL 14 14045 1 m8 37242 40 03345 01313 we 123780 W13N ISN SNIA 1531 038360 1402 60109 1 1 OIN 441 3345 9801123440 1738 1705 V2 5080035 21810319 18056222 1 1 1 09 06 0 141330 330 018 ELSE 440 9 01123135 ONIWIL 1508330 5 310N 335 32830035 1 3108 339 NYB 2 sworl23NNO2 110 v2 A89 778 01A 50553997 EM 5 310N 335 189 9 Nag 2 134 5011238802 1VISIWH3HI 18 2M 104 v2
3. 19 FAN MOTOR 20 COMPRESSOR PLUG 21 LOW VOLTAGE TERMINALS 21 REFRIGERATION SYSTEM 22 24 Refrigerant i EY AS 22 Compressor Oil coe re pee eme meme 22 Servicing Systems on Roofs With Synthetic Materials 22 Br zing cime dela eee ORA E 22 Liquid Line Filter Drier 24 Suction Line Filter 24 Accumulator 24 Thermostatic Expansion Valve 24 LLL AI AI A Wt NN 8 10165 Fig 1 A C and Heat Pump PAGE PISTON BODY CLEANING OR REPLACEMENT 25 26 REFRIGERATION SYSTEM REPAIR 25 Leak Detection 2 2 gt 25 9 8598099 25 Coil REMOVAL REISEN Eus 26 Compressor Removal and Replacement 26 System Clean Up After Burnout 27 Evacuation ico ERR E E Es 27 CHECK 28 TROUBLESHOOTING WITH 28 29 INDOOR AIRFLOW AND AIRFLOW ADJUSTMENTS 29 32 Rettigerant coiere eR e Es 29 Heating Check Charge Procedure 29 Sequence of Operation 32 ECM FAN MOTOR TROUBLES
4. 7 56211 19 09 lt 61 Tesh 61 195 vl 101011 8 1 27 691 09 1 0 2 802 000090 605 v 6L eer 61 966 1 101011 8 1 2 691 90 09 1 02 802 1 000870 606 7 lt 61 eer 61 95 1 101011 8 1 27 51 666 09 L 0 2 902 000270 1 A X 799 7581 90119 18310 8710 LINN NI ALIAVHO 40 81130 1H9I3H LINN 1M LINN 1921819313 1e9H 606 61 eer 61 1956171 0101 8 1 27 091 295 09 1 02 802 V000090 907 91 eer 61 96 71 198 8 1 v 661 Soe 09 1 062 802 17000870 90v 91 697 61 966 71 11981 9 l v 861 606 09 1 0 2 802 vOOO0cvO 1 A X Y 197 581 5211518312 8 2 LINN NI ALIAYY9 30 821N32 1H9IJH LINN IM LINN 191819313 SJeuonipuo 10137 Large Cabinet Unit Base Dimensions Medium 6 Fig Access Compressor Or Other Internal Cabinet Components NOTE Access to most of the components through the side panels of the unit The top will need to be removed to access the evaporator or condenser coil In some instances screws on the back of the unit duct side will need to be accessed If the unit is up against the structure the unit will have to be pulled away for servicing Follow the procedures below to access the different components 1 Access to control box compressor reversing valve metering device accumulator and liquid line drier a Removal of the right front panel opposite the duct flanges will give acce
5. 5 2 8 9 5 0 4 22 12 6 3 3 3 20 11 14 7 8 18 10 REQUIRED SUCTION TUBE TEMPERATURE F MEASURED AT COMPRESSOR SUCTION SERVICE PORT ec SUPERHEAT SUCTION PRESS URE AT SUCTION SERVICE PORT PSIG kPa 107 111 869 130 135 140 145 996 1030 1064 1103 0 0 35 1 7 37 2 8 45 7 2 47 8 3 49 9 4 51 11 2 1 1 37 2 8 39 3 9 47 8 3 49 9 4 51 11 53 12 4 2 2 41 5 0 43 6 1 45 7 2 47 8 3 49 9 4 51 11 53 12 55 13 57 14 51 11 53 12 55 13 43 6 1 45 7 2 47 8 3 49 9 4 51 11 53 12 55 13 57 14 59 15 45 7 2 47 8 3 49 9 4 51 11 53 12 55 13 57 14 59 15 61 16 47 8 3 49 9 4 51 14 7 8 __ 49 9 4 51 11 53 11 53 12 55 13 57 14 59 15 61 16 63 17 12 55 13 57 14 59 15 61 16 63 17 65 18 16 8 9 51 11 53 12 55 13 57 14 59 15 61 16 63 17 65 18 67 19 18 10 0 53 12 55 13 57 14 59 15 61 16 63 17 65 18 67 19 69 21 20 11 1 55 13 57 14 59 22 12 2 57 14 59 15 61 15 61 16 63 17 65 18 6
6. START CAPACITOR LOOSE LEAD AT FAN MOTOR DEFROST RELAY N C CONTACTS OPEN MOTOR DEFECTIVE INCORRECT OFM CAPACITOR DEFECTIVE DEFROST THERMOSTAT COMPRESSOR RUNS BUT INSUFFICIENT COOLING DIRTY AIR FILTERS DUCT RESTRICTED DAMPERS PARTLY CLOSED INDOOR COIL FROSTED SLIGHTLY LOW ON REFRIGERANT LIQUID LINE SLIGHTLY RESTRICTED PISTON RESTRICTED INCORRECT SIZE PISTON INDOOR COIL STRAINER RESTRICTED INDOOR BLOWER MOTOR DEFECTIVE OR CYCLING ON OL Fig 39 Heat Pump Troubleshooting Cooling Cycle 42 HIGH SUCTION LOW HEAD PRESSURE REVERSING VALVE HUNG UP OR INTERNAL LEAK DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON FAILED TXV A90207 INDEX OF TABLES DESCRIPTION rnnt SE sie ERE L IER UNE ER ER VENERE EE EN eras PAGE Required Field Installed Accessories for Air Conditioners amp Heat Pumps 2 2 Defrost Control Speed Up Timing Sequence Table 2 2 2 15 Air Conditioner amp Heat Pump Compressor Information 1 2 2 23 16 TH 25 Minimum Airflow for Safe Electri
7. 0 038 u y18 BS 03345 OIN 038 03345 M01 ng 03395 0001 80151538 48 0409039 AUNT Yd Car 090089 1N3Hd1003 En ONY 2 3215 v 3814 ANNO LINA 9 wig m IH 09 44 ji 10d 114405 01111 22 AINO 9901210902 814402 250 4 9 1101 8635 340338 41404 12138802510 QuvzvH MOOHS 1 01910313 H39NVO 10553840 8100 1 NOTLOINNOD 10029 Fig 36 Typical Heat Pump Unit Electrical Diagram 35 CARE AND MAINTENANCE To assure high performance and minimize possible equipment malfunction it is essential that maintenance be performed periodically on this equipment The frequency with which maintenance is performed is dependent on such factors as hours of operation geographic location and local environmental conditions WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in equipment damage or death Disconnect all electrical power to unit before performing any maintenance or service on outdoor unit Remember to disconnect power supply to air handler as this unit supplies low voltage power to the outdoor unit Lock out and tag switch with suitable warning label The minimum maintenance that should be performed on this equipment is as follows 1 Check outdoor coil for c
8. SJeuonipuo MJA MAA 3015 4330 11721 2 1 X 8 92 6071 9N1N340 1204 09 1971051 812 1925561 8 2 1206 n 91 1 1921921 6 9 418340 LONG 1078051 02 127221 9 6 AULN3 39V110A 31VSN30NO2 MAA LNOYS 83001 1103 IANYA 99300 834018 609 8 L _ u ONIN34O 1210 9 GGE tzer 97 816 6 Weve TANVd 8300 1109 800081 NV 1081802 34055344409 1079901 MAIA 401 NI 38 C1 NI SNOTSN3NTG LINN 40 01108 ON 53800024 2070129 YO JINJA ITBYAONIY V JONVIDSIO 4000110 l 817 10 INJAJYd Ol QINIVINIYW 38 190 S3JNYYYII9 310N SINIWIYINOIY JIN 801 1d30X1 82 u380d HLIM LINN 10 3015 77777 SONINJdO LONG 31150440 LINN 10 3015 i 5 3 1 7310 03 1 034 Qe 0071171717777 S9NIN340 LONG HLIM LINN 10 3015 19011 020 77777077 7771015 AYINI u 3MOd 512 3805 02080089 ONY STIVM 31382802 YO 32018 ANY LINN 777772015 AYINI YIMOd S32vjuns GIONNOYONN ANY LINN Utt 1111771773018 83804 SLIND N33ML38 716 0798 119011 0727 WN SIHONI 980 03 3 INN 2 180138 LINN 10 01108 3015 1331 83 00 1103
9. UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Do not leave system open to atmosphere Compressor oil is highly susceptible to moisture absorption System Clean Up After Burnout Some compressor electrical failures can cause motor to burn When this occurs by products of burn which include sludge carbon and acids contaminate system Test the oil for acidity using POE oil acid test to determine burnout severity If burnout is severe enough system must be cleaned before replacement compressor is installed The 2 types of motor burnout are classified as mild or severe In mild burnout there is little or no detectable odor Compressor oil is clear or slightly discolored An acid test of compressor oil will be negative This type of failure is treated the same as mechanical failure Liquid line strainer should be removed and liquid line filter drier replaced In a severe burnout there is a strong pungent rotten egg odor Compressor oil is very dark Evidence of burning may be present in tubing connected to compressor An acid test of compressor oil will be positive Follow these additional steps 1 TXV must be cleaned or replaced 2 Drain any trapped oil from accumulator if used 3 Remove and discard liquid line strainer and filter drier 4 After system is reassembled install liquid and suction line R 410A filter driers NOTE On heat pumps install suction li
10. e With system running place sensing bulb in ice bath for 1 minute superheat should increase If no response Replace Valve If OK proceed to Step 4 4 Check for even temperature distribution at outlet of each circuit of evaporator If greater than 15 F between circuits distributor or coil has a restriction e proceed to Step 5 Low Superheat with High Suction Pressure NOTE High suction pressure is considered for R 410A gt 135 psig Component failure typically causes this condition 5 Check airflow sensing bulb tightness orientation on vapor tube and ensure bulb is properly wrapped e proceed to Step 6 6 Check that compressor is pumping properly NOTE Loose Rules of Thumb Is discharge saturated 20 F higher than ambient temperature Is discharge superheat between 15 and 50 e proceed to Step 7 7 Recheck Airflow and Subcooling proceed to Replace Valve High Superheat with Normal or Low Pressure NOTE Normal or low suction pressure is considered R 410A 135 psig 8 Check for restriction in liquid line kinked line filter drier restricted etc e proceed to Step 9 9 Check for restriction in suction line kink restricted suction filter drier etc e proceed to Step 10 10 Check power element cap tube is not broken e proceed to Step 11 11 Check that equalizer tube is not kinked or plugged If OK proceed to Step 12 12 Check that
11. 119011 0727 7771016 AYINI 83004 SLINA N334138 WW S3HON SHONVUV3TO 03 1 ISN T3NVd 55222 830018 30S 14916 1278611 4330 117211 2 1 X 892 5071 NIVUO 3179430100 127061 39V170A MOT 127221 10 L 6 1 8 l 1178611 7 1 9 91 1 62 1079511 91 11 62 LINN 40 NOl108 18 2181 MAA 1NOM 834001 1103 TANVd 55322 1102 800081 ONY 08 1041802 80552848402 401 LINN 30 01108 56211 15 395 1331 834001 1104 10136 t ine Small Medium Cab imensions Fig 5 Unit Base D 907 91 697 61 900 1 199 8 1 0 TH 09 1 0 2 802 V0009 0 99 vl egy 61 95 vl 6911 8 1 06 021 p92 09 1 0 2 802 v0000 0 95 vl 61 95 vl 15911 8 1 06 021 892 09 1 0 2 802 1 A x 9 581 5211518312 8 2 LINN NW NI ALTAVYS 10 831130 1H9I3H LINN 1M LINN W21812313 95 vl 90 61 95 vl 1691 8 1 06 21 612 09 1 062 802 37000960 99 vl 607 61 966 71 15911 8 1 06 ELL 6r 09 1 0 2 802 V0000 0 95 vl esr 61 95 vl 15911 8 1 0 801 162 09 1 0 2 802 1 X Y ou S81 SOLISTU3IOVBVHO LINN WW NI ALIAYHO 30 83113 LHOT3H LINN 18 LINN 21812313
12. 2 and Fig 3 for MotorMaster II Low Ambient Kit Sensor Locations 5 S S S S S S S S S S S S S S S S A10165 CABINET ASSEMBLY Basic Cabinet Designs Certain maintenance routines and repairs require removal of the cabinet panels There are 3 cabinet sizes for the air conditioning and heat pump models However all of the units have similar panel construction other than their size The base footprint is the same on all three cabinet sizes ZNSS REAR VIEW A10166 Small and Medium Cabinet 10167 Medium and Large Cabinet Rear View Fig 4 Cabinet Designs ON 53 30 2188 8 YO 32813 8 V XIV 30 NOTLVINDYTIIY 14343864 OL Q3NIVINIVW 38 190 530 12 310N 1975561 i 1279171 1 8621 p 8 6 WA NI NI SNOISN3WIQ 12 8 312 9 8000100 JIN 801 1432 3 OTN OO er PU AMIN u3MOd HLIM LINN 30 3015 291 759818340 LING 31150440 LINN 30 3015 Dyt6 rne c M LINN 30 401 WA 5 5 03 1 3 0 119011 59 18340 LONG 1114 LINN 30 3015 71015 AMIN 83406 512 3805 03080089 STIVM 31382402 YO 92018 ANY LINN 716 079 3015 AYINI YIMOd 52271805 GIONNOYONN ONY LINN
13. Identifying Compressor Terminals Electrical Failures The compressor mechanical pump is driven by an electric motor within its hermetic shell In electrical failures compressor does not run although external electrical and mechanical systems appear normal Compressor must be checked electrically for abnormalities Before troubleshooting compressor motor review this description of compressor motor terminal identification Single Phase Motors To identify terminals C S and R 1 Turn off all unit power 2 Discharge run and start capacitors to prevent shock 3 Remove all wires from motor terminals 4 Read resistance between all pairs of terminals using an ohmmeter on 0 10 ohm scale 5 Determine 2 terminals that provide greatest resistance reading Through elimination remaining terminal must be common C Greatest resistance between common C and another terminal indicates the start winding because it has more turns This terminal is the start S The remaining terminal will be run winding R NOTE If compressor is hot allow time to cool and internal line break to reset There is an internal line break protector which must be closed All compressors are equipped with internal motor protection If motor becomes hot for any reason protector opens Compressor should always be allowed to cool and protector to close before troubleshooting Always turn off all power to unit and disconnect leads at compressor terminals befo
14. QN tA Evacuate tubing and coil as necessary CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage Use a backup wrench and do not over tighten as deformation of the piston body will occur causing the piston to lodge in a partially open or closed position LIQUID TUBE STRAINER FILTER The TXV and refrigerant flow control device is protected by either a wire mesh strainer or filter drier REFRIGERATION SYSTEM REPAIR Leak Detection New installations should be checked for leaks prior to complete charging If a system has lost all or most of its charge system must be pressurized again to approximately 150 psig minimum and 375 psig maximum This can be done by adding refrigerant using normal charging procedures or by pressurizing system with nitrogen less expensive than refrigerant Nitrogen also leaks faster than refrigerants Nitrogen cannot however be detected by an electronic leak detector See Fig 27 25 A95422 Fig 27 Electronic Leak Detection A WARNING PERSONAL HAZARD Failure to follow this warning could result in personal injury or death INJURY AND UNIT DAMAGE Due to the high pressure of nitrogen it should never be used without a pressure regulator on the tank Assuming that a system is pressurized with either all refrigerant or a mixture of nitrogen and refrigerant leaks in the system can be found with an electronic le
15. 14 7 8 16 8 9 16 8 9 16 8 9 15 8 3 50ZP500779 REV 2 0 TG psig kPa 14 7 8 189 61 56 46 41 16 13 8 5 15 8 3 196 63 58 48 43 17 15 9 6 203 66 61 51 46 19 16 10 8 210 68 63 53 48 20 17 11 9 217 70 65 60 55 18 15 224 72 67 62 57 19 16 231 74 69 64 59 20 18 238 76 71 66 61 21 19 245 77 72 67 62 57 25 17 14 252 79 74 69 64 59 26 18 15 260 81 76 71 66 61 27 19 16 268 83 78 73 68 63 29 20 17 276 85 80 75 70 65 30 27 24 284 87 82 77 72 67 31 28 25 292 89 84 79 74 69 32 26 300 91 86 81 76 71 33 27 309 93 88 83 78 73 34 26 318 95 90 85 80 75 35 27 327 97 92 87 82 77 36 28 336 99 94 89 84 79 37 29 345 101 96 91 86 81 38 33 30 27 354 103 98 88 83 39 34 31 28 364 105 100 95 90 85 40 35 32 29 374 107 102 97 92 87 41 36 33 30 384 108 103 98 93 88 42 37 34 394 110 105 100 95 90 44 404 112 107 102 97 92 45 414 114 109 104 99 94 46 7 39 40 4 41 38 35 48 42 39 36 48 43 37 49 44 38 45 46 47 47 EH 3 4 49 50 51 106 107 424 116 106 101 96 434 118 108 103 98 444 119 109 104 454 121 111 106 101 464 123 113 108 103 474 124 484 126 116 111 494 127 117 112 0 29 30 31 32 33 34 35 36 38 39 40 41 38 35 42 36 43 37 44 45 46 47 48 114 109 104 48 49 50 504 124 114 514 126 116 524 127 117 534 129 119 40 41 42 43 44 45 42 46 46 47 48 10039 31 Sequence of Operation FAN OPERATI
16. 57 3 676 159 2 70 7 100 31 2 0 4 202 70 1 21 2 304 97 1 36 2 406 118 1 47 8 508 135 5 57 5 680 159 8 71 0 102 32 2 0 1 204 70 7 21 5 306 97 5 36 4 408 118 5 47 1 510 135 8 57 7 684 160 3 71 3 104 33 2 0 7 206 71 4 21 9 308 98 0 36 7 410 118 8 48 2 512 136 1 57 8 688 160 8 71 6 106 34 1 1 2 208 72 0 22 2 310 98 4 36 9 412 119 2 48 4 514 136 4 58 0 692 161 3 71 8 108 35 1 1 7 210 72 6 22 6 312 98 9 37 2 414 119 6 47 7 516 136 7 57 7 696 161 8 72 1 110 35 5 1 9 212 73 2 22 9 314 99 3 37 4 416 119 9 48 8 518 137 0 58 3 112 36 9 2 7 214 73 8 23 2 316 99 7 37 6 418 120 3 49 1 520 137 3 58 5 39 AIR CONDITIONER TROUBLESHOOTING CHART NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD CONTACTOR OPEN POWER SUPPLY DEFECTIVE LOW VOLTAGE TRANSFORMER OPEN THERMOSTAT OPEN CONTROL CIRCUIT LOSS OF CHARGE CONTACTOR OR COIL DEFECTIVE LOOSE ELECTRICAL CONNECTION CONTACTOR CLOSED COMPRESSOR POWER SUPPLY OPEN LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH OPEN SHORTED OR GROUNDED COMPRESSOR MOTOR WINDINGS COMPRESSOR STUCK COMPRESSOR INTERNAL PROTECTION OPEN DEFECTIVE RUN CAPACITOR DEFECTIVE START CAPACITOR OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING RESTRICTED DISCHARGE TUBE OVERCHARGE OR NON CONDENSABLES IN S
17. INJURY HAZARD Failure to follow this caution may result in personal injury Turn off all power to unit before proceeding Lock out and tag switch with suitable warning label Wear safety glasses protective clothing and gloves when handling refrigerant Acids formed as a result of motor burnout can cause burns CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant and when using brazing torch 1 Shut off all power to unit 2 Remove and recover all refrigerant from system until pressure gauges read 0 psig Use all service ports Never open a system under a vacuum to atmosphere Break vacuum with dry nitrogen holding charge first Do not exceed 5 psig 3 Disconnect electrical leads from compressor Disconnect or remove crankcase heater and remove compressor hold down bolts 4 Cut compressor from system with tubing cutter Do not use brazing torch for compressor removal Oil vapor may ignite when compressor is disconnected 26 5 Scratch matching marks 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
18. Location of Screws Labeling The wiring schematic sub cooling charging tables with instructions and warning labels Refer to Fig 11 for label location FIELD CONNECTIONS BLOWER PANEL WIRING DIAGRAM ON BACKSIDE OF CONTROL FRONT OF CONTROL amp COMPRESSOR PANEL A10163 Fig 11 Label Location ELECTRICAL A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Exercise extreme caution when working on any electrical components Shut off all power to system prior to troubleshooting Some troubleshooting techniques require power to remain on In these instances exercise extreme caution to avoid danger of electrical shock ONLY TRAINED SERVICE PERSONNEL SHOULD PERFORM ELECTRICAL TROUBLESHOOTING Aluminum Wire CAUTION UNIT OPERATION AND SAFETY HAZARD Failure to follow this caution may result in equipment damage or improper operation Aluminum wire may be used in the branch circuit such as the circuit between the main and unit disconnect but only copper wire may be used between the unit disconnect and the unit Whenever aluminum wire is used in branch circuit wiring with this unit adhere to the following recommendations Connections must be made in accordance with the National Electrical Code NEC using connectors approved for aluminum wire The connectors must be UL approved marked Al Cu with the UL symbol for the application and w
19. S 3 81 2 71 1 89 2 16 1 34 1 5 Run Capacitor mfd volts 357370 357370 407370 457370 707370 707370 Heat Pump Compressor Information Unit Size 024 030 036 042 048 060 Type HP HP HP HP HP HP Chassis Size Small Small Meidum Large Large Large Compressor Copeland Scroll Copeland Scroll Copeland Scroll Copeland Scroll Copeland Scroll Copeland Scroll 3MAF Polyo 3MAF Polyo 3MAF Polyo 3MAF Polyo 3MAF Pol 3MAF Polyo Manufacturer Oil Type lester lester lester lester Oil POE lester Oil POE Oil POE Oil POE Oil POE Oil POE Oil Charge fl oz intial recharge 25119 25121 25119 25119 42 1 34 42 1 34 Winding Resistance ohm Start 1 23 0 98 0 87 0 56 0 52 0 45 Winding Resistance ohm Start 5 1 47 1 78 1 47 1 25 0 82 0 79 Winding Resistance ohm Start R S 2 7 2 76 2 34 1 81 1 34 1 24 Run Capacitor mfd volts 407370 407370 457370 45 1370 707370 707370 OUTDOOR COIL FROM INDOOR COIL FROM ACCUMULATOR TO OUTDOOR TO INDOOR COIL ACCUMULATOR COIL INSULATE FOR 3 e ACCURATE READING e TP 4 IPe INSULATE FOR ACCURATE FROM COMPRESSOR READING DISCHARGE LINE 10189 FROM COMPRESSOR Fig 22 Reversing Valve DISCHARGE LINE Cooling Mode or Defrost Mode Solenoid Energized ELECTRONIC THERMOMETER A10188 Fig 23 Reversing Valve Heating Mode Solenoid De Energized 23 Liquid Line Filter Drier Filter driers are specifically designed for R
20. Temperature range is from 60 F 15 6 C to 70 F 21 1 C Resistance goes from zero to when contacts are open 8 If either opening or closing temperature does not fall within above ranges or thermostat sticks in 1 position replace thermostat to ensure proper defrost operation NOTE With timing cycle set at 90 minutes unit initiates defrost within approximately 21 sec When you hear the reversing valve changing position remove screwdriver immediately Otherwise control will terminate normal 10 minute defrost cycle in approximately 2 sec COPELAND DANFOSS SCROLL COMPRESSOR Scroll Gas Flow Compression in the scroll is created by the interaction of an orbiting spiral anda stationary spiral Gas enters an outer opening as one of the spirals orbits 1 ww N G Am 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 9 A ww 5 By the time the gas arrives at the center port discharge pressure has been reached Actually during operation all six gas passages are in various stages of compression at all times resulting in nearly con tinuous suction and discharge 90198 Fig 18 Scroll Compressor Refrigerant Flow The compressors used in these products are specifically designed to operate with designated refrigerant and canno
21. and sealing of metals using a nonferrous metal having a melting point over 800 F 426 6 C Flux A cleaning solution applied to tubing or wire before it is brazed Flux improves the strength of the brazed connection When brazing is required in the refrigeration system certain basics should be remembered The following are a few of the basic rules 1 Clean joints make the best joints To clean Remove all oxidation from surfaces to a shiny finish before brazing Remove all flux residue with brush and water while material is still hot 2 Silver brazing alloy is used on copper to brass copper to steel or copper to copper Flux is required when using silver brazing alloy Do not use low temperature solder 3 Fluxes should be used carefully Avoid excessive application and do not allow fluxes to enter into the system 4 Brazing temperature of copper is proper when it is heated to a minimum temperature of 800 F 426 6 C and it is a dull red color in appearance Reversing Valve In heat pumps changeover between heating and cooling modes is accomplished with a valve that reverses flow of refrigerant in system This reversing valve device is easy to troubleshoot and replace The reversing valve solenoid can be checked with power off with an ohmmeter Check for continuity and shorting to ground With control circuit 24v power on check for correct voltage at solenoid coil Check for overheated solenoid With unit o
22. e cs ANANTA IENEI EENI EG NLS 50 UGA F LUSI G LDII ILDI 18003 8 LIES EE 10306 Heat Pump 060 Fig 2 Low Ambient Sensor Locations Heat Pumps Se lt 2 gt 9 8 47 E ea o a e gt e gt e 2 z Q O lt n va xli gt eon eros gt erre eres gt c3 es cod C gt C 0 9 C23 gt C3 gt 6 0 lt gt gt e ot eR CON sco c5 c3 st 3c3500c3c2400203 3200020 300 2 c3 6540 N N eD 9 L c 8 5 8 lt vmm 10307 Air Conditioner 060 Fig 3 Low Ambient Sensor Locations Air Conditioners LOW AMBIENT COOLING GUIDE LINE The minimum operating temperature for these units in cooling mode is 40 F 4 4 C outdoor ambient without additional accessories This equipment may be operated in cooling mode at ambient temperatures below 40 F 4 4 C when the accessories listed in Table 1 are installed Refer to Fig
23. feature built into the software to prevent compressor short cycling The indoor fan motor ECM has a built in fan off delays on the first two taps of the motor The third motor tap will shut off immediately after the 24v signal is gone See the following for details Tap 1 60 second off delay Tap 2 30 second off delay Tap 3 0 second off delay The only other timing feature in the heat pump units are built into the defrost board See defrost board sequence for more details on defrost time delays and setups 32 Pressure Switches The R 410A air conditioner contains one pressure switch to prevent system operation of the pressures get excessively high The high pressure switch opens at 650 psig and closes at 420 psig The pressure switch setting is considerably higher than on comparably sized R 22 units The high pressure switch can be identified by their pink stripe on the switch s electrical wires The R 410A heat pump contains a loss of charge switch in the liquid line which opens at 20 psig and closes at 45 psig See troubleshooting section for sequence when a pressure switch trip occurs Accumulator Reversing Valve RVS The R 410A heat pumps have a specifically designed reversing valve for R 410A application and an accumulator for storing excess liquid refrigerant during the heating mode to prevent damaging flood back 00 10170 Fig 31 ECM Motor POWER CONNECTOR
24. inlet screen is not restricted e proceed to Step 13 13 Replace Valve High Superheat with Normal or High Suction Pressure NOTE Normal to High suction pressure is considered for R 410A gt 110 psig An application issue or other system component failure typically causes this condition 14 Check airflow sensing bulb tightness orientation on vapor tube and ensure bulb is properly wrapped e proceed to Step 15 15 R 410A Systems Make sure proper valve is used Not R 22 proceed to Step 16 16 Check for even temperature distribution at outlet of each circuit of evaporator If OK proceed to Step 17 28 17 Check for high evaporator load Return Air Leaks high indoor wet bulb and or dry bulb temp undersized system etc e proceed to Step 18 18 Check that compressor is pumping properly Loose Rule of Thumb 15 discharge saturated 20 F higher than ambient temperature Is discharge superheat between 15 F 9 4 C and 50 F 10 C Hunting Superheat NOTE Hunting is when the valve superheat swings more than 10 F Superheat in repetition This is typically an application issue 19 Check for obvious kinked or pinched distributor capillary tubes causing imbalance to the circuiting e proceed to Step 20 20 Check that proper size valve is used per Product Literature e If OK proceed to Step 21 21 Check airflow sensing bulb tightness orientation on vapor tube an
25. is defective A94006 Fig 12 Capacitors Cycle Protector Corporate thermostats have anti cycle protection built in to protect the compressor If cycle protection is needed consult factory authorized aftermarket offering Crankcase Heater Crankcase heater is a device for keeping compressor oil warm By keeping oil warm refrigerant does not migrate to and condense in compressor shell when the compressor is off This prevents flooded starts which can damage compressor On units that have a single pole contactor the crankcase heater is wired in parallel with contactor contacts and in series with compressor See Fig 13 When contacts open a circuit is completed from line side of contactor through crankcase heater through run windings of compressor and to other side of line When contacts are closed there is no circuit through crankcase heater because both leads are connected to same side of line This allows heater to operate when system is not calling for cooling The heater does not operate when system is calling for cooling CRANKCASE HTR BLK BLK 11 Q Fig 13 Wiring for Single Pole Contactor 2 10174 Pressure Switches Pressure switches are protective devices wired into control circuit low voltage They shut off compressor if abnormally high or low pressures are present in the refrigeration circuit R 410A pressure switches are specifically designed to opera
26. not met When heating demand is met W3 W2 and Y sequentially de energize shutting the compressor indoor fan and the outdoor fan CONTINUOUS FAN With the continuous indoor fan option selected on the thermostat G is continuously energized The continuous fan speed will be the same as the cooling fan speed DEFROST Defrost board DB is a time and temperature control which includes a field selectable time period between checks for defrost 30 60 90 and 120 minutes The time period is factory set at 60 minutes and should only be adjusted by a trained service person Electronic timer and defrost cycle start only when contactor is energized and defrost thermostat DFT is closed Defrost mode is identical to Cooling mode The outdoor fan motor stops because of OF1 and OF2 contacts opening on the defrost board a bank of optional electric heat turns on to warm air supplying the conditioned space ELECTRIC RESISTANCE HEATING If accessory electric heaters are installed on a call for Emergency Heat the thermostat energizes W which energizes the heater relay and in turn energizes the electric heaters The IFM is energized which starts the indoor fan motor If the heaters are staged W2 is energized when the second stage of heating is required When the need for heating is satisfied the heater and IFM are de energized ECM Fan Motor Troubleshooting Caution Do not disconnect motor plugs under load Check the
27. note superheat Where a dash appears on table do not attempt to charge unit under these conditions or refrigerant slugging may occur In this situation refrigerant must be evacuated and weighed in See rating plate for charge quantity 7 Refer to Required Suction Tube Temp Table Table 7 Find superheat temperature located in Step 6 and suction pressure At this intersection note suction line temperature 8 If unit has a higher suction line temperature than charted temperature add refrigerant until charted temperature is reached 9 If unit has a lower suction line temperature than charted temperature reclaim refrigerant until charted temperature is reached 10 If outdoor air temperature or pressure at suction port changes charge to new suction line temperature indicated on chart Heating Check Chart Procedure NOTE When charging is necessary during heating season charge must be weighed in accordance with unit rating plate 29 Table 5 Minimum Airflow for Safe Electric Heater Operation Air Conditioner cadet Minimum Airflow CFM AC Unit Size 5 kW 7 5 kW 10 kW 15 kW 20 kW 24 600 750 750 X X 30 600 750 750 X X 36 600 750 750 1050 X 42 600 750 750 1050 X 48 600 750 750 1050 1400 60 600 750 750 1050 1400 X Not Approved Combination Heat Pump Unit Minimum Airflow CFM Size 5 kw 7 5 kW 10 kW 15 kW 20 kW 24 750 800 800 X X 30 750 800 800 X X 36
28. ohmmeter lead on motor case ground Replace any motor that shows resistance to ground arcing burning or overheating Compressor Plug The compressor electrical plug provides a quick tight connection to compressor terminals The plug completely covers the compressor terminals and the mating female terminals are completely encapsulated in plug Therefore terminals are isolated from any moisture so corrosion and resultant pitted or discolored terminals are reduced The plug is oriented to relief slot in terminal box so cover cannot be secured if wires are not positioned in slot assuring correct electrical connection at the compressor The plug can be removed by simultaneously pulling while rocking plug However these plugs can be used only on specific compressors The configuration around the fusite terminals is outlined on the terminal covers The slot through which wires of plug are routed is oriented on the bottom and slightly to the left The correct plug can be connected easily to compressor terminals and plug wires can easily be routed through slot terminal cover It is strongly recommended to replace the compressor plug should a compressor fail due to a suspected electrical failure At a minimum inspect plug for proper connection and good condition on any compressor replacement Low Voltage Terminals The low voltage terminal designations and their description and function are used on all Small Packaged Products SPP co
29. on the determination If you are at this stage it is assumed you have already checked the subcooling once and believe the charge is correct From this point the airflow must be verified prior to proceeding hence step 1 below 1 Check or verify proper indoor airflow Indoor air filter Duct dampers and supply registers are open Indoor coil for debris 2 Check subcooling at OD coil and discharge high flow valve Outdoor airflow debris on coil etc e Setthe subcooling at value listed on rating plate 3 Check superheat at suction high flow service valve e If low lt 2 F proceed to Low SuperHeat section e If between 2 and 20 F 6 7 C valve is probably operating properly e If operation erratic hunting proceed to Hunting Superheat F Superheat in repetition section NOTE Hunting is when the valve superheat swings more than 10 Low Superheat with Normal or Low Suction Pressure NOTE Normal or low suction pressure is considered for R 410A lt 135 psig 1 Re check airflow and then check sensing bulb tightness orientation on vapor tube and is properly wrapped Low Superheat with Normal or Low Suction Pressure If OK proceed to Step 2 2 Check superheat at suction high flow service valve and Pseudo Evaporator Superheat e If both are less than 2 likely not controlling properly i e stuck open gt REPLACE VALVE e fsuperheat is higher than 15 F proceed to Step 3 3 Perform TXV function check
30. probably normal Usually a considerable difference in reading is noted if a turn to turn short is present System Clean Up After Burnout Turn off all power to unit before proceeding Wear safety glasses and gloves when handling refrigerants Acids formed as a result of motor burnout can cause burns NOTE To analyze level of suspected contamination from compressor burnout use Total Test See your distributor branch Some compressor electrical failures can cause motor to overheat When this occurs byproducts which include sludge carbon and acids contaminate system If burnout is severe enough system must be cleaned before replacement compressor is installed The 2 types of motor burnout are classified as mild or severe In mild burnout there is little or no detectable odor Compressor oil is clear or slightly discolored An acid test of compressor oil will be negative This type of failure is treated the same as mechanical failure Liquid line strainer should be removed and liquid line filter drier installed In a severe burnout there is a strong pungent rotten egg odor Compressor oil is very dark Evidence of burning may be present in tubing connected to compressor An acid test of compressor oil will be positive Complete system must be reverse flushed with refrigerant Metering device must be cleaned or replaced In a heat pump accumulator and reversing valve are replaced These components are also removed and bypassed duri
31. refrigerant 1 Apply heat with torch to solder joint and remove switch CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses when using torch Have quenching cloth available Oil vapor in line may ignite when switch is removed 2 Braze in a new pressure switch Loss of Charge Switch HP Only Located on liquid line of heat pump only the liquid line pressure switch functions similar to conventional low pressure switch Because heat pumps experience very low suction pressures during normal system operation a conventional low pressure switch cannot be installed on suction line This switch is installed in liquid line instead and acts as loss of charge protector The liquid line is the low side of the system in heating mode It operates identically to low pressure switch except it opens at 20 5 psig and closes at 45 10 psig for R 410A Troubleshooting and removing this switch is identical to procedures used on other switches Observe same safety precautions 11 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 32 3 F and open at 65 5 F Check Defrost Thermostat There is a liquid header with a brass distributor an
32. runs and turns compressor and compressor is pumping Usually an internal problem such as blown head gasket or broken internal discharge line causes compressor to pump hot discharge gas back into its own shell rather than through system Using pressure gages on high flow service valves shows high suction and low discharge pressure readings Motor currents are lower than normal Because hot gas is being discharged into shell the shell becomes hot The hot gas causes compressor motor to cycle off on its internal protection Runs and Pumps Low Capacity This failure type is difficult to pinpoint because extent of damage varies Compressor is a pump with internal valves that enable compressor to pump properly The cylinder has a set of suction and discharge valves Any of these parts may become damaged or broken causing loss in pumping capacity Severity of damage determines amount of capacity loss Use pressure gages to find any abnormal system pressures if system charge and other conditions are normal An owner may complain that a unit is not handling the building s heating or cooling load The compressor current draw may be abnormally low or high Although this type of failure does occur all other possible causes of capacity loss must be eliminated before condemning compressor Noisy Compressor Noise may be caused by a variety of internal problems such as loosened hardware broken mounting springs etc System problems such as overch
33. sure all panels and screws are in place and tight 37 410 REFRIGERANT QUICK REFERENCE GUIDE R 410A refrigerant operates at 50 70 percent higher pressures than R 22 Be sure that servicing equipment and replacement components are designed to operate with R 410A refrigerant R 410A refrigerant cylinders are rose colored Recovery cylinder service pressure rating must be 400 psig DOT 4BA400 or DOT BW400 R 410A refrigerant systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose when charging into suction line with compressor operating 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 rating Leak detectors should be designed to detect HFC refrigerant R 410A refrigerant as with other HFCs is only compatible with POE or PVE oils Vacuum pumps will not remove moisture from oil Do not use liquid line filter driers with rated working pressures less than 600 psig Do not leave R 410A refrigerant suction line filter driers in line longer than 72 hours Do not install a suction line filter drier in liquid line POE and PVE oils absorb moisture rapidly Do not expose oil to atmosphere POE and PVE oils may cause damage to certain plastics and roofing materials Wrap all filter driers with wet cloth when brazing A factory approved liquid line filter drier is required on every unit Do NOT use an
34. the need for a rain shield For the correct position of fan blade assembly the fan hub should be flush with the motor shaft Replacement motors and blades may vary slightly 20 AC UNIT SIZE in mm 024 13 16 0 812 030 13 16 0 812 036 0 042 0 048 0 060 3 16 0 188 10020 HP UNIT A SIZE in mm 024 13 16 0 812 030 13 16 0 812 036 0 042 0 048 1 2 0 50 060 1 2 0 50 10057 Fig 21 Outdoor Fan Adjustment 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Turn off all power before servicing or replacing fan motor Be sure unit main power switch is turned off Lock out and tag with suitable warning label The bearings are permanently lubricated therefore no oil ports are provided For suspected electrical failures check for loose or faulty electrical connections or defective fan motor capacitor Fan motor is equipped with thermal overload device in motor windings which may open under adverse operating conditions Allow time for motor to cool so device can reset Further checking of motor can be done with an ohmmeter Set scale on R X 1 position and check for continuity between 3 leads Replace motors that show an open circuit in any of the windings Place 1 lead of ohmmeter on each motor lead At same time place other
35. the transformer Then check the secondary side of the transformer If there is line voltage on the transformer primary and no voltage on the secondary replace the transformer e there is 24volts between and C jump R and together in the low voltage control box Check to see if there is a 24 volt signal at pins 1 2 or 3 referenced to common ground at the motor s low voltage plug If there is no voltage between common and one of the pins trace the wires back to the low voltage control box If there is power at the high voltage plug voltage at pins 1 2 or 3 on the low voltage plug the connections are good between the plugs and motor and the motor is not running replace the motor Two 24 volt signal wires will be connected from the thermostat to the low voltage control plug One wire signal will be for constant fan cooling speed and the other will be for electric heat If there is an intermittent motor operation issue check the 1000 ohm resistor between the green G wire and the brown C wire in the units wiring harness See unit s wiring diagram The resistor could be blown open This resistor is in line with the fan motor to provide a load for the thermostat s triacs or relay Time Delays The unit system time delays include The air conditioning or heat pump units do not have any built in time delays to start the cooling or heating cycle Most residential thermostats have an electronic safety start
36. 00 4500 4000 m 3500 5 3000 2500 2000 1500 1000 500 LEAK IN SYSTEM VACUUM TIGHT TOO WET TIGHT DRY SYSTEM 0 1 2 3 4 5 6 7 MINUTES 95424 Fig 29 Deep Vacuum Graph Triple Evacuation Method The triple evacuation method should be used when vacuum pump is only capable of pumping down to 28 in of mercury vacuum and system does not contain any liquid water Refer to Fig 31 and proceed as follows 1 Pump system down to 28 in of mercury and allow pump to continue operating for an additional 15 minutes 2 Shut off vacuum pump 3 Connect a nitrogen cylinder and regulator to system and open until system pressure is 2 psig 4 Allow system to stand for 1 hr During this time dry nitrogen will be able to diffuse throughout the system absorbing moisture 5 Repeat this procedure as indicated in Fig 30 System will then be free of any contaminants and water vapor BREAK VACUUM WITH DRY NITROGEN v v EVACUATE BREAK VACUUM WITH DRY NITROGEN WAIT CHECK FOR TIGHT DRY SYSTEM IF IT HOLDS DEEP VACUUM Y CHARGE SYSTEM A95425 Fig 30 Triple Evacuation Method 27 Check Charge See Charging Tables 7 and 8 Factory charge amount and desired subcooling are shown on unit rating plate Charging method is shown on information plate inside unit To properly check or adjust charge conditions must be favorable for subcool
37. 11 2 44 0 472 129 7 53 2 608 150 1 65 6 66 12 6 10 8 168 59 0 15 0 270 88 9 31 6 372 111 6 44 2 474 130 0 54 4 612 150 6 65 9 68 13 8 10 1 170 59 8 15 4 272 89 4 31 9 374 112 0 44 4 476 130 3 54 6 616 151 2 66 2 70 15 1 9 4 172 60 5 15 8 274 89 9 32 2 376 112 4 44 7 478 130 7 54 8 620 151 7 66 5 72 16 3 8 7 174 61 1 16 2 276 90 4 32 4 378 112 6 44 8 480 131 0 55 0 624 152 3 66 8 74 17 5 8 1 176 61 8 16 6 278 90 9 32 7 380 113 1 45 1 482 131 3 55 2 628 152 8 67 1 76 18 7 7 4 178 62 5 16 9 280 91 4 33 0 382 113 5 45 3 484 131 6 55 3 632 153 4 67 4 78 19 8 6 8 180 63 1 17 3 282 91 9 33 3 384 113 9 45 5 486 132 0 55 6 636 153 9 67 7 80 21 0 6 1 182 63 8 17 7 284 92 4 33 6 386 114 3 45 7 488 132 3 55 7 640 154 5 68 1 82 22 1 5 5 184 64 5 18 1 286 92 8 33 8 388 114 7 45 9 490 132 6 55 9 644 155 0 68 3 84 23 2 4 9 186 65 1 18 4 288 93 3 34 1 390 115 0 46 1 492 132 9 56 1 648 155 5 68 6 86 24 3 4 3 188 65 8 18 8 290 93 8 34 3 392 115 5 46 4 494 133 3 56 3 652 156 1 68 9 88 25 4 3 7 190 66 4 19 1 292 94 3 34 6 394 115 8 46 6 496 133 6 56 4 656 156 6 69 2 90 26 4 3 1 192 67 0 19 4 294 94 8 34 9 396 116 2 46 8 498 133 9 56 6 660 157 1 69 5 92 27 4 2 6 194 67 7 19 8 296 95 2 35 1 398 116 6 47 0 500 134 0 56 7 664 157 7 69 8 94 28 5 1 9 196 68 3 20 2 298 95 7 35 4 400 117 0 47 2 502 134 5 56 9 668 158 2 70 1 96 29 5 1 4 198 68 9 20 5 300 96 2 35 7 402 117 3 47 4 504 134 8 57 1 672 158 7 70 4 98 30 5 0 8 200 69 5 20 8 302 96 6 35 9 404 117 7 47 6 506 135 2
38. 3 Control Box Wiring LOW VOLTAGE WIRING ENTRY HOLE grommet hole HIGH VOLTAGE POWER WIRING ENTRY HOLE A08407 Fig 34 Unit Electrical Connection 33 9400967209 Nag SdH 310 338 S 310 339 2 11 03145 TH 318 54011234402 43345 03 03 43345 MOT N8 110A v2 NUD a ONTDTAYAS SWHO 0001 03 015153 y 25 MOOD ILON IIS gt 038 ge 13 w 4007 ng AUWALUd 9 310N 33S ie us T 2 3503 422 134 2H 09 OVA 0 2 802 114405 01313 wo AINO SYOLONGNOD 834402 ISN 1 350339 93 4 123NNOOSIO 20 1 21412113 9 10 83041 939 0 800152 N d 36503131111 A8 GIYNLOVANNYW ISNA 8 ATNO 53818 14089 3AVH Su3lV3H 39915 319 15 5 831 3 3918 11 10 0 0 u3QNn 9014 12388402510 LON OQ 79811135 4 1 03345 1238800 3NINU313Q 01 5 01120815 1 NOIIVTIVISNI 1105802 SIYIN 9831131 21812313 Q311V1SNI 01313 98150 N3HM 11S IWUJHL 83410034 38 AVW 54 1 03345 30 ONTONVHD 9014 80123135 03345 801 ONIUIM 4801074 on NOIIVTIVISNI 01313 803 03114405 3 191 2 51 15731 1Y 404 318 1105 58012008402 ISN E 61314 IVISONS3HI 804 S39Vd 39149 335 72 5 11 YO 3814 30 141 1031100311 IWYS JHL HLI
39. 39 9 10 9NIJIM NOTLOINNOD 00523840 quo 10024 Fig 35 Typical Air Conditioning Single Phase Unit Electrical Diagram 34 115005 705 2 214 2 c 73 0808 1508430 0001 80151538 4 038 134 802 ITI 43345 KOT 118 310N 339 5 18 04 0039 8 3108 335 M 08 08 1508230 Nd NUD 18 0 9110 110 0 12 14344100 gt 2 80 e we Hdl 2 09 OVA 0 2 802 YIMOd 114405 01314 AINO SYOLINGNOD 834402 ISN ONTOTAYAS 340438 81404 123NNOOSIQ QuvzvH 420HS 1 01410313 130 2 19 140 1 614 122 214 eM 9 3 11 4 0 1 4 y 54011238802 1VISINH3HI LIOA 72 W3N80 ISNYUL 60062 N d 535013111 48 asna 01043105 JAWA 941534144 AINO 3014 ONY JAYH 30 15 319415 WHOHS 3OIS LYON L MOLTAS 220401 914 13 210 LON 00 79 3uNSS3 d MO S41 SNILLSS dYI 03345 1338802 ININA3130 NYS 80001 NJI OL SNOLIODHISNI NOIIVTTISNI 1105402 20738 SU31Y34 21812313 OJVWISNI 01313 9815 NIHA
40. 410A refrigerant Only operate with the appropriate drier using factory authorized components There is a liquid line drier located inside the unit in the compressor section The liquid line drier also acts as a strainer Suction Line Filter Drier The suction line drier is specifically designed to operate with R 410A use only factory authorized components Suction line filter drier is used in cases where acid might occur such as burnout Heat pump units must have the drier installed between the compressor and accumulator only Remove after 10 hours of operation Never leave suction line filter drier in a system longer than 72 hours actual time Accumulator The accumulator is specifically designed to operate with R 410A pressures use only factory authorized components Under some light load conditions on indoor coils liquid refrigerant is present in suction gas returning to compressor The accumulator stores liquid and allows it to boil off into a vapor so it can be safely returned to compressor Since a compressor is designed to pump refrigerant in its gaseous state introduction of liquid into it could cause severe damage or total failure of compressor The accumulator is a passive device which seldom needs replacing Occasionally its internal oil return orifice or bleed hole may become plugged Some oil is contained in refrigerant returning to compressor It cannot boil off in accumulator with liquid refrigerant The bleed hole allo
41. 7 19 69 21 71 22 16 63 17 65 18 67 19 69 21 71 22 73 23 24 13 3 59 15 61 16 63 17 65 18 67 19 69 21 71 22 73 23 75 24 26 14 4 61 16 63 17 65 18 67 19 69 21 71 22 73 23 75 24 77 25 28 15 6 63 17 65 18 67 30 16 7 65 18 67 19 69 19 69 21 71 22 73 23 75 24 77 25 79 26 21 71 22 73 23 75 24 77 25 79 26 81 27 32 17 8 67 19 69 21 1 22 73 23 75 24 77 25 79 26 81 27 83 28 34 18 9 69 21 71 22 73 23 75 24 79 26 79 26 81 27 28 85 29 36 20 0 71 22 73 23 75 38 21 1 73 23 75 24 83 24 81 27 81 27 81 27 83 28 85 29 87 31 28 83 28 83 28 83 28 85 29 87 31 89 32 40 22 2 75 24 85 29 5 29 85 29 85 29 5 29 87 31 89 32 91 33 50ZH500518 REV 2 0 Required Subcooling F C A10038 Table 8 Required Subcooling Required Liquid Line Temperature for a Specific Subcooling R 410A Outdoor Ambient Temperature F C Required Subcooling F Required Subcooling C 75 24 85 29 95 35 105 41 15 8 3 15 8 3 15 8 3
42. 750 800 800 1200 X 42 750 800 800 1200 X 48 750 800 800 1200 1700 60 750 800 800 1200 1700 X Not Approved Combination Table 6 Wet Coil Air Delivery Deduct 10 percent for 208 Volt Operation Air Conditioner 2 EXTERNAL STATIC PRESSURE in W C SEEEB TAR 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 1 SCFM 965 818 777 731 670 617 563 489 451 391 024 2 5 1003 921 890 850 809 756 700 659 597 539 3 SCFM 1103 1068 1034 996 962 930 892 821 791 742 1 SCFM 1052 1018 984 943 914 879 833 795 732 678 030 2 5 1141 1107 1069 1036 1006 974 932 899 856 784 3 SCFM 1246 1213 1181 1144 1108 1078 1043 1015 973 931 1 SCFM 1281 1225 1178 1142 1098 1053 1008 935 878 840 036 2 5 1359 1321 1278 1236 1201 1160 1109 1068 992 941 3 SCFM 1476 1441 1403 1366 1323 1289 1245 1201 1159 1117 1 SCFM 1453 1408 1373 1337 1295 1255 1215 1177 1134 1068 042 2 5 1544 1507 1475 1436 1397 1359 1326 1290 1246 1201 3 SCFM 1614 1575 1542 1509 1467 1430 1395 1358 1323 1267 1 SCFM 1657 1625 1590 1554 1517 1486 1448 1417 1381 1340 048 2 5 1707 1673 1644 1614 1586 1549 1515 1479 1449 1407 3 SCFM 1931 1900 1870 1840 1809 1778 1749 1714 1683 1646 1 SCFM 1837 1798 1753 1716 1677 1637 1590 1549 1497 1445 060 2 5 1910 1872 1835 1795 1748 1711 1673 1623 1568 1525 3 SCFM 2098 2065 2032 1996 1956 1917 1877 1839 1798 1753
43. 9 5 26 4 336 104 2 40 1 438 123 9 51 1 540 140 4 60 2 32 13 8 25 4 134 46 3 7 9 236 80 0 26 7 338 104 6 40 3 440 124 2 51 2 544 141 0 60 6 34 11 9 24 4 136 47 1 8 4 238 80 6 27 0 340 105 1 40 6 442 124 6 51 4 548 141 6 60 9 36 10 1 23 4 138 47 9 8 8 240 811 27 3 342 105 4 40 8 444 124 9 51 6 552 142 1 61 2 38 8 3 22 4 140 48 7 93 242 81 6 27 6 344 105 8 41 0 446 125 3 51 8 556 142 7 61 5 40 6 5 21 4 142 49 5 9 7 244 82 2 27 9 346 106 3 41 3 448 125 6 52 0 560 143 3 61 8 42 4 5 20 3 144 50 3 10 2 246 82 7 28 2 348 106 6 41 4 450 126 0 52 2 564 143 9 62 2 44 3 2 19 6 146 51 1 10 6 248 83 3 28 5 350 107 1 41 7 452 126 3 52 4 568 144 5 62 5 46 1 6 18 7 148 51 8 11 0 250 83 8 28 8 352 107 5 41 9 454 126 6 52 6 572 145 0 62 8 48 0 0 17 8 150 52 5 11 4 252 84 3 29 1 354 107 9 42 2 456 127 0 52 8 576 145 6 63 1 50 1 5 16 9 152 53 3 11 8 254 84 8 29 3 356 108 3 42 4 458 127 3 52 9 580 146 2 63 4 52 3 0 16 1 154 54 0 12 2 256 85 4 29 7 358 108 8 42 7 460 127 7 53 2 584 146 7 63 7 54 4 5 15 3 156 54 8 12 7 258 85 9 29 9 360 109 2 42 9 462 128 0 53 3 588 147 3 64 1 56 5 9 14 5 158 55 5 13 1 260 86 4 30 2 362 109 6 43 1 464 128 3 53 5 592 147 9 64 4 58 7 3 13 7 160 56 2 13 4 262 86 9 30 5 364 110 0 43 3 466 128 7 53 7 596 148 4 64 7 60 8 6 13 0 162 57 0 13 9 264 87 4 30 8 366 110 4 43 6 468 129 0 53 9 600 149 0 65 0 62 10 0 12 2 164 57 7 14 3 266 87 9 311 368 110 8 43 8 470 129 3 54 1 604 149 5 65 3 64 11 3 11 5 166 58 4 14 7 268 88 4 31 3 370 1
44. HOOTING 32 33 Time Delays ive bos eerie ee 32 Pressure Switches 33 Accumulator Reversing Valve 5 33 Control BOX eis oe ue e ee dos 33 CARE AND MAINTENANCE 36 37 R 410A QUICK REFERENCE GUIDE 38 INDEX OF TABLES 43 SAFETY CONSIDERATIONS Installation service and repair of these units should be attempted only by trained service technicians familiar with standard service instruction and training material All equipment should be installed in accordance with accepted practices and unit Installation Instructions and in compliance with all national and local codes Power should be turned off when servicing or repairing electrical components Extreme caution should be observed when troubleshooting electrical components with power on Observe all warning notices posted on equipment and in instructions or manuals 4 WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in personal injury or equipment damage R 410A systems operate at higher pressures than standard R 22 systems Do not use R 22 service equipment or components on these R 410A units Ensure service equipment is rated for R 410A Refrigeration systems contain refrigerant under pressure Extreme caution should be observed when handling refrigerants Wear safety glasses and gl
45. M Q32v1d3H 38 190 11 0307 638 Q3HSINU6j 93814 9180 JHL 30 ANY dI 101122 Nau XO 7041402 8000100 800011000 1N3W3ONVHUY IN3NOdNOO LINN H LIMS 340155399 HOIH SdH 01140 YO 18055322 800081 ONINIM YIMOd 01313 AVIS 911604 306100 01313 405554400 SNIUIM 18013 UilV3H 35V HJJ 191745 e 1102 3012010 29 0 o 034 010002 av o 03348 5009 5 301145 013134 09 0 908023 134018 0139311 1 310 339 i 2 330 NO 1 SN01123NNO2 M 49 DAMM M 19 ZM diy Qiu 1 489 2 110 ve 12830015 NVA ous 1V3H 21812313 NOT4 N33UD 1 9 1 OIA EM 8055322 UE NON NYG 1 EM 3018 nie y18 cio 1002 40102 9 58401123402 1YLSIN JHL 110 v2 NYE 5 558 nue 0001 30151538 310 335 Auv0N0038 4844184 1090553027 3 9 JUVWSHOS 355 SIBIV3H 201254 HM uod 080089 1843461003 n OMY 2 3215 ia xdg os n 4 aoa m D Aem 136403 119 5 340338 YIMOd 123 02510 087070 0 9 1v2IU12113 9
46. OMPRESSOR STUCK COMPRESSOR INTERNAL OVERLOAD OPEN OPEN SHORTED OR GROUNDED COMPRESSOR WINDINGS DEFECTIVE RUN CAPACITOR DEFECTIVE START CAPACITOR DIRTY FILTERS OR INDOOR COIL INDOOR FAN STOPPED OR CYCLING ON OVERLOAD DAMAGED REVERSING VALVE RESTRICTION IN DISCHARGE LINE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR 1 PH COMPRESSOR BEARINGS HIGH LOAD CONDITION REVERSING VALVE JAMMED IN MIDPOSITION HIGH SUPERHEAT DEFECTIVE START CAPACITOR DEFECTIVE FAN MOTOR CAPACITOR LOOSE LEADS FAN MOTOR FAN MOTOR BURNED OUT LOW SUCTION LOW HEAD OUTDOOR FAN STOPPED LOOSE LEADS AT OUTDOOR FAN MOTOR INTERNAL FAN MOTOR KLIXON OPEN FAN MOTOR BURNED OUT DEFROST RELAY N C CONTACTS OPEN ON CIRCUIT BOARD FAN MOTOR CONTACTS WELDED CLOSED IN DEFROST RELAY REVERSING VALVE DID NOT SHIFT UNIT NOT OUTDOOR FAN RUNNING REVERSING VALVE STUCK RESTRICTED LIQUID LINE PISTON RESTRICTED OR IS CLOGGED UNDER CHARGED OUTDOOR COIL DIRTY STRAINER RESTRICTED OUTDOOR COIL HEAVILY FROSTED PROPERLY CHARGED Fig 38 Heat Pump Troubleshooting Heating Cycle 41 DEFECTIVE DEFROST THERMOSTAT DEFROST THERMOSTAT IN POOR PHYSICAL CONTACT WITH TUBE DEFECTIVE CIRCUIT BOARD BAD ELECTRICAL C
47. ON The FAN switch on the thermostat controls indoor fan operation When the FAN switch is placed in the ON position the indoor evaporator fan motor IFM is energized through the G terminal on the thermostat The motor s internal logic then provides power to the indoor evaporator fan motor IFM The IFM will run continuously when the FAN switch is set to ON When the FAN switch is set to AUTO the thermostat deenergizes the IFM provided there is not a call for cooling The contacts open and the IFM is deenergized The IFM will be energized only when there is a call for cooling in heat pump heating mode or if the unit is equipped with accessory electric heat the indoor fan motor will also run while the accessory electric heat is energized NOTE Motors on this product are programmed for 60 second time delay on tap 1 and 30 second time delay on tap 2 There is no time delay on tap 3 The indoor fan will remain ON for the set time delay after G or W2 is de energized COOLING OPERATION With a call for cooling Y the compressor outdoor fan and indoor fan start immediately When the cooling demand is met Y de energizes shutting the compressor indoor fan and the outdoor fan HEATING OPERATION With a call for heating Y the compressor outdoor fan and indoor fan start immediately If Y cannot satisfy the heating demand the auxiliary or backup heat W2 energizes In case of staged heating W3 is energized if the demand is
48. ONNECTION ANYWHERE IN DEFROST CIRCUIT STRIP HEATERS NOT OPERATING OUTDOOR THERMOSTAT DEFECTIVE ODT SETTING TOO LOW CAP TUBE PINCHED OR BULB NOT SENSING TRUE ODT STRIP HEATER RELAY OR CONTACTOR DEFECTIVE OPENING IN POWER CIRCUIT TO HEATER ELEMENTS BROKEN FUSE LINK BROKEN HEATER ELEMENT OPEN KLIXON OVER TEMPERATURE THERMOSTAT DEFECTIVE ROOM THERMOSTAT 2ND STAGE A90206 HEAT PUMP TROUBLESHOOTING COOLING CYCLE NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD CONTACTOR OPEN POWER SUPPLY DEFECTIVE LOW VOLTAGE TRANSFORMER OPEN THERMOSTAT OPEN CONTROL CIRCUIT LOSS OF CHARGE CONTACTOR OR COIL DEFECTIVE LOOSE ELECTRICAL CONNECTION CONTACTOR CLOSED COMPRESSOR POWER SUPPLY OPEN LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH OPEN SHORTED OR GROUNDED COMPRESSOR MOTOR WINDINGS COMPRESSOR STUCK COMPRESSOR INTERNAL PROTECTION OPEN DEFECTIVE RUN CAPACITOR DEFECTIVE START CAPACITOR OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING DAMAGED OR STUCK REVERSING VALVE RESTRICTED DISCHARGE TUBE OVERCHARGE OR NON CONDENSABLES SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT DEFECTIVE
49. R 22 TXV Never open system to atmosphere while it is under a vacuum When system must be opened for service recover refrigerant evacuate then break vacuum with dry nitrogen and replace filter driers Evacuate to 500 microns prior to recharging Do not vent R 410A refrigerant into the atmosphere Observe all warnings cautions and bold text 38 Table 9 Pressure vs Temperature Chart R 410A Refrigerant PSIG F c PSIG F c PSIG F c PSIG F c PSIG F c PSIG F c 12 37 7 38 7 114 37 8 3 2 216 74 3 23 5 318 100 2 37 9 420 120 7 49 3 522 137 6 58 7 14 34 7 37 0 116 38 7 3 7 218 74 9 23 8 320 100 7 38 2 422 121 0 49 4 524 137 9 58 8 16 32 0 35 6 118 39 5 4 2 220 75 5 24 2 322 101 1 37 4 424 121 4 47 7 526 138 3 59 1 18 29 4 34 1 120 40 5 4 7 222 76 1 24 5 324 101 6 37 8 426 121 7 49 8 528 138 6 59 2 20 26 9 32 7 122 41 3 5 2 224 76 7 24 8 326 102 0 38 9 428 122 1 50 1 530 138 9 59 4 22 24 5 31 3 124 42 2 5 7 226 77 2 25 1 328 102 4 39 1 430 122 5 50 3 532 139 2 59 6 24 22 2 30 1 126 43 0 6 1 228 77 8 25 4 330 102 9 39 4 432 122 8 50 4 534 139 5 59 7 26 20 0 28 9 128 43 8 6 6 230 78 4 25 6 332 103 3 39 6 434 123 2 50 7 536 139 8 59 9 28 17 9 28 7 130 44 7 7 1 232 78 9 26 1 334 103 7 39 8 436 123 5 50 8 538 140 1 60 1 30 15 8 26 6 132 45 5 7 5 234 7
50. Residential Mobile Home Small Package Products Air Conditioners and Heat Pumps Using R 410A Refrigerant Service Manual TABLE OF CONTENTS PAGE SAFETY CONSIDERATIONS 2 INTRODUCTION 2i m Ret 2 INSTALLATION GUIDELINE 2 ACCESSORY DESCRIPTIONS 2 LOW AMBIENT 5 CABINET ASSEMBLY amp COMPONENTS 5 9 ELECTRICAL veniet RUE RR ORA EE 10 11 Aluminum mE PRI RU coe 10 Contactor Less qe eres oen eee eiae 10 Capactlof zer erR chek xe EVE EUER A b EV 10 Cycle Protector zou pires mare PERSEO Parere 11 Crankcase Heater ese pr Re Y 11 PRESSURE SWITCHES 11 12 Low Pressure 5 11 High Pressure Switch amp 11 Loss Of Charge Switch HP only 11 DEFROST THERMOSTAT 12 DEFROST CONTROL BOARD 12 14 Defrost Control 12 COPELAND SCROLL DANFOSS SCROLL 15 17 Compressor 16 Mechanical 16 Electrical Failures bien 17 RECIPROCATING COMPRESSOR 18 19 Mechanical Failures 18 Electrical Failures 2 22
51. SIGNAL CONNECTOR A10169 Fig 32 ECM Module Plug Control Box Contactor Capacitor and Board Removal of the front right compressor control panel will expose most of the unit s components Both the air conditioner and heat pump control boxes will be in the upper right corner of the unit There will be a contractor that cycles components off and on The capacitor will assist the outdoor fan and compressor to operate The heat pump models will have a circuit board to control the defrost cycle Always replace these devices with the Factory Approved Components Incoming Power Incoming power is attached to the two power wire stripped leads A ground lug is also provided Unit should always be grounded through the ground lug to the unit disconnect and from the disconnect to the electrical fuse box Failure to do so can cause serious injury or death Electric Heat Control Box shown uninstalled o BP Electric Heat wiring interconnection electric heater controls removed for clarity 5 10030 Air Conditioning Control Box Wiring Electric Heat Control lo shown uninstalled lol c Electric Heat wiring interconnection electric heater controls removed for clarity e 898 uy gat o 10031 Heat Pump Control Box Wiring Fig 3
52. YSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT DEFECTIVE START CAPACITOR LOOSE LEAD AT FAN MOTOR MOTOR DEFECTIVE INCORRECT OFM CAPACITOR COMPRESSOR RUNS BUT INSUFFICIENT COOLING LOW SUCTION PRESSURE DIRTY AIR FILTERS DUCT RESTRICTED DAMPERS PARTLY CLOSED INDOOR COIL FROSTED SLIGHTLY LOW ON REFRIGERANT LIQUID LINE SLIGHTLY RESTRICTED PISTON RESTRICTED INCORRECT SIZE PISTON INDOOR COIL STRAINER RESTRICTED INDOOR BLOWER MOTOR DEFECTIVE OR CYCLING ON OL Fig 37 Air Conditioner Troubleshooting Chart 40 HIGH SUCTION LOW HEAD PRESSURE DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON FAILED TXV A90208 TROUBLESHOOTING HEATING CYCLE NO HEATING OR INSUFFICIENT HEATING COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD COMPRESSOR WILL NOT RUN COMPRESSOR RUNS INSUFFICIENT HEATING CONTACT OPEN DEFECTIVE LOW VOLTAGE TRANSFORMER REMOTE CONTROL CENTER DEFECTIVE CONTACTOR COIL OPEN OR SHORTED OPEN INDOOR THERMOSTAT LIQUID LINE PRESSURE SWITCH OPEN LOSS OF CHARGE OPEN CONTROL CIRCUIT CONTACTOR CLOSED COMPRESSOR POWER SUPPLY LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH C
53. ak detector that is capable of detecting specific refrigerants If system has been operating for some time first check for a leak visually Since refrigerant carries a small quantity of oil traces of oil at any joint or connection is an indication that refrigerant is leaking at that point A simple and inexpensive method of testing for leaks is to use soap bubbles See Fig 28 Any solution of water and soap may be used Soap solution is applied to all joints and connections in system A small pinhole leak is located by tracing bubbles in soap solution around leak If the leak is very small several minutes may pass before a bubble will form Popular commercial leak detection solutions give better longer lasting bubbles and more accurate results than plain soapy water The bubble solution must be removed from the tubing and fittings after checking for leaks as some solutions may corrode the metal LEAK DETECTOR SOLUTION A95423 Fig 28 Bubble Leak Detection You may use an electronic leak detector designed for specific refrigerant to check for leaks See Fig 28 This unquestionably is the most efficient and easiest method for checking leaks There are various types of electronic leak detectors Check with manufacturer of equipment for suitability Generally speaking they are portable lightweight and consist of a box with several switches and a probe or sniffer Detector is turned on and probe is passed around all fiti
54. arged compressor especially at start up or too much oil in compressor may also cause excessive noise Excess oil in compressor is normally encountered only after a replacement compressor has been added without purging oil from previous compressor As new compressor pumps excess oil in system returns and adds to volume already present causing noise Compressor Leaks CAUTION UNIT DAMAGE AND OR PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury and or unit component damage High flow service valves are equipped with Schrader valves Wear safety glasses and gloves when handling refrigerant 18 EXAMPLE TO DETERMINE INTERNAL CONNECTIONS OF SINGLE PHASE MOTORS C S R EXCEPT SHADED POLE 8 e POWER OFF DEDUCTION 2 1 83 GREATEST RESISTANCE RUN WINDING R 5 89 OHM START WINDING S OHMMETER 2 SMALLEST RESISTANCE 2 is COMMON REMAINING RESISTANCE 5 20 BY ELIMINATION 2 is COMMON THEREFORE 1718 START WINDING S IS RUN WINDING 88344 Fig 20 Identifying Internal Connections Sometimes a leak is detected at weld seam around girth of compressor or a fitting that joins compressor shell Many of these leaks can be repaired and the compressor saved if correct procedure is followed 1 Turn off all power to unit 2 Remove and recover all refrigerant from system so that
55. art and minimizes the chance of liquid slugging Usage Guideline Required in low ambient cooling applications Suggested in all commercial applications 2 Evaporator Freeze Thermostat An SPST temperature actuated switch that stops unit operation when evaporator reaches freeze up conditions Usage Guideline Required when low ambient kit has been added 3 Isolation Relay An SPDT relay which switches the low ambient controller out of the outdoor fan motor circuit when the heat pump switches to heating mode Usage Guideline Required in all heat pumps where low ambient kit has been added 4 Outdoor Thermostat Kit Locks out the accessory electric heater until outdoor ambient conditions falls below the pre set temperature This kit will activate the electric heat when additional heat is required at lower ambient making it a more efficient system 5 LAE Soo c c3 5 9 e 5 a 3 _ 9 TERE ETU 8 i inea SS 25 E TEETSITI 00 0 i TE e gt c2 c3 ca p p c3 c3 ca c3 c3 gt b N e 2 2 a I
56. at of approximately 32 F 0 C Check resistance across defrost thermostat leads using ohmmeter Resistance of zero indicates defrost thermostat is closed and operating properly 9 Short between the speed up terminals using a thermostat screwdriver This reduces the timing sequence to 1 256 of original time See Table 2 Table 2 Defrost Control Speed Up Timing Sequence MINIMUM MAXIMUM SPEED UP PARAMETER MINUTES MINUTES NOMINAL 30 minute cycle 27 33 7 50 45 55 12 90 minute cycle 81 99 21 sec 10 minute cycle 9 11 2 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Exercise extreme caution when shorting speed up pins If pins are accidentally shorted to other terminals damage to the control board will occur 10 Unit is now operating in defrost mode Check between C and W2 using voltmeter Reading on voltmeter should indicate 24v This step ensures defrost relay contacts have closed energizing supplemental heat W2 and reversing valve solenoid O 11 Unit should remain in defrost no longer than 10 minutes Actual time in defrost depends on how quickly speed up jumper is removed If it takes 2 sec to remove speed up jumper after unit has switched to defrost the unit will switch back to heat mode 12 After a few minutes in defrost cooling operation liquid lin
57. c Heater Operation 4 30 Wet Coill Air Delivery Table mi ror seek qu Seales madd menos ea PURI 30 Superheat Charging Table cas NE te wal Saeed Beads EP RU EE Pa aaa ee 31 Required Subcoolmg Table Meee he __ e da 31 Pressure vs Temperature Chart Tabl else I rte 6 E Slee Dew IR RR bine E II 39 43 Copyright 2010 e 7310 W Morris St e Indianapolis 46231 Printed in U S A Edition Date 06 10 Catalog No 5 10 02 Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Replaces 6 10 01 44
58. compressor removal Oil vapor may ignite when compressor is disconnected 5 Scratch matching marks on stubs in old compressor Make corresponding marks on replacement compressor 6 Use torch to remove stubs from old compressor and to reinstall them in replacement compressor 7 Use copper couplings to tie compressor back into system 8 Evacuate system recharge and check for normal system operation 9 Compressors have copper plated steel suction ports Excess heat during brazing will burn off copper plating See Brazing section for additional information Outdoor Fan Adjustment P CAUTION UNIT OPERATION HAZARD Failure to follow this caution may result in damage to unit components Keep the condenser fan free from all obstructions to ensure proper cooling operation Never place articles on top of unit 1 Shut off unit power supply and install lockout tag 2 Remove outdoor fan assembly grille motor motor cover and fan by removing screws and flipping assembly onto unit top cover 3 Inspect the fan blades for cracks or bends 4 If fan needs to be removed loosen the setscrew and slide the fan off the motor shaft 5 When replacing fan blade position blade as shown in Fig 21 Tighten setscrews Fan Motor The fan motor rotates the fan blade that draws air through the outdoor coil to exchange heat between the refrigerant and the air Motors are totally enclosed to increase reliability This eliminates
59. d Replace compressor A compressor of 1 ton capacity or less is probably grounded if resistance is below 1 million ohms On larger sized single phase compressors resistance to ground should not be less than 1000 ohms per volt of operating voltage Example 230 volts X 1000 ohms volt 230 000 ohms minimum SHORT CIRCUIT To determine if any wires within windings have broken through their insulation and made contact with other wires thereby shorting all or part of the winding s be sure the following conditions are met 1 Correct motor winding resistances must be known before testing either from previous readings or from manufacturer s specifications 2 Temperature of windings must be as specified usually about 70 F 21 190 19 3 Resistance measuring instrument must have an accuracy within 5 10 percent This requires an accurate ohmmeter such as Wheatstone bridge or null balance type instrument 4 Motor must be dry or free from direct contact with liquid refrigerant Make This Critical Test Not advisable unless above conditions are met 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals C S and R 4 Place instrument probes together and determine probe and lead wire resistance 5 Check resistance readings from C R C S and R S 6 Subtract instrument probe and lead resistance from each reading If any reading is within 20 percent of known resistance motor is
60. d airflow operation Refrigerant Charge Refrigerant Charge The refrigerant system is fully charged with R 410A refrigerant and is tested and factory sealed Amount of refrigerant charge is listed on unit s rating plate Unit must operate a minimum of 15 minutes before checking charge NOTE Adjustment of the refrigerant charge is not required unless the unit is suspected of not having the proper R 410A charge NOTE Unit sizes 024 048 have fixed orifice refrigerant metering devices the 060 size has a TXV There is a different charging procedure for both expansion devices Refer to the correct procedure for your unit NO CHARGE Use standard evacuating techniques After evacuating system weigh in the specified amount of refrigerant refer to unit s rating plate LOW CHARGE COOLING 024 048 Units Fixed Metering Device 1 Operate unit a minimum of 10 minutes before checking charge 2 Measure suction pressure by attaching an accurate gauge to compressor suction side service port 3 Measure suction side temperature by attaching an accurate thermisitor type or electronic thermometer to suction line about 10 in from compressor 4 Measure outdoor air dry bulb temperature with thermo meter 5 Measure indoor air return air wet bulb temperature with a sling psychrometer or electronic equivalent 6 Using Superheat Charging Table Table 7 find outdoor temperature and indoor air wet bulb temperature At this intersection
61. d be contributing to the failure Runs Does Not Pump In this type of failure compressor motor runs and turns compressor but compressor does not pump refrigerant A clamp on ammeter on common leg shows a very low current draw much lower than rated load amp RLA value stamped on compressor nameplate Because no refrigerant is being pumped there is no 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 and external factors Careful attention to the type of noise may help identify the source The following are some examples of abnormal conditions that may create objectionable noise 1 gurgling sound may indicate a liquid refrigerant floodback during operation This could be confirmed if there is no compressor superheat A compressor superheat of 0 degrees would indicate liquid refrigerant returning to the compressor Most common reasons for floodback are loss of evaporator blower dirty coils and improper airflow 2 A rattling noise may indicate loose hardware Inspect all unit hardware including the compressor grommets 3 An internal thunking thumping grinding rattling noise could indicate compressor internal failures and may be verified by comparing the compressor amperage to what the compressor should be drawing according to a manufacturer s performance data 4 A wh
62. d ensure bulb is properly wrapped e proceed to Step 22 22 Check for even temperature distribution x5 difference at outlet of each circuit of evaporator and for even air distribution over all evaporator slabs e If OK proceed to Step 23 23 Move sensing bulb further down suction line If problem not corrected replace valve Indoor Airflow and Airflow Adjustments 4 WARNING UNIT OPERATION HAZARD Failure to follow this caution may result in equipment damage or improper operation For cooling operation the recommended airflow is 350 to 450 cfm for each 12 000 Btuh of rated cooling capacity Table 6 shows wet coil air delivery for horizontal discharge units NOTE Be sure that all supply and return air grilles are open free from obstructions and adjusted properly WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Disconnect electrical power to the unit and install lockout tag before changing blower speed Blower speed tap can be changed by replacing the factory installed blue low speed tap wire cooling with the unused black high speed wire in unit control box The red medium speed wire is factory installed to operate with a call for supplemental electric heat See unit wiring diagram Be sure new airflow meets the range noted above and minimum electric heat CFM if equipped Refer to Table 5 All model sizes are factory wired or rate
63. d feeder tubes going into outdoor coil At the end of 1 of the feeder tubes there is a 3 8 in OD stub tube approximately 3 in long See Fig 14 The defrost thermostat should be located on stub tube Note that there is only 1 stub tube used with a liquid header and on most units it is the bottom circuit See Fig 16 and Fig 17 for DFT Sensor Location FEEDER TUBE STUB TUBE EFROST THERMOSTAT A97517 Fig 14 Defrost Thermostat Location NOTE The defrost thermostat must be located on the liquid side of the outdoor coil on the bottom circuit and as close to the coil as possible Defrost Control Board Troubleshooting defrost control involves a series of simple steps that indicate whether or not board is defective NOTE This procedure allows the service technician to check control board and defrost thermostat for defects First troubleshoot to make sure unit operates properly in heating and cooling modes This ensures operational problems are not attributed to the defrost control board Defrost Control The defrost control is used in all R 410A Mobile Home series heat pump models Its features include selectable defrost intervals of 30 60 90 minutes and standard defrost speed up capability This section describes the sequence of operation and trouble shooting methods for this control Cooling Sequence of Operation On a call for cooling thermostat mak
64. e should be warm enough to have caused defrost thermostat contacts to open Check resistance across defrost thermostat Ohmmeter should read infinite resistance indicating defrost thermostat has opened at approximately 65 F 13 Shut off unit power and reconnect fan lead 14 Remove jumper between DFT and R terminals Reconnect defrost thermostat leads Failure to remove jumper causes unit to switch to defrost every 30 60 or 90 minutes and remain in defrost for full 10 minutes 15 Replace access panel Restore power to unit If defrost thermostat does not check out following above items or incorrect calibration is suspected check for defective thermostat as follows 1 Follow items 1 5 above 2 Route sensor or probe using thermocouple temperature measuring device Attach to liquid line near defrost thermostat Insulate for more accurate reading 3 Turn on power to outdoor unit 4 Restart unit in heating 5 Within a few minutes liquid line temperature drops within a range causing defrost thermostat contacts to close Temperature range is from 35 F 1 7 C to 29 F 1 7 C Notice temperature at which ohmmeter reading goes from oo 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
65. e to another The condenser is the outdoor coil in the cooling mode and the evaporator is the indoor coil In a heat pump the condenser is the indoor coil in the heating mode and the evaporator is the outdoor coil In the typical air conditioning mode compressed hot gas leaves the compressor and enters the condensing coil As gas passes through the condenser coil it rejects heat and condenses into liquid The liquid leaves condensing unit through liquid line and enters metering device at evaporator coil As it passes through metering device it becomes a gas liquid mixture As it passes through indoor coil it absorbs heat and the refrigerant moves to the compressor and is again compressed to hot gas and cycle repeats Compressor Oil A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation The compressor in a R 410A system uses a polyolester POE or polyvinyl ether PVE oil This oil is extremely hygroscopic meaning it absorbs water readily POE PVE oils can absorb 15 times as much water as other oils designed for HCFC and CFC refrigerants Take all necessary precautions to avoid exposure of the oil to the atmosphere See Table 3 Brazing This section on brazing is not intended to teach a technician how to braze There are books and classes which teach and refine brazing techniques The basic points below are listed only as a reminder Definition The joining
66. eated it can be analyzed for cause of failure when it is returned 3 Braze new valve onto used stubs Keep stubs oriented correctly Scratch corresponding matching marks on old valve and stubs and on new valve body to aid in lining up new valve properly When brazing stubs into valve protect valve body with wet rag to prevent overheating 4 Use slip couplings to install new valve with stubs back into system Even if stubs are long wrap valve with a wet rag to prevent overheating 5 After valve is brazed in check for leaks Evacuate and charge system Operate system in both modes several times to be sure valve functions properly 22 Table 3 Air Conditioner Compressor Information Unit Size 024 030 036 042 048 060 Type AC AC AC AC AC AC Chassis Size Small Small Small Medium Medium Large Compressor Bristol Recip Bristol Recip Bristol Recip Bristol Recip Copeland Scroll Danfoss Scroll Manufacturer Oil Type Hatcol 32BCE Hatcol 32BCE Hatcol 32BCE Hatcol 32BCE 3MAF Polyolester Polyvinyl Ether Polyolester POE Polyolester POE Polyolester POE Polyolester POE Oil POE Oil PVE Oil Charge 1 02 intial recharge 30 27 30 27 40737 40737 42734 45 139 Winding Resistance ohm Start 1 43 0 98 0 63 0 52 0 52 0 43 Winding Resistance ohm Start 5 2 38 1 73 1 26 1 64 0 82 1 06 Winding Resistance ohm Start R
67. elded or hermetic shell In a mechanical failure motor or electrical circuit appears normal but compressor does not function normally 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Do not supply power to unit with compressor terminal box cover removed 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Exercise extreme caution when reading compressor currents when high voltage power is on Correct any of the problems described below before installing and running a replacement compressor Locked Rotor In this type of failure compressor motor and all starting components are normal When compressor attempts to start it draws locked rotor current and cycles off on internal protection Locked rotor current is measured by applying a clamp on ammeter around common blk lead of compressor Current drawn when it attempts to start is then measured Locked rotor amp LRA value is stamped on compressor nameplate If compressor draws locked rotor amps and all other external sources of problems have been eliminated compressor must be replaced Because compressor is a sealed unit it is impossible to determine exact mechanical failure However complete system should be checked for abnormalities such as incorrect refrigerant charge restrictions insufficient airflow across indoor or outdoor coil etc which coul
68. em pressure could result in personal injury and or death 1 Relieve pressure and recover all refrigerant before servicing existing equipment and before final unit disposal Use all service ports 2 Federal regulations require that you do not vent refrigerant into the atmosphere Recover during system repair or final unit disposal CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage Damage may occur to the scroll compressor if operated at a negative suction pressure during a system pumpdown 1 Recover refrigerant from tubing and coil through high flow service port on suction and discharge lines Disconnect refrigerant liquid tube from distributor body See Fig 26 2 Avoid damaging seal ring or machined surfaces on piston bore and retainer 3 Using small wire with a hook on end of it remove piston from body TEFLON SEAL PISTON PISTON DISTRIBUTOR RETAINER BODY BRASS HEX NUT A10176 Fig 26 Refrigerant Flow Control Device CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage When cleaning the piston orifice be careful not to scratch or enlarge the opening as this will affect operation 4 Install new or cleaned piston into body Replace seal ring on retainer Reconnect refrigerant tube to piston body Pressurize tubing and coil then leak check
69. es R O R Y and R G Circuit R O energizes reversing valve switching it to cooling position Circuit R Y sends low voltage through the safeties and energizes the contactor which starts the compressor and energizes the T1 terminal on the circuit board This will energize the OF2 fan relay which starts the outdoor fan motor When the cycle is complete R Y is turned off and compressor and outdoor fan should stop With corporate thermostats the O terminal remains energized in the cooling mode If the mode is switched to heat or Off the valve is de energized There is no compressor delay built into this control OUTDOOR FAN RELAY F2 DEFROST THERMOSTAT MUST BE CLOSED BEFORE DEFROST TIMER BEGINS T1 ENABLES DEFROST TIMER MUST BE Y OUTPUT TO PRESSURE SWITCHES AND CONTACTOR ENERGIZED FOR DEFROST TIMER START oe ____ O REVERSING VALVE or eum y DX ss T1660 pea Or or OR NY SPEEDUP THERMOSTAT INPUTS A05332 Fig 15 Defrost Control Heating Sequence of Operation On call for heating thermostat makes R Y R G Circuit R Y sends low voltage through the safeties and energizes the contactor which starts the compressor and energizes the terminal on the circuit board The T1 terminal energizes the defrost logic This will energize the OF2 fan relay star
70. fective capacitor as it may explode Sometimes under adverse conditions a standard run capacitor in a system is inadequate to start compressor In these instances a start assist device is used to provide an extra starting boost to compressor motor This device is called a positive temperature coefficient PTCR or PTC or start thermistor It is a resistor wired in parallel with the run capacitor As current flows through the PTC 10 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 and resistance value returns to normal until next time system starts Thermistor device is adequate for most conditions however in systems where off cycle is short device cannot fully cool and becomes less effective as a start device It is an easy device to troubleshoot Shut off all power to system Check thermistor with ohmmeter as described below Shut off all power to unit Remove PTC from unit Wait at least 10 minutes for PTC to cool to ambient temperature Measure resistance of PTC with ohmmeter The cold resistance RT of any PTC device should be approximately 100 180 percent of device ohm rating 12 5 ohm PTC 12 5 22 5 ohm resistance beige color If PTC resistance is appreciably less than rating or more than 200 percent higher than rating device
71. gage pressures are 0 psig 3 Clean area around leak to bare metal 4 Apply flux and repair joint with silver solder Do not use low temperature solder such as 50 50 5 Clean off excess flux check for leaks and apply paint over repaired area to prevent corrosion Do not use this method to repair a compressor leak due to severe corrosion Never attempt to repair a compressor leaking at electric terminals This type of failure requires compressor replacement Electrical Failures The compressor mechanical pump is driven by an electric motor within its hermetic shell In electrical failures compressor does not run although external electrical and mechanical systems appear normal Compressor must be checked electrically for abnormalities Before troubleshooting compressor motor review this description of compressor motor terminal identification Single Phase Motors To identify terminals C S and R 1 Turn off all unit power 2 Short the run and start capacitors to prevent shock 3 Remove all wires from motor terminals 4 Read resistance between all pairs of terminals using an ohmmeter on 0 10 ohm scale 5 Determine 2 terminals that provide greatest resistance reading Through elimination remaining terminal must be common C Greatest resistance between common C and another terminal indicates start winding because it has more turns This terminal is start S Remaining terminal will be run winding R See Fig 20 NOTE If compress
72. ge system Pour and measure oil quantity if any from old accumulator If more than 20 percent of oil charge is trapped in accumulator add new POE or PVE oil to compressor to make up for this loss See Table 3 430 FUSE ELEMENT A88410 Fig 24 Accumulator Thermostatic Expansion Valve TXV The five ton air conditioning and heat pump units have a factory installed thermostatic expansion valve The will be a bi flow hard shutoff with an external equalizer and a balance port pin A hard shut off TXV does not have a bleed port Therefore minimal equalization takes place after shutdown TXVs specifically designed to operate with R 410A refrigerant use only factory authorized TXV s Do not interchange R 410A and R 22 TXVs TXV Operation The TXV is a metering device that is used in air conditioning and heat pump systems to adjust to changing load conditions by maintaining a preset superheat temperature at the outlet of the evaporator coil The volume of refrigerant metered through the valve seat is dependent upon the following 1 Superheat temperature is sensed by cap tube sensing bulb on suction tube at outlet of evaporator coil This temperature is converted into pressure by refrigerant in the bulb pushing downward on the diaphragm which opens the valve via the pushrods 2 The suction pressure at the outlet of the evaporator coil is transferred via the external equalizer tube to the under
73. gerous Defective capacitors may explode when power is applied Insulating fluid inside is combustible and may ignite causing burns Capacitors are used as a phase shifting device to aid in starting certain single phase motors Check capacitors as follows 1 With power off discharge capacitors as outlined above Disconnect capacitor from circuit Put ohmmeter on R X 10k scale Using an analog ohmmeter check each terminal to ground use capacitor case Discard any capacitor which measures 1 2 scale deflection or less Place ohmmeter leads across capacitor and place on R X 10k scale Meter should jump to a low resistance value and slowly climb to higher value Failure of meter to do this indicates an open capacitor If resistance stays at 0 or a low value capacitor is internally shorted 2 Capacitance testers are available which will read value of capacitor If value is not within 10 percent value stated on capacitor it should be replaced If capacitor is not open or shorted the capacitance value is calculated by measuring voltage across capacitor and current it draws 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Exercise extreme caution when taking readings while power is on Use following formula to calculate capacitance Capacitance mfd 2650 X amps volts 3 Remove any capacitor that shows signs of bulging dents or leaking Do not apply power to a de
74. high voltage supply to motor The ECM fan motor will always have high voltage to the motor even when the motor is off The 24 volt signal cycles the motor on and off The motor can accept more than one 24 volt control signal to the different motor taps without damaging it The motor will default to the highest speed tap that see a 24 volt signal Fan won t run e Cycle power off to the unit Disconnect the two plugs going into the motor One plug is the high voltage supply and the other is the low voltage control e Cycle power back on and measure the high voltage supply plug to determine if there is voltage at plug If there is no voltage at plug determine if there is power to the unit The easiest place to measure the voltage is on the line side of the contactor If there is voltage at the contactor and no voltage at the plug cycle the power back off and inspect the wiring harness and plug for loose or broken connections Replace the wiring harness and plug if it is found to be defective e fthere is power at the high voltage plug check the low voltage control signal With the power on to the unit verify that there is 24volts between R and C in the low voltage control box If there is not 24 volts at R and C check the inline 3 amp fuse If the fuse is blown check for shorted bare or chaffed wires before installing another fuse in the holder If the fuse is good make sure there is line voltage on the primary side of
75. ing charging Favorable conditions exist when the outdoor temperature is between 70 F and 100 F 21 11 C and 37 78 C and the indoor temperature is between 70 F and 80 F 21 11 C and 26 67 C Follow the procedure below To check charge allow system to operate in cooling mode at least 15 minutes If conditions are favorable check system charge by subcooling method If any adjustment is necessary adjust charge slowly and allow system to operate for 15 minutes to stabilize before declaring a properly charged system If the indoor temperature is above 80 F 26 67 C and the outdoor temperature is in the favorable range adjust system charge and allow the indoor temperature to drop to 80 F 26 67 C before attempting to check system charge by subcooling method as described above If the indoor temperature is below 70 F 21 11 C or the outdoor temperature is not in the favorable range the charge level could then be checked at another time when the both indoor and outdoor temperatures are in a more favorable range Troubleshooting with SuperHeat This troubleshooting routine was developed to diagnose cooling problems using superheat in TXV systems It is effective on heat pumps in cooling mode as well as air conditioners The system must utilize a TXV as the expansion device in cooling mode Basic Diagnostics NOTE When checking refrigerant charge and troubleshooting operating systems the indoor airflow has significant effect
76. ire size The wire size selected must have a current capacity not less than that of the copper wire specified and must not create a voltage drop between service panel and unit in excess of 2 of unit rated voltage To prepare wire before installing connector all aluminum wire must be brush scratched and coated with a corrosion inhibitor such as Pentrox A When it is suspected that connection will be exposed to moisture it is very important to cover entire connection completely to prevent an electrochemical action that will cause connection to fail very quickly Do not reduce effective size of wire such as cutting off strands so that wire will fit a connector Proper size connectors should be used Check all factory and field electrical connections for tightness This should also be done after unit has reached operating temperatures especially if aluminum conductors are used Contactor The contactor provides a means of applying power to unit using low voltage 24v from transformer in order to power contactor coil Depending on unit model you may encounter single or double pole contactors Exercise extreme caution when troubleshooting as 1 side of line may be electrically energized The contactor coil is powered by 24vac If contactor does not operate 1 With power off check whether contacts are free to move Check for severe burning or arcing on contact points 2 With power off use ohmmeter to check for continuity of coil Disc
77. istling or squealing noise during operation may indicate a partial blockage of the refrigerant charge 5 A whistle on shut down could indicate a partial leak path as refrigerant is equalizing from high to low side On occasion an in line discharge check valve has prevented this sound 6 If a compressor hums but won t start it could indicate either a voltage or amperage issue Verify adequate voltage and operational start components if installed If it is drawing excessive amperage and voltage doesn t appear to be the problem it may be assumed a locked condition Ensure refrigerant has had ample time to equalize and boil out of the compressor before condemning 7 When a heat pump switches into and out of defrost a swooshing noise is expected due to the rapid pressure change within the system Check that the defrost thermostat or thermistor is operating properly Insulating the defrost sensing device may also help 16 EXAMPLE 2 DETERMINE INTERNAL CONNECTIONS OF SINGLE e PHASE MOTORS 8 EXCEPT SHADED POLE e POWER OFF DEDUCTION 2 17 3 GREATEST RESISTANCE RUN WINDING R 5 80 OHM START WINDING 5 OHMMETER 2 G SMALLEST RESISTANCE 2 is 0 1082 SCALE 0 62 BY ELIMINATION 1 2 REMAINING RESISTANCE 2 is COMMON 5 20 2 THEREFORE 1718 5 80 0 60 5 9 START WINDING 5 3 IS RUN WINDING A88344 Fig 19
78. label Locked Rotor In this type of failure compressor motor and all starting components are normal When compressor attempts to start it draws locked rotor current and cycles off on the internal protection Locked rotor current is measured by applying a clamp on ammeter around common blk lead of the compressor on single phase compressor Current drawn when it attempts to start is then measured LRA locked rotor amp value is stamped on compressor nameplate If compressor draws locked rotor amps and all other external sources of problems have been eliminated compressor must be replaced Because compressor is a sealed unit it is impossible to determine exact mechanical failure However complete system should be checked for abnormalities such as incorrect refrigerant charge restrictions insufficient airflow across indoor or outdoor coil etc which could be contributing to the failure Runs Does Not Pump In this type of failure compressor motor runs and turns compressor but compressor does not pump the refrigerant A clamp on ammeter on common leg of a single phase compressor shows a very low current draw much lower than RLA rated load amps value stamped on compressor nameplate Because no refrigerant is being pumped there is no return gas to cool compressor motor It eventually overheats and shuts off on its internal protection Runs Does Not Pump High To Low Side Leak In this type of failure compressor motor
79. lastic will hold moisture possibly causing corrosion Cleaning Coil 1 Remove side panel See Remove Side Panel in Cabinet section of this manual CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Coil fin damage can result in higher operating costs or compressor damage Do not use flame high pressure water steam volatile or corrosive cleaners on fins or tubing 2 Clean coil using vacuum cleaner and its crevice tool Move crevice tool vertically close to area being cleaned making sure tool touches only dirt on fins and not fins to prevent fin damage do not scrub fins with tool or move tool horizontally against fins 3 If oil deposits are present spray coil with ordinary household detergent Wait 10 minutes and proceed to next step 4 Using garden hose spray coil vertically downward with constant stream of water at moderate pressure Keep nozzle at a 15 to 20 angle about 3 in from coil face and 18 in from tube Spray so debris is washed out of coil and basepan 5 Reinstall side panel 6 Reconnect electrical power and check for proper operation Cleaning Outdoor Fan Motor and Blade 1 Remove grille fan motor and blade Be careful not to bend or dent fan blade 2 Clean motor and blade with soft brush or cloth Be careful not to disturb balance weights on fan blade 3 Check fan blade setscrew for tightness 4 Reinstall fan mot
80. leanliness each heating and cooling season and clean as necessary 2 Check fan motor and blade for cleanliness each month during cooling season and clean as necessary 3 Check electrical connections for tightness and controls for proper operation each cooling season and service as necessary CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Because of possible damage to the equipment or personal injury maintenance should be performed by qualified personnel only Desert and Seacoast Locations Special consideration must be given to installation and maintenance of condensing 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 Preventive measures can be taken during installations such as 1 Locate unit on side of structure opposite prevailing winds 2 Install unit where drifting sand cannot pile up against coil Maintenance in desert and seacoast locations 1 Frequent inspection of coil and basepan especially after storms and or high winds 2 Clean coil by flushing out sand from between coil fins and out of basepan as frequently as inspection determines necessary 3 In off season cover with covering that allows air to circulate through but prevents sand from sifting in such as canvas material Do not use plastic as p
81. ndensers W Energizes first stage supplemental heat through defrost relay R Energizes 24 v power from transformer Y Energizes contactor for first stage cooling or first stage heating for heat pumps O Energizes reversing valve on heat pumps C Common side of transformer Ground Circuit To determine if a wire has broken or come in direct contact with shell causing a direct short to ground follow these steps 1 Recover all refrigerant charge 2 Using an ohmmeter on R X 10 000 ohm scale or megohmmeter follow manufacturer s instructions Be sure all power is off Discharge all capacitors Remove compressor plug RO Place one meter probe on ground or 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 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 Temperatu
82. ne drier between compressor and accumulator 5 Operate system for 10 hr Monitor pressure drop across drier If pressure drop exceeds 3 psig replace suction line and liquid line filter driers Be sure to purge system with dry nitrogen when replacing filter driers If suction line driers must be replaced retest pressure drop after additional 10 hours run time Continue to monitor pressure drop across suction line filter drier After 10 hr of run time remove suction line filter drier and replace liquid line filter drier Never leave suction line filter drier in system longer than 72 hr actual time 6 Charge system See unit information plate A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Only suction line filter driers should be used for refrigerant and oil clean up Use of non approved products could limit system life and void unit warranty Evacuation Proper evacuation of the system will remove non condensibles and assure a tight dry system before charging The 2 methods used to evacuate a system are the deep vacuum method and the triple evacuation method Deep Vacuum Method The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gauge capable of accurately measuring this vacuum depth The deep vacuum method is the most positive way of assuring a system is free of air and moisture See Fig 29 50
83. ng reverse flushing procedure Remove and discard liquid line strainer After system is reassembled install liquid and suction line filter driers Run system for 2 hrs Discard both driers and install new liquid line drier only Compressor Removal and Replacement Once it is determined that compressor has failed and the reason established compressor must be replaced CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant and observe the following The high flow service valve is equipped with Schrader valves 4 WARNING PERSONAL INJURY AND ENVIRONMENTAL HAZARD Failure to follow this warning could result in personal injury or death Relieve pressure and recover all refrigerant before system repair or final unit disposal Use all service ports and open all flow control devices including solenoid valves Federal regulations require that you do not vent refrigerant to the atmosphere Recover during system repair or final unit disposal 1 Shut off all power to unit 2 Remove and recover all refrigerant from system until pressure gages read zero psig Use all service ports 3 Disconnect electrical plug from compressor Disconnect or remove crankcase heater if equipped and remove compressor holddown nuts and washers 4 Cut compressor from system with tubing cutters Do not use brazing torch for
84. ngs and connections in system Leak is detected by either the movement of a pointer on detector dial a buzzing sound or a light In all instances when a leak is found system charge must be recovered and leak repaired before final charging and operation After leak testing or leak is repaired replace liquid line filter drier evacuate system and recharge with correct refrigerant quantity Coil Removal Coils are easy to remove if required for compressor removal or to replace coil 1 Shut off all power to unit 2 Recover refrigerant from system through high flow service valves 3 Break vacuum with nitrogen 4 Remove top cover See Access Compressor or other internal cabinet component Fig 7 Fig 9 5 Remove screws in coil panels 4 WARNING FIRE HAZARD Failure to follow this warning could result in personal injury or equipment damage Cut tubing to reduce possibility of personal injury and fire 6 Use midget tubing cutter to cut liquid and vapor lines at both sides of coil Cut in convenient location for easy reassembly with copper slip couplings 7 Lift coil vertically from basepan and carefully place aside 8 Reverse procedure to reinstall coil 9 Replace filter drier evacuate system recharge and check for normal systems operation Compressor Removal and Replacement Once it is determined that compressor has failed and the reason established compressor must be replaced CAUTION PERSONAL
85. nterval is 90 min the speed up will take 90 256 min x 60seconds minute 21 seconds max This could be shorter depending on how much time has elapsed since the defrost thermostat closed 3 Remove the short immediately when the unit shifts into defrost Failure to remove the short immediately will result in a very short forced defrost cycle the 10 minute timer will be sped through in 2 seconds 4 When defrost begins it will continue until the defrost thermostat opens or 10 minutes has elapsed NOTE The T1 terminal on the defrost board powers the defrost timing function This terminal must be energized before any defrost function will occur Defrost thermostat can either be located on the bottom of tube as shown or on the top and must not interfere with any other tubing A10172 If defrost thermostat is stuck closed Whether the unit is in heating or cooling mode it will run a defrost cycle for 10 minutes each time the compressor has been energized for the selected time interval The board will terminate automatically after 10 minutes of defrost time regardless of defrost thermostat position If defrost thermostat is stuck open The unit will not defrost If unit will not defrost 1 Perform the speedup function as described above to test the defrost function of the circuit board 2 If the unit does not go into defrost after performing the speed up check for 24 volts on the T1 terminal This terminal powers the defr
86. on Instructions for any additional installation detail Add On Replacement Retrofit Specifications for these units in the add on replacement retrofit market require the unit to be installed outdoors and meet all local codes and requirements Clearances power supply system static needs to be check to ensure that the replacement unit can perform within the design parameter desired specified in the Product Data ACCESSORIES Table 1 Required Field Installed Accessories for Air Conditioners and Heat Pumps Required for low ambient Accesso cooling Accessory Part ry applications Number Below 40 F 4 4 HU Low Ambient Yes CPLOWAMBOO1A00 Hecom Evaporator Freeze Thermostat mended KAAFT0101AAA Compressor Start Assist CTCR Yes CPHSTART002A00 Outdoor Thermostat Kit No CPODSTATO001A00 Isolation Relay Required for Heat Pumps Yes HN 65KJ 016 Crankcase Heater See below AC 24 30 36 42 Yes CPCRKHTRO007A00 AC 48 60 HP 42 48 60 Yes CPCRKHTRO004A00 HP 24 30 36 Yes CPCRKHTRO008A00 ACCESSORY DESCRIPTIONS Refer to Table 1 for an Accessory Usage Guide for Air Conditioners and Heat Pumps Refer to the appropriate section below for a description of each accessory and its use 1 Crankcase Heater An electric resistance heater which mounts to the base of the compressor to keep the lubricant warm during off cycles Improves compressor lubrication on rest
87. onnect 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 Capacitor 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or equipment damage Capacitors can store electrical energy when power is off Electrical shock can result if you touch the capacitor terminals and discharge the stored energy Exercise extreme caution when working near capacitors With power off discharge stored energy by shorting across the capacitor terminals with a 15 000 ohm 2 watt resistor 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or equipment damage Always check capacitors with power off Attempting to troubleshoot a capacitor with power on can be dan
88. or and blade to grille and check for alignment 5 Reinstall grille and position blade 6 Reconnect electrical power and check for proper operation Electrical Controls and Wiring 1 Disconnect power to unit 2 Check all electrical connections for tightness Tighten all screws on electrical connections If any connections appear to be burned or smoky disassemble the connection clean all parts and stripped wires and reassemble Use a new connector if old one is burned or corroded and crimp tightly 3 Reconnect electrical power to unit and observe unit through 1 complete operating cycle 4 If there are any discrepancies in operating cycle 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 2 If any leaks are found remove and reclaim or isolate charge pumpdown if applicable Make necessary repairs 3 Evacuate recharge and observe unit through 1 complete operating cycle 36 Final Check Out After the unit has been operating the following items should be checked 1 Check that unit operational noise is not excessive due to vibration of component tubing panels etc If present isolate problem and correct 2 Check to be sure caps are installed on high flow valves and are tight 3 Check to be sure tools loose parts and debris are removed from unit 4 Check to be
89. or is hot allow time to cool and internal line break to reset There is an internal line break protector which must be closed Open Circuit To determine if any winding has a break in the internal wires and current is unable to pass through 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals 5 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 Be sure internal line break overload is not temporarily open Ground Circuit To determine if a wire has broken or come in direct contact with shell causing a direct short to ground 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals C S and R 4 On hermetic compressors allow crankcase heaters to remain on for several hours before checking motor to ensure windings are not saturated with refrigerant 5 Use an ohmmeter on R X 10 000 ohm scale A megohmmeter may be used in place of ohmmeter Follow manufacturer s instructions 6 Place 1 meter probe on ground or on compressor shell Make a good metal to metal contact Place other probe on terminals C S and R in sequence 7 Note meter scale 8 If reading of zero or low resistance is obtained motor is grounde
90. or is the heart of the refrigeration system It pumps refrigerant through the system If it malfunctions system capacity and efficiency could be negatively affected 4 WARNING FIRE EXPLOSION HAZARD Failure to follow this warning could result in personal injury or death and or property damage Wear safety glasses and gloves when handling refrigerants Keep torches and other ignition sources away from refrigerants and oils The compressor is an electrical as well as mechanical device Exercise extreme caution when working near compressors Power should be shut off if possible for most troubleshooting techniques Refrigerants in system present other safety hazards Always wear safety glasses and gloves when handling refrigerants Compressor Failures Compressor failures are classified in 2 broad failure categories mechanical and electrical Both types are discussed below Mechanical Failures A compressor is a mechanical pump driven by an electric motor contained in a welded or hermetic shell In a mechanical failure motor or electrical circuit appears normal but compressor does not function normally 4 WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning
91. ost circuit and must be energized before any defrost function can occur The T1 should be energized once the Y terminal is energized and the pressure Switches are closed Ensure the T1 wire is connected at the contactor and that 24 volts is present on the T1 terminal 3 If all voltages are present and unit will still not run defrost remove thermostat pigtail harness from board and perform checks directly on input pins with jumper wires The pigtail may have a bad connection or be mis wired To fully troubleshoot defrost thermostat and control function 1 Turn thermostat to OFF Shut off all power to outdoor unit 2 Remove control box cover for access to electrical components and defrost control board 3 Disconnect defrost thermostat leads from control board and connect to ohmmeter Thermostat leads are black insulated wires connected to DFT and R terminals on control board Resistance reading may be zero indicating closed defrost thermostat or infinity for open thermostat depending on outdoor temperature 4 Jumper between DFT and R terminals on control board as shown in Fig 10 5 Disconnect outdoor fan motor lead from OF2 Tape lead to prevent grounding 14 6 Turn power to outdoor unit 7 Restart unit in heating mode allowing frost to accumulate on outdoor coil 8 After a few minutes in heating mode liquid line temperature at defrost thermostat should drop below closing set point of defrost thermost
92. oves to prevent personal injury During normal system operations some components are hot and can cause burns Rotating fan blades can cause personal injury Appropriate safety considerations are posted throughout this manual where potentially dangerous techniques are addressed Follow all safety codes Wear safety glasses protective clothing and work gloves Have a fire extinguisher available Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the unit Consult local building codes the current editions of the National Electrical Code NEC NFPA 70 In Canada refer to the current editions of the Canadian Electrical Code CSA C22 1 INTRODUCTION This document provides required system information necessary to install service repair or maintain the small package products SPP air conditioners and heat pumps using R 410A refrigerant Refer to the unit Product Data Technical specifications for rating information electrical data required clearances additional component part numbers and related pre sale data Installation Instructions are also available per specific models Information in this document refers to units produced in 2010 to current INSTALLATION GUIDELINE Residential New Construction Specifications for these units in the residential new construction market require the unit to be installed outdoors and meet all local code and requirements Consult the Installati
93. perating other items can be checked such as frost or condensate water on refrigerant tubes The sound made by a reversing valve as it begins or ends defrost is a whooshing sound as the valve reverses and pressures in system equalize An experienced service technician detects this sound and uses it as a valuable troubleshooting tool Using a remote measuring device check inlet and outlet line temperatures DO NOT touch lines If reversing valve is operating normally inlet and outlet temperatures on appropriate lines should be close to each other Any difference would be due to heat loss or gain across valve body Temperatures are best checked with a remote reading electronic type thermometer with multiple probes Route thermocouple leads to inside of coil area through service valve mounting plate area underneath coil Fig 22 and Fig 23 show test points TP on reversing valve for recording temperatures Insulate points for more accurate reading If valve is defective 1 Shut off all power to unit and remove charge from system 2 Remove solenoid coil from valve body Remove valve by cutting it from system with tubing cutter Repair person should cut in such a way that stubs can be easily re brazed back into system Do not use hacksaw This introduces chips into system that cause failure After defective valve is removed wrap it in wet rag and carefully unbraze stubs Save stubs for future use Because defective valve is not overh
94. r tubing Fig 16 DFT Sensor Location 024 048 13 PUEDE 242824 2222 DO AMES DETAIL L L TD pees SEE DETAIL 060 Fig 17 DFT Sensor Location 060 Troubleshooting If unit will not run 1 Does the Y input has 24 volts from thermostat If not check thermostat or wire If yes proceed to 2 2 The Y spade terminal on the circuit board should have 24 volts if Y input is energized This output goes through the pressure switches and to the contactor If 24 volts is present on the Y spade terminal and the contactor is not closed check voltage on contactor coil If no voltage is present check for opened pressure switch 3 If voltage is present and contactor is open contactor may be defective Replace contactor if necessary 4 If contactor is closed and unit will still not run check wiring capacitor and compressor Defrost Speedu To test the defrost function on these units speed up pins are provided on the circuit board To force a defrost cycle the defrost thermostat must be closed or the defrost thermostat pins must be jumpered Follow the steps below to force a defrost cycle 1 Jumper the DFT input 2 Short the speed up pins This speeds up the defrost timer by a factor of 256 The longer the defrost interval setting the longer the pins must be shorted to speed through the timing For example if i
95. re of windings must be as specified usually about 70 F 21 C 3 Resistance measuring instrument must have an accuracy within 5 10 percent This requires an accurate ohmmeter such as Wheatstone bridge or null balance type instrument 4 Motor must be dry or free from direct contact with liquid refrigerant 21 Make This Critical Test Not advisable unless above conditions are met Be sure all power is off Recover all refrigerant charge Discharge all capacitors Remove wires from terminals C S and R Place instrument probes together and determine probe and lead wire resistance Check resistance readings from C R C S and R S 7 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 Refrigerant WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in personal injury or equipment damage R 410A refrigerant which has higher pressures than R 22 and other refrigerants No other refrigerant may be used in this system Gauge set hoses and recovery system must be designed to handle R 410A If you are unsure consult the equipment manufacturer In an air conditioning and heat pump system refrigerant transfers heat from one replac
96. re taking readings Most common motor failures are due to either an open grounded or short circuit When a compressor fails to start or run 3 tests can help determine the problem First all possible external causes should be eliminated such as overloads improper voltage pressure equalization defective capacitor s relays wiring etc Compressor has internal line break overload so be certain it is closed Open Circuit 4 WARNING UNIT PERSONAL INJURY HAZARD Failure to follow this warning could result in personal injury Use caution when working near compressor terminals Damaged terminals have the potential to cause personal injury Never put face or body directly in line with terminals To determine if any winding has a break in the internal wires and current is unable to pass through follow these steps 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals C S and R 4 Check resistance from C R C S and R S using an ohmmeter on 0 1000 ohm scale Because winding resistances are usually less than 10 ohms each reading appears to be approximately 0 ohm If resistance remains at 1000 ohms an open or break exists and compressor should be CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation Be sure internal line break overload is not temporarily open 17 RECIPROCATING COMPRESSOR The compress
97. side of the diaphragm This is needed to account for the indoor coil pressure drop Coils typically have a high pressure drop which requires this valve feature 3 The pin is spring loaded which exerts pressure on the underside of the diaphragm Therefore the bulb pressure works against the spring pressure and evaporator suction pressure to open the valve If the load increases the temperature increases at the bulb which increases the pressure on the top side of the diaphragm This opens the valve and increases the flow of refrigerant The increased refrigerant flow causes the leaving evaporator temperature to decrease This lowers the pressure on the diaphragm and closes the pin The refrigerant flow is effectively stabilized to the load demand with negligible change in superheat 24 Table 4 Piston TXV Table Air Conditioner Outdoor Unit Size Indoor Cooling Piston TXV Heating ton Number Piston Number 24 59 30 59 36 67 42 73 48 82 60 EA36YD100 Heat Pump Outdoor Unit Size Indoor Cooling Piston TXV Heating ton Number Piston Number 24 59 49 30 59 49 36 70 57 42 73 61 48 82 70 60 EA36YD159 73 10 O CLOCK 2 O CLOCK SENSING BULB STRAP A 08083 Fig 25 Position of Sensing Bulb PISTON BODY CLEANING OR REPLACEMENT A WARNING PERSONAL INJURY AND ENVIRONMENTAL HAZARD Failure to relieve syst
98. ss to the component above See Fig 7 2 Access to the indoor fan motor and electric heater a Removal of the right side side with electric access right back panel to access components above See Fig 8 3 Access or removal of the condenser coil a Removal of the top the control compressor panel the front left side louver panel b Screws from the compressor compartment and either the side of the unit or below the condenser fan depending on the shape of coil will need to be removed to remove condenser coil See Fig 9 4 Access or removal of the evaporator coil a 024 to 036 The indoor evaporator coil is held in place by screws located in the compressor compartment and behind the return air duct The 14 return collar must be removed to access these screws b 042 to 060 The indoor evaporator coil is held in place by screws located in the compressor compartment and on the rectangular duct flange The rectangular duct flange does not need to be removed but the left side screws will have to be removed See Fig 9 and 10 A10160 A10159 Fig 8 Removal of Right Side Back Panel 1355 61 DUCT OPENING EVAPORATOR CONDENSOR COILS 10161 Fig 9 Access of Condenser Coil 9 3 8 18 3 4 1238 11 1416 21 1355 61 DUCT OPENINGS REAR VIEW SMALL MEDIUM CHASSIS 3 4 1355 61 DUCT OPENING d REAR VIEW 113 0 MEDIUM LARGE CHASSIS 10173 Fig 10
99. t at a cooling airflow that is less than 350 cfm for each 12 000 Btuh of rated cooling capacity Evaporator coil frosting may occur at air flows below this point 2 Standard Cubic Feet per Minute 0 7 549 866 833 932 1015 958 497 668 SCFM 1052 1018 795 899 895 94 552 724 678 784 931 729 882 30 Table 7 Superheat Charging SUPERHEAT CHARGING TABLE SUPERHEAT F C AT COMPRESSOR SUCTION SERVICE PORT OUTDOOR EVAPORATOR ENTERING AIR F C WB TEMP F C 55 12 7 12 6 7 14 7 8 17 9 4 20 11 23 13 26 14 29 16 32 18 35 19 37 21 40 22 42 23 45 25 76 24 60 15 6 10 5 6 12 6 7 15 8 3 18 10 21 12 24 13 27 15 30 17 33 18 35 19 38 21 40 22 43 24 13 7 2 16 8 9 19 11 41 23 65 18 3 6 3 3 70 21 1 75 23 9 10 5 6 13 7 2 16 8 9 39 22 12 6 7 3 18 10 12 24 13 28 16 31 17 34 19 37 21 80 26 7 8 4 4 7 15 8 3 21 12 25 14 28 16 31 17 35 19 85 29 4 15 8 3 19 11 22 12 26 14 30 17 33 18 90 32 2 95 35 0 13 7 2 16 8 9 10 5 6 14 7 8 18 10 22 12 25 14 29 16 100 37 7 8 4 4 12 67 15 8 3 20 11 23 13 27 15 105 40 6 110 43 3 115 46 1
100. t be interchanged The compressor is an electrical as well as mechanical device Exercise extreme caution when working near compressors Power should be shut off if possible for most troubleshooting techniques Refrigerants present additional safety hazards A CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant 15 The scroll compressor pumps refrigerant through the system by the interaction of a stationary and an orbiting scroll See Fig 12 The scroll compressor has no dynamic suction or discharge valves and it is more tolerant of stresses caused by debris liquid slugging and flooded starts The compressor is equipped with an internal pressure relief port The pressure relief port is a safety device designed to protect against extreme high pressure The relief port has an operating range between 550 to 625 psig differential pressure Copeland and 550 to 650 psig differential pressure Danfoss for R 410A refrigerant Scrolls have a variety of shut down solutions depending on model to prevent backward rotation and eliminate the need for cycle protection Compressor Failures Compressor failures are classified in 2 broad failure categories mechanical and electrical Both types are discussed below Mechanical Failures A compressor is a mechanical pump driven by an electric motor contained in a w
101. t the outdoor motor The T1 terminal must be energized for defrost to function When the cycle is complete R Y is turned off and the compressor and outdoor fan should stop There is no compressor delay built into this control Defrost Sequence The defrost control is a time temperature control that has field selectable settings of 30 60 and 90 minutes These represent the amount of time that must pass after closure of the defrost thermostat before the defrost sequence begins The defrost thermostat senses coil temperature throughout the heating cycle When the coil temperature reaches the defrost thermostat setting of approximately 32 F 0 C it will close which energizes the DFT terminal and begins the defrost timing sequence When the DTF has been energized for the selected time the defrost cycle begins and the control shifts the reversing valve into cooling position and turns the outdoor fan off This shifts hot gas flow into the outdoor coil which melts the frost from the coil The defrost cycle is terminated when defrost thermostat opens at approximately 65 F 18 3 C or automatically after 10 minutes 12 048 10171 XC rfr 4 1 C YOY OY ls OG 660606066060 01464 2 6 8 2 i 024 030 Defrost thermostat can either be located on the bottom of tube as shown or on the top and must not interfere with any othe
102. te with R 410A systems R 22 pressure switches must not be used as replacements for the R 410A air conditioners or heat pumps R 410A pressure switches are identified by a pink stripe down each wire Low Pressure Switch Neither of the air conditioner or heat pump units have a low pressure switch The heat pump models have a loss of charge switch located downstream of the liquid line filter drier See loss of charge for more details High Pressure Switch AC amp HP The high pressure switch is located in the discharge line and protects against excessive condenser coil pressure It opens around 650 psig and closes at 420 25 psig for R 410A High pressure may be caused by a dirty condenser coil failed fan motor or condenser air re circulation To check switch 1 Turn off all power to unit 2 Disconnect leads on switch 3 Apply ohmmeter leads across switch You should have continuity on a good switch NOTE Because these switches are attached to refrigeration system under pressure it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists If switch must be removed remove and recover all system charge so that pressure gauges read 0 psig Never open system without breaking vacuum with dry nitrogen CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling
103. ws 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 24 This fusible element will melt at 430 F 221 C and vent the refrigerant if this temperature is reached either internal or external to the system If fuse melts the accumulator must be replaced To change accumulator 1 Shut off all power to unit 2 Recover all refrigerant from system 3 Break vacuum with dry nitrogen Do not exceed 5 psig NOTE Refer to appropriate sections of Service Manual for instructions CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant 4 Remove accumulator from system with tubing cutter 5 Tape ends of open tubing 6 Scratch matching marks on tubing studs and old accumulator Scratch matching marks on new accumulator Unbraze stubs from old accumulator and braze into new accumulator 7 Thoroughly rinse any flux residue from joints and paint with corrosion resistant coating such as zinc rich paint 8 Install factory authorized accumulator into system with copper slip couplings 9 Evacuate and char

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