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Application Guideline and Service Manual

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1. ia r AN AN amp 30 MAX fe A Ww wwe PT pe x g A95453 Application Air conditioner installed above indoor unit e A crankcase heater must be installed on compressor The above requirements provide protection against refrigerant migration to compressor when outdoor temperature is lower than indoor temperature e Maximum elevation between units is 30 ft Maximum equivalent total line length is 175 ft Fig 6 Indoor Unit Below Outdoor Unit SECTION 2 SERVICE MANUAL SEES RATING us Aone PLATE 4 CONTROL BOX A SERVICE INFO u VALVE LABEL gl PLATE JL uo TUBE T WARNING LABEL 1 y ACCESS PANEL o o o o Nc BASE PAN NR BASE PAN Fig 7 Callouts for R 410A Air Conditioner A95410 A WARNING Improper installation adjustment alteration service mainte nance or use can cause explosion fire electrical shock or other conditions which may cause personal injury death or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified installer or agency must us
2. X Carrier ME ff 9 HEATING amp COOLING Air Conditioner with R 410A Refrigerant Application Guideline and Service Manual SAFETY CONSIDERATIONS Installation service and repair of these units should be attempted only by trained service technicians familiar with standard service UNIT IDENTIFICATION Model Number Nomenclature Serial Number Nomenclature instruction and training material CABINET ASSEMBLY 8 All equipment should be installed in accordance with accepted Remove Top over i i Remove Fan Motor Assembly practices and unit Installation Instructions and in compliance with Information Plate all national and local codes Power should be turned off when servicing or Tepaning electrical Components Extreme caution ELECTRICAL sni dnd dtd e iod 9 should be observed when troubleshooting electrical components Aluminum Wire with power on Observe all warning notices posted on equipment Contactor and in instructions or manuals Capacitor PTC Devices A CAUTION Cycle Protector R 410A systems operate at higher pressures than standard Crankcase Heater R 22 systems Do not use R 22 service equipment or com Time Delay Relay ponents on R 410A equipment Pressure Switches Fan Motor Refrigeration system contains refrigerant under pressure Extreme Compressor Plug caution should be observed when handling refrigerants Wear Low Voltage Terminals safety glasses and gloves to prevent personal i
3. SERVICE k PORT ENTRANCE SEAT i FRONT SEAT POSITION FIELD SIDE FORGED BACK SEATING VALVE A91435 Fig 21 Service Valve pressurized To pressurize the service port this valve must be moved off the back seating position This valve does not contain a Schrader fitting The service valves are designed for sweat connection to field tubing The service valves in outdoor unit come from factory front seated This means that refrigerant charge is isolated from line set connection ports The interconnecting tubing line set can be brazed to service valves using either silver bearing or non silver bearing brazing material Consult local codes Before brazing line set to valves belled ends of sweat connections on service valves must be cleaned so that no brass plating remains on either inside or outside of bell joint To prevent damage to valve and or cap O ring use a wet cloth or other acceptable heat sinking material on valve before brazing To prevent damage to unit use a metal barrier between brazing area and unit After the brazing operation and the refrigerant tubing and evapo rator coil have been evacuated valve stem can be turned counter clockwise until it opens or back seats which releases refrigerant into tubing and evaporator coil The system can now be operated Back seating service valves must be back seated turned counter clockwise until seated before service port caps can b
4. N G 2 mec The open passage is sealed off as gas is drawn into the spiral W d 5 SAAN Actually during operation all six gas passages are in various stages of compression at all times resulting in nearly con tinuous suction and discharge W d 4 ue By the time the gas arrives at the center port discharge pressure has been reached 90198 Fig 19 Scroll Compressor Refrigerant Flow Table 4 Oil Charging COMPRESSOR COLD RECHARGE PART NO OZ ZP23 26 38 ZP32 41 42 MECHANICAL FAILURES A compressor is a mechanical pump driven by an electric motor contained in a welded or hermetic shell In a mechanical failure motor or electrical circuit appears normal but compressor does not function normally A WARNING Do not supply power to unit with compressor terminal box cover removed Failure to follow this warning can cause a fire personal injury or death A WARNING Exercise extreme caution when reading compressor currents when high voltage power is on Correct any of the problems described below before installing and running a replacement compressor Wear safety glasses and gloves when handling refrigerants Failure to follow this warning can cause a fire personal injury or death LOCKED ROTOR In this type of failure compressor motor and all starting components are normal When compressor at tempts to start it draws locked rotor current and cycles off on t
5. 14 Before troubleshooting compressor motor review this description of compressor motor terminal identification SINGLE PHASE MOTORS To identify terminals C S and R 1 Turn off all unit power 2 Discharge run and start capacitors to prevent shock 3 Remove all wires from motor terminals 4 Read resistance between all pairs of terminals using an ohmmeter on 0 10 ohm scale 5 Determine 2 terminals that provide greatest resistance reading Through elimination remaining terminal must be common C Greatest resistance between common C and another terminal indicates start winding because it has more turns This terminal is start S Remaining terminal will be run winding R See Fig 20 NOTE If compressor is hot allow time to cool and internal line break to reset There is an internal line break protector which must be closed NOTE Ohm readings in Fig 20 are examples not actual mea surements All compressors are equipped with internal motor protection If motor becomes hot for any reason protector opens Compressor should always be allowed to cool and protector to close before troubleshooting Always turn off all power to unit and disconnect leads at compressor terminals before taking readings Most common motor failures are due to either an open grounded or short circuit When a compressor fails to start or run 3 tests can help determine the problem First all possible external causes should be elimi
6. 8 Reinstall factory authorized accumulator into system with copper slip couplings 9 Evacuate and charge system Pour and measure oil quantity if any from old accumulator If more than 20 percent of oil charge is trapped in accumulator add new POE oil to compressor to make up for this loss See Table 4 ACCURATER AccuRater piston has a refrigerant metering hole through it The retainer forms a sealing surface for liquid line flare connection Any R 22 piston must be replaced with factory approved piston for R 410A If unit is shipped with a piston ring located in piston bag be sure it is installed per Fig 23 The piston ring will ensure the piston stays seated during all operating conditions To check clean or replace piston follow these steps See Fig 23 1 Shut off power to unit 2 Pump unit down using pumpdown procedure described in this service manual 3 Loosen nut and remove liquid line flare connection from AccuRater 4 Pull retainer out of body being careful not to scratch flare sealing surface If retainer does not pull out easily carefully use locking pliers to remove it 5 Slide piston and piston ring out by inserting a small soft wire with small kinks through metering hole Do not damage metering hole sealing surface around piston cones or fluted portion of piston 6 Clean piston refrigerant metering hole 17 7 Install a new retainer O ring or retainer assembly before reassembling Ac
7. ACCESSORY ORDERING NUMBER LOW AMBIENT LONG LINE COAST APPLICA APPLICATION APPLICATIONT TION Crankcase Heater All Sizes KAACH1201AAA YES NO Evaporator Freeze Thermostat All KAAFT0101AAA NO NO Sizes Winter Start Control All Sizes KAAWS0101AAA NO NO Compressor Start Assist PTC KAACSO201PTC OR YES NO Capacitor Relay All KSAHS0401AAA Sizes Low Ambient Controller P251 0083 RCD OR YES NO NO Sizes Wind Baffle Fig SEE LOW AMBIENT 1 AII Sizes Dus INSTRUCTIONS ne pg Coastal Filter All Sizes KAACF0201MED NO YES Magic Rau KSASF0101AAA RECOMMENDED NO RECOMMENDED Fan motor with ball bearings required T Liquid line solenoid may be required See Fig 4 ACCESSORY DESCRIPTIONS LOW AMBIENT CONTROLLER Low ambient controller is a cycle control device activated by a temperature sensor mounted on a header tube of the outdoor coil It is designed to cycle the outdoor fan motor in order to maintain condensing temperature within normal operating limits approximately 130 to 110 F high 70 to 50 F low The control will maintain working head pressure at low ambient temperatures down to 20 F when properly in stalled COMPRESSOR CRANKCASE HEATER An electric heater which mounts to base of compressor to keep lubricant warm during off cycles Improves compressor lubrication on restart and minimizes chance of refrigerant slugging May or may not include a thermostat control EVAPORATOR FREEZE THERMOSTAT A
8. 7 8 3 4 42 000 7 8 7 8 1 1 8 3 4 48 000 7 8 7 8 1 1 8 oO o 25 oi2 2 2 jo o mi o nm 1 4125 11 7 1 A 3 4 eo 60 000 1 1 8 NMN O o0 o o o o o o o o o o 7 8 1 1 8 eo Standard vapor line diameter required per outdoor unit presale literature tVapor line diameter that may be selected for a long line application If smaller vapor lines are selected but not specified within the table large capacity losses will occur and defrost capacities will be reduced If larger vapor lines are selected but not specified within the table refrigerant oil return will be impaired due to velocity losses The estimated percentage of cooling capacity that must be subtracted from Detailed Cooling Capacities specified in outdoor unit presale literature for any given indoor outdoor combination Not approved due to excessive loss of capacity TUBE SIZE OD IN OoO m o oiloj 2 ojo 2 o 2 oj ojoj nmj o o mijo oj j ro ojoj n j o j j joc oj j o ojor mnm 1 415 1 7 1 5 11 511 5 1 151 1 Table 3 Fitting Losses in Equivalent Ft 90 STD FIG 3 A 90 L R FIG 3 B 17 1 125 11 1 25 1 1 m oc o o 2 45 STD FIG 3 C 5 8 1 6 1 0 0 8 3 4 1 8 1 2 0 9 7 8 2 0 1 4
9. Reinstall top cover and position blade See Fig 7 6 Reconnect electrical power and check for proper operation Cleaning Outdoor Fan Motor and Blade 1 Remove fan motor and blade Be careful not to bend or dent fan blade 2 Clean motor and blade with soft brush or cloth Be careful not to disturb balance weights on fan blade 3 Check fan blade setscrew for tightness 4 Reinstall fan motor and blade to top cover and check for alignment 5 Reinstall top cover and position blade See Fig 7 6 Reconnect electrical power and check for proper operation Electrical Controls and Wiring 1 Disconnect power to both outdoor and indoor units 2 Check all electrical connections for tightness Tighten all screws on electrical connections If any connections appear to be burned or smokey disassemble the connection clean all parts and stripped wires and reassemble Use a new connector if old one is burned or corroded and crimp tightly 3 Reconnect electrical power to indoor and outdoor units and observe unit through 1 complete operating cycle 4 If there are any discrepancies in operating cycle troubleshoot to find the 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 22 2 If any leaks are found remove and reclaim or isolate charge pumpdown if applicable Make necessary repairs 3 Evacua
10. such as in long line applications may cause unit to relieve pressure through internal pressure relief valve indicated by sudden rise of suction pressure before suction pressure reaches 50 psig 350 Kpa If this occurs shut off unit immediately front seat suction valve and recover remaining refrigerant FILTER DRIER The filter drier is specifically designed to operate with R 410A use only factory authorized components When removing a filter drier use a tubing cutter to cut drier from system Do not unsweat a filter drier from system Heat from unsweating will release moisture and contaminants from drier into the system ACCUMULATOR The accumulator is specifically designed to operate with R 410A 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 replac ing Occasionally its internal oil return orifice or bleed hole may become plugged Some oil is contained in refrigerant returning to compressor It cannot boil off in accumulator with liquid refriger ant The bleed hole allows a small amount of oil
11. 1 1 2 pc101 Catalog No 563 817 Printed in U S A Form 38TXA 1SM Pg 26 1 96 Replaces New Tab 3a 5a 1a
12. If reading of 0 or low resistance is obtained motor is grounded Replace compressor Compressor resistance to ground should not be less than 1000 ohms per volt of operating voltage Example 230 volts X 1000 ohms volt 230 000 ohms minimum SHORT CIRCUIT To determine if any wires within windings have broken through their insulation and made contact with other wires thereby shorting all or part of the winding s be sure the following conditions are met 1 Correct motor winding resistances must be known before testing either from previous readings or from manufacturer s specifications 2 Temperature of windings must be as specified usually about 70 F 3 Resistance measuring instrument must have an accuracy within 5 10 percent This requires an accurate ohmmeter such as a Wheatstone bridge or null balance type instrument 4 Motor must be dry or free from direct contact with liquid refrigerant MAKE THIS CRITICAL TEST Not advisable unless above conditions are met 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals C S and R 4 Place instrument probes together and determine probe and lead wire resistance Check resistance readings from C R C S and R S eA 6 Subtract instrument probe and lead resistance from each reading If any reading is within 20 percent of known resistance motor is probably normal Usually a considerable difference in reading is noted if a
13. SUPPLY OPEN LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH OPEN SHORTED OR GROUNDED COMPRESSOR MOTOR WINDINGS COMPRESSOR STUCK COMPRESSOR INTERNAL PROTECTION OPEN DEFECTIVE RUN CAPACITOR COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD LOOSE LEAD AT FAN MOTOR OUTDOOR AIR RESTRICTED OR MOTOR RECIRCULATING DEFECTIVE RESTRICTED INCORRECT DISCHARGE OFM TUBE CAPACITOR OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT 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 Air Conditioner Troubleshooting Chart 25 HIGH SUCTION LOW HEAD PRESSURE DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON A90208 ATTENTION INSTALLERS AND SERVICE TECHNICIANS AIR CONDITIONER WITH R 410A QUICK REFERENCE GUIDE e R 410A refrigerant operates at 5096 7096 higher pressures than R 22 Be sure that servicing equi
14. encapsu lated in plug Therefore terminals are isolated from any moisture so corrosion and resultant pitted or discolored terminals are reduced The plug is oriented to relief slot in terminal box so cover cannot be secured if wires are not positioned in slot assuring correct electrical connection at compressor The plug can be removed by simultaneously pulling while rocking plug How ever these plugs are specialized and vary in terminal orientation Therefore plugs can be used on only specific compressor The configuration around fusite terminals is outline of terminal covers The slot through which wires of plug are routed is oriented on bottom and slightly to left The correct plug can be connected easily to compressor terminals and plug wires routed easily through slot in terminal cover LOW VOLTAGE TERMINALS The low voltage terminal designations and description function are used on all split system condensers their G Energizes indoor blower circuit R Energizes 24 v power from transformer Y Energizes contactor for cooling C Common side of transformer COPELAND SCROLL COMPRESSOR R 410A REFRIGERANT The compressor used in this product is specifically designed to operate with R 410A refrigerant and cannot be interchanged The compressor is an electrical as well as mechanical device Exercise extreme caution when working near compressors Power should be shut off if possible for most troubleshooting tech n
15. end of equalizer tube on TXV to 1 4 in fitting on adapter 8 Attach TXV bulb to horizontal section of suction line using clamps Fig 24 C See Fig 25 for proper placement of bulb and insulate with field supplied tape 9 Attach straight flare Fig 24 D to TXV Braze field supplied tubing to belled ends of liquid and vapor lines 10 Insulate liquid line between TXV assembly and coil connec tions with field supplied insulation tape to prevent sweating 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 Ib minimum 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 R 410A Nitrogen cannot however be detected by an electronic leak detector See Fig 28 18 10 O CLOCK 2 O CLOCK Pd ONE zx SUCTION TUBE 4 w 8 O CLOCK 4 O CLOCK 7 IN OD amp SMALLER LARGER THAN 7 IN OD A81032 Fig 25 Position of Sensing Bulb SENSING BULB EQUALIZER TUBE PN THERMOSTATIC EXPANSION VALVE A95616 Fig 26 Typical TXV Installation A WARNING Due to the high pressure of nitrogen it should never be used without a pressure regulator on the tank Failure to follow this warning can cause a fire
16. power to system prior to trouble shooting Some troubleshooting techniques require power to remain on In these instances exercise extreme caution to avoid danger of electrical shock ONLY TRAINED SER VICE PERSONNEL SHOULD PERFORM ELECTRICAL TROUBLESHOOTING Failure to follow this warning can cause a fire personal injury or death ALUMINUM WIRE CAUTION Aluminum wire may be used in the branch circuit such as the circuit between the main and unit disconnect but only copper wire may be used between the unit disconnect and the unit Whenever aluminum wire is used in branch circuit wiring with this unit adhere to the following recommendations OW A95508 Fig 11 Information Plate Removed Installed Below Control Box Connections must be made in accordance with the National Electrical Code NEC using connectors approved for aluminum wire The connectors must be UL approved marked Al Cu with the UL symbol for the application and wire size The wire size selected must have a current capacity not less than that of the copper wire specified and must not create a voltage drop between service panel and unit in excess of 2 percent of unit rated voltage To prepare wire before installing the connector all aluminum wire must be brush scratched and coated with a corrosion inhibiter such as Pentrox A When it is suspected that connection will be exposed to moisture it is very important to cover entire c
17. salt damage without restricting airflow SUPPORT FEET Four stick on plastic feet which raise unit 4 in above mounting pad This allows sand dirt and other debris to be flushed from unit base minimizes corrosion LOW AMBIENT GUIDELINE The recommended minimum operating temperature for this system is 55 F outdoor ambient R 410A air conditioner may be applied at ambient temperatures below 55 F when required accessories are installed See Table 1 and Fig 1 LONG LINE GUIDELINE This guideline provides the required system changes for the R 410A air conditioner having piping requirements greater than 50 ft or installations where indoor unit is located above or below outdoor unit by more than 8 ft This guide is intended to cover applications outside the standard Installation Instructions INTERCONNECTING TUBING Table 2 lists the recommended interconnecting vapor line diam eters for equivalent total line lengths The R 410A air conditioner installed in long line applications must use only 3 8 in liquid lines Equivalent line lengths equal the linear length measured of the interconnecting vapor tubing plus losses due to elbows See Table 3 and Fig 3 Liquid lines larger than 3 8 in Od will greatly increase the charge quantity of the system Excessive charge will increase risk of migration and compressor damage Table 2 provides estimated percentage of nominal cooling capacity losses based on the standard required vapor line
18. through outdoor coil to perform heat exchange Motors are totally enclosed to increase reliability This also eliminates need for rain shield For the correct position of fan blade assembly the fan hub should be flush with the motor shaft Replacement motors and blades may vary slightly A WARNING Turn off all power to unit before servicing or replacing fan motor Be sure unit main power switch is turned off Failure to do so may result in electric shock death or injury from rotating fan blade The bearings are permanently lubricated therefore no oil ports are provided For suspected electrical failures check for loose or faulty electrical connections or defective fan motor capacitor Fan motor is equipped with thermal overload device in motor windings which may open under adverse operating conditions Allow time for motor to cool so device can reset Further checking of motor can be done with an ohmmeter Set scale on R X 1 position and check for continuity between 3 leads Replace motors that show an open circuit in any of the windings Place 1 lead of ohmmeter on each motor lead At same time place other 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 compressor terminals and mating female terminals are completely
19. turn to turn short is present 15 REFRIGERATION SYSTEM REFRIGERANT 4 CAUTION This system uses refrigerant R 410A which has higher pressures than R 22 and other refrigerants No other refrig erant may be used in this system Gage set hoses and recovery system must be designed to handle R 410A If you are unsure consult the equipment manufacturer In an air conditioning system refrigerant transfers heat from one place to another It is useful to understand flow of refrigerant in a system In a straight cooling system compressed hot gas leaves compressor and enters condensing coil As gas passes through condenser coil it rejects heat and condenses into liquid The liquid leaves condensing unit through liquid line and enters metering device at indoor coil As it passes through metering device it becomes a gas liquid mixture As it passes through indoor coil it absorbs heat and the refrigerant moves to the compressor and is again compressed to a hot gas and cycle repeats COMPRESSOR OIL 4 CAUTION The compressor in this system uses a polyol ester POE oil Mobil EAL ARTIC 22CC This oil is extremely hygroscopic meaning it absorbs water readily POE oils can 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 BRAZING When brazing is required in the refrigeration system certain basics should be remembere
20. valve Therefore bulb pressure equals evaporator pres sure at outlet of coil plus spring pressure If load increases temperature increases at bulb which increases pressure on topside of diaphragm which pushes pin carrier away from seat opening valve and increasing flow of refrigerant The increased refrigerant flow causes increased leaving evaporator pressure which is transferred via equalizer tube to underside of diaphragm This tends to cause the pin carrier spring pressure to close valve The refrigerant flow is effectively stabilized to load demand with negligible change in superheat IUSTOK A95504 Fig 24 R 410A TXV Kit Components REPLACING TXV An existing R 22 TXV must be replaced with a factory approved TXV specifically designed for R 410A To replace an R 22 TXV follow these steps Remove piston retainer or existing TXV If existing piston is not removed TXV will not function properly 2 Use tubing cutter to remove flare nut from distributor 3 Braze a field fabricated tube from distributor to outside of cabinet Leave enough exposed tubing to attach supplied coupling See Fig 24 E 4 Attach coupling Fig 24 E to exposed end of tube Use silver solder 5 Attach TXV to coupling Use a backup wrench to avoid damaging tubing Follow flow arrow on valve 6 Install TXV equalizer adapter Fig 24 B on indoor coil suction line Adapter has a 1 4 in male flare connection 7 Connect free
21. 0v and 30v Contactor should pull in if voltage is correct and coil is good If contactor does not pull in replace contactor 10 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 A WARNING Capacitors can store electrical energy when power is off Electrical shock can result if you touch the capacitor termi nals and discharge the stored energy Exercise extreme caution when working near capacitors With power off discharge stored energy by shorting across the capacitor terminals with a 15 000 ohm 2 watt resistor Failure to follow this warning can cause a fire personal injury or death NOTE If bleed resistor is wired across start capacitor it must be disconnected to avoid erroneous readings when ohmmeter is applied across capacitor See Fig 13 A94006 Fig 13 Capacitor A WARNING Always check capacitors with power off Attempting to troubleshoot a capacitor with power on can be dangerous Defective capacitors may explode when power is applied Insulating fluid inside is combustible and may ignite causing burns Failure to follow this warning can cause a fire personal injury or death Capacitors are used as a phase shifting device to aid in starting certain single phase motors Check capacitors a
22. 1 0 1 1 8 2 6 177 1 3 A95451 Application Air conditioner installed in horizontal configuration A hard shut off TXV or liquid line solenoid must be installed at indoor unit A crankcase heater must be installed on compressor Vapor line should slope toward indoor unit The above requirements provide refrigerant migration protection during off cycle due to temperature or slight elevation differences between indoor and outdoor units Maximum equivalent line length is 175 ft between indoor and outdoor units Fig 4 Units Installed in a Horizontal Configuration MR M NS TRAP i 30 MAX NN GROUND LEVEL Y a ME A95452 Application Air conditioner installed below indoor unit A crankcase heater must be installed on compressor An inverted vapor line trap must be installed at indoor unit The top peak of trap must be greater than height of indoor coil The above requirements provide protection against condensed refrigerant collecting in the vapor line Maximum elevation between units is 30 ft Maximum equivalent total line length is 175 ft Fig 5 Indoor Unit Above Outdoor Unit
23. 688 160 8 106 34 1 208 72 0 310 98 4 412 119 2 514 136 4 692 161 3 108 35 1 210 72 6 312 98 9 414 119 6 516 136 7 696 161 8 110 35 5 212 73 2 314 99 3 416 119 9 518 137 0 112 36 9 214 73 8 316 99 7 418 120 3 520 137 3 Based on ALLIED SIGNAL Data 23 A95505 REQUIRED LIQUID LINE TEMPERATURE LIQUID PRESSURE REQUIRED SUBCOOLING TEMPERATURE F AT SERVICE VALVE PSIG 10 12 14 16 18 189 56 54 52 50 48 195 58 56 54 52 50 202 60 58 56 54 52 208 62 60 98 96 54 215 64 62 60 58 56 222 66 64 62 60 58 229 68 66 64 62 60 236 70 68 66 64 62 243 72 70 68 66 64 251 74 72 70 68 66 259 76 74 72 70 68 266 78 76 74 72 70 274 80 78 76 74 72 283 82 80 78 76 74 291 84 82 80 78 76 299 86 84 82 80 78 308 88 86 84 82 80 317 90 88 86 84 82 326 92 90 88 86 84 335 94 92 90 88 86 345 96 94 92 90 88 354 98 96 94 92 90 364 100 98 96 94 92 374 102 100 98 96 94 384 104 102 100 98 96 395 106 104 102 100 98 406 108 106 104 102 100 416 110 108 427 112 110 439 114 112 110 450 116 114 112 110 118 116 114 112 110 118 116 114 112 118 116 114 118 116 120 118 Subcooling Charging Table A95617 24 AIR CONDITIONER TROUBLESHOOTING CHART NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN CONTACTOR OPEN POWER SUPPLY DEFECTIVE LOW VOLTAGE TRANSFORMER OPEN THERMOSTAT CONTROL RCUIT CONTACTOR OR COIL DEFECTIVE LOOSE ELECTRICAL CONNECTION CONTACTOR CLOSED COMPRESSOR POWER
24. 85 4 358 108 8 460 127 7 584 146 7 54 45 156 54 8 258 85 9 360 109 2 462 128 0 588 147 3 56 5 9 158 55 5 260 86 4 362 109 6 464 128 3 592 147 9 58 7 3 160 562 262 86 9 364 110 0 466 128 7 596 148 4 60 8 6 162 57 0 264 87 4 366 110 4 468 129 0 600 149 0 62 10 0 164 57 7 266 87 9 368 110 8 470 129 3 604 149 5 64 11 3 166 58 4 268 88 4 370 111 2 472 129 7 608 150 1 66 12 6 168 59 0 270 88 9 372 111 6 474 130 0 612 150 6 68 13 8 170 59 8 272 89 4 374 112 0 476 130 3 616 151 2 70 15 1 172 60 5 274 89 9 376 112 4 478 130 7 620 151 7 72 16 3 174 61 1 276 90 4 378 112 6 480 131 0 624 152 3 74 17 5 176 61 8 278 90 9 380 113 1 482 131 3 628 152 8 76 18 7 178 62 5 280 91 4 382 113 5 484 131 6 632 153 4 78 19 8 180 63 1 282 91 9 384 113 9 486 132 0 636 153 9 80 21 0 182 63 8 284 92 4 386 114 3 488 132 3 640 154 5 82 22 1 184 64 5 286 92 8 388 114 7 490 132 6 644 155 0 84 232 186 65 1 288 93 3 390 115 0 492 132 9 648 155 5 86 243 188 65 8 290 93 8 392 115 5 494 133 3 652 156 1 88 25 4 190 66 4 292 94 3 394 115 8 496 133 6 656 156 6 90 26 4 192 67 0 294 94 8 396 116 2 498 133 9 660 157 1 92 27 4 194 67 7 296 95 2 398 116 6 500 134 0 664 157 7 94 28 5 196 68 3 298 95 7 400 117 0 502 134 5 668 158 2 96 29 5 198 68 9 300 96 2 402 117 3 504 134 8 672 158 7 98 30 5 200 69 5 302 96 6 404 117 7 506 135 2 676 159 2 100 31 2 202 70 1 304 97 1 406 118 1 508 135 5 680 159 8 102 322 204 70 7 306 97 5 408 118 5 510 135 8 684 160 3 104 332 206 71 4 308 98 0 410 118 8 512 136 1
25. Because no refrigerant is being pumped there is no return gas to cool compressor motor It eventually overheats and shuts off on its internal protection NOISY COMPRESSOR Noise may be caused by a variety of internal or external problems such as loosened hardware System problems such as an overcharged compressor especially at start up may also cause excessive noise COMPRESSOR LEAKS Sometimes a leak is detected at weld seam around girth of compressor or at a fitting that joins compressor shell Many of these leaks can be repaired and the compressor saved if correct procedure is followed 1 Turn off all power to unit 2 Remove and recover all refrigerant from system so that gage pressures are 0 psi 3 Clean area around leak to bare metal 4 Apply flux and repair joint with silver brazing alloy 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 abnormali ties
26. across leads with ohmmeter Do not look for a specific resistance reading Check for resistance or an open circuit Change heater if an open circuit is detected TIME DELAY RELAY The TDR is a solid state control recycle delay timer which keeps the indoor blower operating for 90 sec after thermostat is satisfied This delay enables blower to remove residual cooling in coil after compression shutdown thereby improving efficiency of system The sequence of operation is that on closure of wall thermostat and at end of a fixed on delay of 1 sec fan relay is energized When thermostat is satisfied an off delay is initiated When fixed delay of 90 20 sec is completed fan relay is de energized and fan motor stops If wall thermostat closes during this delay TDR is reset and fan relay remains energized The TDR is a 24 v device that operates within a range of 15v to 30v and draws about 0 5 amps If the blower runs continuously instead of cycling off when fan switch is set on AUTO TDR is probably defective and must be replaced 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 The low and high pressure switches are specifically designed to operate with R 410A systems R 22 pressure switches must not be used as replacements for the R 410A air conditioner R 410A pressure switches are ident
27. actor through crankcase heater through run windings of compressor and to other side of line When contacts are closed there is no circuit through crankcase heater because both leads are connected to same side of line This allows heater to operate when system is not calling for cooling The heater does not operate when system is calling for cooling The crankcase heater is powered by high voltage power of unit Use extreme caution troubleshooting this device with power on The easiest method of troubleshooting is to apply voltmeter across crankcase heater leads to see if heater has power Do not touch heater Carefully feel area around crankcase heater If warm crankcase heater is probably functioning Do not rely on this method as absolute evidence heater is functioning If compressor has been running the area will still be warm 3 OPERATING SA SEC a TIME ee dee EM T2 BLK DENOTES CLOSED CONTACTS HN67ZA008 A94009 Fig 16 Cycle Protector Sequence CUT YELLOW WIRE BETWEEN CONTACTOR AND LOW PRESSURE SWITCH LA LA SAFETY 7 x zT ve CONTE YEL ve XcX BRN C TERMINAL YEL VIO TERMINAL BOARD BOARD CONNECTION CONNECTION u LOGIC T3 BLK IE T2 A88415 Fig 17 Cycle Protector Wiring CH caused by such events as loss of charge low airflow across indoor A94008 Fig 18 Wiring for Single Pole Contactor With power off and heater leads disconnected check
28. ance that should be performed on this equipment is as follows 1 Check outdoor coil for cleanliness each month during cooling season and clean as necessary 2 Check fan motor and blade for cleanliness each heating and cooling season and clean as necessary 3 Check electrical connections for tightness and controls for proper operation each cooling season and service as necessary 4 CAUTION Because of possible damage to the equipment or personal injury maintenance should be performed by qualified person nel only CLEANING Cleaning Coil 1 Remove top cover See Remove Top Cover in Cabinet section of this manual CAUTION Coil fin damage can result in higher operating costs or compressor damage Do not use flame high pressure water steam volatile or corrosive cleaners on fins or tubing 2 Clean coil using vacuum cleaner and its crevice tool Move crevice tool vertically close to area being cleaned making sure tool touches only dirt on fins and not fins To prevent fin damage do not scrub fins with tool or move tool horizontally against fins 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
29. and refrigerant to enter the return line where velocity of refrigerant returns it to compressor If bleed hole plugs oil is trapped in accumulator and compressor will eventually fail from lack of lubrication If bleed hole is plugged accumulator must be changed The accumulator has a fusible element located in the bottom end bell See Fig 22 This fusible element will melt at 430 F 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 Remove and reclaim all refrigerant from system 3 Break vacuum with dry nitrogen Do not exceed 5 psig NOTE Coil may be removed for access to accumulator Refer to appropriate sections of Service Manual for instructions es 430 FUSE ELEMENT A88410 Fig 22 Accumulator A WARNING Wear safety glasses and gloves when working on refrigerants and when using brazing torch Failure to follow this warning can cause a fire personal injury or death 4 When accumulator is exposed remove it from system with tubing cutter 5 Tape ends of open tubing 6 Scratch matching marks on tubing stubs 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
30. by preventing short cycling After a system shutdown cycle protector provides for a 5 2 minute delay before compressor restarts On normal start up a 5 minute delay occurs before thermostat closes After thermostat closes cycle protector device provides a 3 sec delay See Fig 15 16 and 17 Cycle protector is simple to troubleshoot Only a voltmeter capable of reading 24v is needed Device is in control circuit therefore troubleshooting is safe with control power 24v on and high voltage power off With high voltage power off attach voltmeter leads across T1 and T3 and set thermostat so that Y terminal is energized Make sure all protective devices in series with Y terminal are closed Voltmeter should read 24v across T1 and T3 With 24v still applied move voltmeter leads to T2 and T3 After 5 2 minutes voltmeter should read 24v indicating control is functioning normally If no time delay is encountered or device never times out change control 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 the contactor contacts and in series with the compressor See Fig 18 When contacts open a circuit is completed from line side of the cont
31. cuRater PISTON RETAINER PISTON PISTON a 6 PISTON 7 BODY B P d P dl d P d BA CONNECTION A STRAINER XS a FLARE A ADAPTOR LIQUID LINE STRAINER APPROX 2 LONG STRAINER LABEL AFFIX TO LIQ LINE NEAR STRAINER LOCATION A95615 Fig 23 AccuRater Components THERMOSTATIC EXPANSION VALVE TXV The thermostatic expansion valve is specifically designed to operate with R 410A Do not use an R 22 TXV HARD SHUT OFF HSO Has no bleed port and allows no bleed through after system shutdown No pressure equalization occurs The standard TXV is a metering device that is used in air conditioning systems to adjust to changing load conditions by maintaining a preset superheat temperature at the outlet of evapo rator coil The volume of refrigerant metered through valve seat is dependent upon the following See Fig 26 1 Superheat temperature sensed by cap tube sensing bulb on suction tube at outlet of evaporator coil As long as this bulb and cap tube contains some liquid refrigerant this temperature is converted into suction pressure pushing downward on diaphragm which tends to open valve via pushrods 2 The suction pressure at outlet of evaporator coil is transferred via external equalizer tube to underside of diaphragm 3 The needle valve on pin carrier is spring loaded which exerts pressure on underside of diaphragm via pushrods and tends to close
32. d The following are a few of the basic rules 1 Clean joints make the best joints To clean a Remove all oxidation from surfaces to a shiny finish before brazing b Remove all flux residue with brush and water while material is still hot 2 Use sil fos or phos copper for copper to copper only No flux is required 3 Silver solder is used on copper to brass copper to steel or copper to copper Flux is required when using silver solder Low temperature solder is not recommended 4 Fluxes should be used carefully Avoid excessive application and do not allow fluxes to enter into the system 5 Brazing temperature of copper is proper when it is heated to a dull red color This section on brazing is not intended to teach a technician how to braze There are books and classes which teach and refine brazing techniques The basic points above are listed only as a reminder SERVICE VALVES AND PUMPDOWN Service valves provide a means for holding original factory charge in outdoor unit prior to hookup to indoor coil They also contain gage ports for measuring system pressures and provide shut off convenience for certain types of repairs See Fig 21 The service valve is a combination front seating back seating valve which has a metal to metal seat in both the open and closed positions When it is fully back seated the service port is not STAINLESS SEE NL STEM
33. e and temperature changes are slower with long lines Adding or removing charge must be done slowly to allow time for system to stabilize 7 32 x 3 8 5 56 x 9 53 SLOT L d 4 REQ D 9 54 3 45 DIA HOLE S 2 REQ D 1712 3 8 6 146 9 6 J 154 0 TYP Ft Le G EL c nl 1 2 12 7 SUPPORT TP MAT L 18 GA STEEL c I The 11 6 TYP E 9 64 3 45 DIA HOLE 1 REQ D K B The J __ 0116 u TYP 7 32 5 56 DIA HOLE Z REQ D e a j M gt 114 A 6 3 6 3 L TYP TYP ae D 10 REQ D 1 _ BAFFLE SCREW MAT L 20 GA STEEL Tigo X 2 5 56 x 50 8 SLOT SUPPORT 7 4 REQ D t OUTDOOR n BAFFLE UNIT 2 REQ D BAFFLE ASSEMBLY A95444 DIMENSIONS AA A B D E F G H K L M Unit Size Unit Height In In In In In In In In In In In TECH2000 23 13 16 17 25 1 4 10 3 8 19 3 4 20 1 2 34 19 11 16 20 7 16 0 0 6 1 8 Small 27 1 2 27 13 16 17 25 1 4 10 3 8 23 3 4 24 1 2 34 23 11 16 24 7 16 0 11 7 8 6 1 8 33 13 16 17 25 1 4 103 8 29 3 4 30 1 2 34 29 11 16 30 7 16 0 14 7 8 6 1 8 27 13 16 21 32 11 3 16 23 3 4 24 1 2 42 23 11 16 24 7 16 19 11 16 11 7 8 6 11 16 InVir
34. e factory authorized kits or accessories when modifying this product Troubleshooting Chart for the R 410A Air Conditioner is provided in appendix at back of this manual It will enable the service technician to use a systematic approach to locating the cause of a problem and correcting system malfunctions UNIT IDENTIFICATION This section explains how to obtain model and serial number from unit rating plate These numbers are needed to service and repair the R 410A air conditioner MODEL NUMBER NOMENCLATURE Model number is found on unit rating plate See Fig 7 and 8 SERIAL NUMBER NOMENCLATURE Serial number is found on unit rating plate See Fig 7 and 9 38TXA Electric Air Conditioner Nominal Capacity 024 24 000 Btuh 042 42 000 Btuh 030 30 000 Btuh 048 48 000 Btuh 036 36 000 Btuh 060 60 000 Btuh 4 Disconnect fan motor wires and cut wire ties Remove wires from control box Refer to unit wiring label 5 Remove screws holding top cover to coil grille and corner posts 6 Lift top cover from unit 7 Reverse sequence for reassembly REMOVE FAN MOTOR ASSEMBLY 1 Perform items 1 through 6 from above 2 Remove nuts securing fan motor to top cover 3 Remove motor and fan blade assembly 4 Reverse sequence for reassembly 5 Prior to applying power check that fan rotates freely INFORMATION PLATE The information plate is secured to front of control box and provides the contr
35. e removed and hoses of gage manifold connected In this position refrigerant has access from and through outdoor and indoor unit The service valve stem cap is tightened to 20 ft Ib torque and service port caps to 9 2 ft lb torque The seating surface of valve stem has a knife set edge against which caps are tightened to attain a metal to metal seal The service valve cannot be field repaired therefore only a complete valve or valve stem and service port caps are available for replacement 16 If service valve is to be replaced a metal barrier must be inserted between valve and unit to prevent damaging unit exterior from heat of the brazing operations A WARNING Wear safety glasses and gloves when handling refrigerants Failure to follow this warning can cause a fire personal injury or death PUMPDOWN PROCEDURE Service valves provide a conve nient shut off valve useful for certain refrigeration system repairs System may be pumped down to make repairs on low side without losing complete refrigerant charge 1 Attach pressure gage to suction service valve gage port 2 Front seat liquid line valve 3 Start unit in cooling mode Run until low pressure switch opens at 50 psig 350kPa Do not allow compressor to pump to a vacuum 4 Shut off unit Front seat suction valve 5 Recover remaining refrigerant NOTE All outdoor unit coils will hold only factory supplied amount of refrigerant Excess refrigerant
36. em must be charged correctly for normal system operation and reliable operation of components If system has lost all charge weigh in charge using dial a charge designed for R 410A refrigerant or digital scale System charge should be fine tuned by using superheat method CHARGE ACCURATELY Undercharge Proper Charge Overcharge LOW LOW SIDE LONG LIFE HIGH HIGH SIDE PRESSURE SAFE PRESSURE HIGH OPERATION HIGH DISCHARGE SUPERHEAT DESIGN TEMPERATURE OVERHEATED CAPACITY FLOODBACK a AND PEAK LOW SYSTEM EFFICIENCY CAPACITY LOW SYSTEM POOR EFFICIENCY CAPACITY NR CIENG POOR EFFICIENCY CARBONIZATION SLUDGE CARBONIZATION Fig 32 Charging CHECKING CHARGE Superheat charging is the process of charging refrigerant in a system until temperature superheat of suction gas entering compressor reaches a prescribed value Small variations of charge affect suction gas superheat temperatures greatly Therefore this method of charging is very accurate This method can be used with fixed restrictor type metering devices such as AccuRater For units using a TXV subcooling method must be used To charge by superheat a service technician will need an accurate superheat thermocouple or thermistor type thermometer a sling psychrom 21 eter and a gage manifold Do not use mercury or small dial type thermometers as they are not adequate for this type of measure ment Refer to unit information plate for supe
37. g Tubing SECTION 3 APPENDIX 7c e 23 26 Metering Device Tubing Configuration PRESSURE vs TEMPERATURE CHART FOR R 410A Charging Information SUBCOOLING CHARGING TABLE SECTION 2 SERVICE MANUAL 8 22 TROUBLESHOOTING CHART QUICK REFERENCE GUIDE Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book 1 1 2 pc 101 Catalog No 563 817 Printed in U S A Form 38TXA 1SM Pg 1 1 96 Replaces New Tab 3a 5a 1a SECTION 1 APPLICATION GUIDELINE INSTALLATION GUIDELINE RESIDENTIAL NEW CONSTRUCTION Specifications for this unit in the residential new construction market require the outdoor unit indoor unit refrigerant tubing sets metering device and filter drier listed in Product Data Digest PDD There can be no deviation Consult unit Installation Instructions for detailed information ADD ON REPLACEMENT RETROFIT Specifications for this unit in the add on replacement retrofit market require change out of outdoor unit metering device and all capillary tube coils Change out of indoor coil is recommended There can be no deviation l If system is being replaced due to compressor electrical failure assume acid is in system If system is being replaced for any other reason use approved acid test kit to determine acid level If even low levels of acid are detected install factory approved 100 activated a
38. he internal protection Locked rotor current is measured by applying e 72 EXAMPLE e 9 e POWER OFF DEDUCTION O MER OO 9 O Og TO DETERMINE INTERNAL CONNECTIONS OF SINGLE PHASE MOTORS C S R EXCEPT SHADED POLE GREATEST RESISTANCE 5 80 OHM SMALLEST RESISTANCE 0 60 REMAINING RESISTANCE 5 20 RUN WINDING R START WINDING S 2 is COMMON C BY ELIMINATION 2 is COMMON THEREFORE 0 IS START WINDING S 3 IS RUN WINDING R A88344 Fig 20 Identifying Internal Connections a clamp on ammeter around common bIk lead of compressor Current drawn when it attempts to start is then measured Locked rotor amp LRA value is stamped on compressor nameplate If compressor draws locked rotor amps and all other external sources of problems have been eliminated compressor must be replaced Because compressor is a sealed unit it is impossible to determine exact mechanical failure However complete system should be checked for abnormalities such as incorrect refrigerant charge restrictions insufficient airflow across indoor or outdoor coil etc which could be contributing to the failure RUNS DOES NOT PUMP In this type of failure compressor motor runs and turns compressor but compressor does not pump refrigerant A clamp on ammeter on common leg shows a very low current draw much lower than rated load amp RLA value stamped on compressor nameplate
39. ified by a pink stripe down each wire LOW PRESSURE SWITCH The low pressure switch is lo cated on suction line and protects against low suction pressures 12 coil dirty filters etc It opens on a pressure drop at about 50 psig If system pressure is above this switch should be closed HIGH PRESSURE SWITCH The high pressure switch is lo cated in liquid line and protects against excessive condenser coil pressure It opens at 610 psig High pressure may be caused by a dirty condenser coil failed fan motor or condenser air recircula tion To check switch turn off all power to unit disconnect leads on switch and apply ohmmeter leads across switch You should have continuity on a good switch Because these switches are attached to refrigeration system under pressure it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists If switch must be removed remove and recover all system charge so that pressure gages read 0 psi Never open system without breaking vacuum with dry nitrogen A WARNING Wear safety glasses and gloves when working with refriger ants Apply heat with torch to solder joint and remove switch Wear safety glasses when using torch Have quenching cloth available Oil vapor in line may ignite when switch is removed Braze in 1 4 in flare fitting and replace pressure switch FAN MOTOR Fan motor rotates fan blade that either draws or blows air
40. iques Refrigerants present additional safety hazards A WARNING Wear safety glasses and gloves when handling refrigerants Failure to follow this warning can cause a fire personal injury or death The scroll compressor pumps refrigerant through the system by the interaction of a stationary and an orbiting scroll See Fig 19 The scroll compressor has no dynamic suction or discharge valves and it is more tolerant of stresses caused by debris liquid slugging and flooded starts The compressor is equipped with an anti rotational device and an internal pressure relief port The anti rotational device prevents the scroll from turning backwards and replaces the need for a cycle protector The pressure relief port is a safety device designed to protect against extreme high pressure The relief port has an operating range between 550 and 625 psi differential pressure The Copeland scroll compressor uses Mobil EAL ARTIC 22CC the only oil recommended for oil recharge See Table 4 COMPRESSOR FAILURES Compressor failures are classified in 2 broad failure categories mechanical and electrical Both types are discussed below 13 Scroll Gas Flow Compression in the scroll is created by the interaction of an orbiting spiral and a stationary spiral Gas enters an outer opening as one of the spirals orbits SIAN N Ww 0 m As the spiral continues to orbit the gas is compressed into an increasingly smaller pocket
41. ive Follow these steps 1 TXV must be cleaned or replaced 2 Drain any trapped oil from accumulator if used 20 3 Remove and discard liquid line strainer and filter drier 4 After system is reassembled install liquid and suction line R 410A filter driers 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 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 5000 4500 4000 3500 3000 2500 2000 1500 1000 LEAK IN SYSTEM MICRONS VACUUM TIGHT TOO WET TIGHT 500 DRY SYSTEM 0 1 2 3 4 5 6 7 MINUTES A95424 Fig 30 Deep Vacuum Graph EVACUATION Proper evacuation of a unit 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 re quires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth The deep vacuum method is the most positive way of assuring a sys
42. lectronic Leak Detection LEAK DETECTOR SOLUTION A95423 Fig 29 Bubble Leak Detection plain soapy water The bubble solution should be removed from the tubing and fittings after checking for leaks as some solutions may corrode the metal 19 Use an electronic leak detector designed for HFCs to check for leaks This unquestionably is the most efficient and easiest method for checking leaks There are various types of electronic leak detectors Electronic leak detectors must be suitable for R 410A refrigerant Check with manufacturer of equipment for suitability Generally speaking they are portable lightweight and consist of a box with several switches and a probe or sniffer Detector is turned on and probe is passed around all fittings and connections in system Leak is detected by either the movement of a pointer on detector dial a buzzing sound or a light In all instances when a leak is found system charge must be recovered and leak repaired before final charging and operation After leak testing or leak is repaired evacuate system reclaiming refrigerant and recharge with correct refrigerant charge COIL REMOVAL Coils are easy to remove if required for compressor removal or to replace coil Shut off all power to unit Remove and recover refrigerant from system through service valves 1 Remove top cover See Remove Top Cover in Cabinet section of the manual 2 Remove screws in base pan to coil grille 3 Remo
43. lumina suction line filter drier in addition to the factory supplied liquid line filter drier 2 Drain oil from low points or traps in suction line and evaporator if they were not replaced 3 Change out indoor coil or verify existing coil is listed in the PDD 4 Change out metering device to factory supplied device spe cifically designed for R 410A 5 Replace outdoor unit with R 410A outdoor unit 6 Install factory supplied liquid line filter drier A WARNING Never install a suction line filter drier in the liquid line of an R 410A system Failure to follow this warning can cause a fire personal injury or death 7 If suction line filter drier was installed for system clean up operate system for 10 hr Monitor pressure drop across drier If pressure drop exceeds 3 psig replace suction line and liquid line filter driers Be sure to purge system with dry nitrogen when replacing filter driers Continue to monitor pressure drop across suction line filter drier After 10 hr of run time remove suction line filter drier and replace liquid line filter drier Never leave suction line filter drier in system longer than 72 hr actual time 8 Charge system See unit information plate SEACOAST Installation of these units in seacoast locations requires the use of a coastal filter See section on cleaning Table 1 Required Field Installed Accessories REQUIRED FOR REQUIRED FOR REQUIRED FOR SEA
44. n SPST tempera ture activated switch stops unit operation when evaporator reaches freeze up conditions WINTER START CONTROL An SPST delay relay which bypasses the low pressure switch for approximately 3 minutes to permit start up for cooling operation under low load conditions WIND BAFFLE A field fabricated sheet metal cover used to stop prevailing winds or where outdoor ambient temperature is less than O F during unit operation COMPRESSOR START ASSIST PTC Solid state electrical device which gives a soft boost to the compressor at each start MOTOR MASTER CONTROL A fan speed control device activated by a temperature sensor Designed to control condenser fan motor speed in response to the saturated condensing tempera ture during operation in cooling mode only For outdoor tempera ture down to 20 F it maintains condensing temperature at 100 F 10 F COMPRESSOR START ASSIST CAPACITOR RELAY Start capacitor and start relay gives hard boost to compressor motor at each start LIQUID LINE SOLENOID An electrically operated shut off valve to be installed at outdoor or indoor unit depending on tubing configuration and which stops and starts refrigerant liquid flow in response to compressor operation Maintains a column of refrig erant liquid ready for action at next compressor operation cycle COASTAL FILTER A mesh screen inserted under top cover and inside base pan to protect condenser coil from
45. nated such as overloads improper voltage pres sure equalization defective capacitor s relays wiring etc Com pressor has internal line break overload so be certain it is closed OPEN CIRCUIT To determine if any winding has a break in the internal wires and current is unable to pass through follow these steps 1 Be sure all power is off 2 Discharge all 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 replaced CAUTION Be sure internal line break overload is not temporarily open GROUND CIRCUIT To determine if a wire has broken or come in direct contact with shell causing a direct short to ground follow these steps 1 Allow crankcase heaters to remain on for several hr before checking motor to ensure windings are not saturated with refrigerant 2 Using an ohmmeter on R X 10 000 ohm scale or megohmme ter follow manufacturer s instructions Be sure all power is off Discharge all capacitors Remove wires from terminals C S and R 9 RO 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
46. njury During normal system operation some components are hot and can cause COPELAND SCROLL COMPRESSOR 13 burns Rotating fan blades can cause personal injury Appropriate Mechanical Failure safety considerations are posted throughout this manual where Electrical Failure potentially dangerous techniques are addressed REFRIGERATION SYSTEM 1 15 INTRODUCTION Refrigerant Section 1 of this Application Guideline and Service Manual Compressor Oil provides the required system information necessary to install the Brazing R 410A air conditioner in all applications Section 2 provides the Service Valves and Pumpdown necessary information to service repair and maintain the family of Filter Drier R 410A air conditioners Section 3 of this manual is an appendix Accumulator Use table of contents to locate desired topic AccuRater Thermostatic Expansion Valve TXV TABLE OF CONTENTS Page REFRIGERATION SYSTEM REPAIR 19 SECTION 1 APPLICATION GUIDELINE 2 7 Leak Detection Coil Removal INSTALLATION GUIDELINE Compressor Removal and Replacement Residential New Construction System Clean Up After Burnout Add On Replacement Retrofit Evacuation Desert or Seacoast R 410A Refrigerant Charging REQUIRED FIELD INSTALLED ACCESSORIES Checking Charge ACCESSORY DESCRIPTIONS CARE AND MAINTENANCE enne 21 LOW AMBIENT GUIDELINE Cleaning LONG LINE GUIDELINE Desert and Seacoast Locations Interconnectin
47. oFlow Top Medium 34 15 16 33 13 16 21 32 11 3 16 29 3 4 30 1 2 42 29 11 16 30 7 16 19 11 16 14 7 8 6 11 16 39 13 16 21 32 11 3 16 35 3 4 36 1 2 42 35 11 16 36 7 16 19 11 16 17 7 8 6 11 16 Large 45 3313 16 253 16 42 12 15 16 29 3 4 30 1 2 50 7 16 29 11 16 30 7 16 22 11 16 14 7 8 7 1 16 3913 16 253 16 42 12 15 16 35 3 4 36 1 2 50 7 16 35 11 16 36 7 16 22 11 16 17 7 8 7 1 16 Fig 1 Wind Baffle Construction Dimensions NOTE Avoid contact between tubing and structure OUTDOOR WALL CAULK INDOOR WALL F LIQUID TUBE 3 amp 1 Wh INSULATION t VAPOR TUBE THROUGH THE WALL AROUND VAPOR TUBE ONLY 09 HANGER OR N 0 O O INSULATION VAPOR TUBE 6 3 1 MIN LIQUID TUBE SUSPENSION A94028 Fig 2 Tubing Support 90 STD 90 LONG RAD ke HE 45 STD A92498 Fig 3 Tube Bend Losses Table 2 Estimated Percentage of Nominal Cooling Capacity Losses UNIT NOMINAL SIZE BTU STANDARD VAPOR 11351 IN LONG LINE VAPOR PERCENTAGE OF COOLING CAPACITY LOSS BTU VERSUS EQUIVALENT LENGTH LINE IN 25 Ft 50 Ft 75 Ft 100 Ft 125 Ft 150 Ft 175 Ft 5 8 4 6 N 24 000 5 8 3 4 7 8 5 8 30 000 3 4 3 4 7 8 ESENIN ERSS 5 8 36 000 3 4 3 4
48. ol box cover See Fig 10 This plate also provides a surface to attach the wiring schematic superheat charging tables with instructions and warning labels The plate has 2 tabs on top edge that are bent down at slightly more than 90 When information plate is removed these tabs can be inserted into 2 mating slots in bottom front edge of control box and plate will 0 1 0 Model 1 Packaging Series Electrical 3 208 230 1 Fig 8 Model Number Nomenclature 01 96 Week of Manufacture Year of Manufacture A95405 00001 Serial Number Manufacturing Site A95406 Fig 9 Serial Number Nomenclature CABINET ASSEMBLY Certain maintenance routines and repairs require removal of cabinet panels See Fig 7 REMOVE TOP COVER 1 Turn off all power to outdoor and indoor units 2 Remove access panel 3 Remove information plate hang down forming a lower front panel See Fig 11 This is convenient when access to controls is required while unit is operating The information plate on small size casing completely covers opening below control box On larger models information plate may not cover entire opening In this instance top cover can be removed and placed on its side to cover additional space A95506 Fig 10 Information Plate f i A95507 ELECTRICAL A WARNING Exercise extreme caution when working on any electrical components Shut off all
49. onnection 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 See Fig 12 Depending on unit model you may encounter single or double pole contactors to break power Exercise extreme caution when troubleshooting as 1 side of line may be electrically energized A88350 Fig 12 Contactor The contactor coil is powered by 24vac If contactor does not operate 1 With power off check whether contacts are free to move Check for severe burning or arcing on contact points 2 With power off use ohmmeter to check for continuity of coil Disconnect leads before checking A low resistance reading is normal Do not look for a specific value as different part numbers will have different resistance values 3 Reconnect leads and apply low voltage power to contactor coil This may be done by leaving high voltage power to outdoor unit off and turning thermostat to cooling Check voltage at coil with voltmeter Reading should be between 2
50. ot use brazing torch for compressor removal Oil vapor may ignite when compressor is disconnected 5 Scratch matching marks on stubs in old compressor Make corresponding marks on replacement compressor 6 Use torch to remove stubs from old compressor and to reinstall them in replacement compressor 7 Use copper couplings to tie compressor back into system 8 Replace filter drier evacuate system recharge and check for normal system operation A CAUTION Do not leave system open to atmosphere Product damage could occur 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 byproducts of burn 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 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 posit
51. personal injury or death Assuming that a system is pressurized with either all refrigerant or a mixture of nitrogen and refrigerant leaks in the system can be found with an electronic leak detector that is capable of detecting HFC refrigerant If system has been operating for some time make first check for a leak visually Since refrigerant carries a small quantity of oil traces of oil at any joint or connection is an indication that refrigerant is leaking at that point A simple and inexpensive method of testing for leaks is to use soap bubbles Any solution of water and soap may be used Soap solution is applied to all joints and connections in system A small pinhole leak is located by tracing bubbles in soap solution around leak 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 CAPILLARY TUBE DIAPHRAGM m lt m PUSHRODS ZF FEEDER TUBES SZ INLET A gt OUTLET 5 LMA COIL A NEEDLE VALVE SPRING HE m DISTRIBUTOR s BULB EXTERNAL EQUALIZER TUBE A94056 Fig 27 TXV Operation Cay 3 A95422 Fig 28 E
52. pment and replacement components are designed to operate with R 410A R 410A refrigerant cylinders are rose colored e R 410A refrigerant cylinders have a dip tube which allows liquid to flow out of cylinder in upright position R 410A systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose R 410A as with other HFCs is only compatible with POE oils e 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 install a suction line filter drier in liquid line POE oils absorb moisture rapidly Do not expose oil to atmosphere Wrap all filter driers and service valves with wet cloth when brazing A liquid line filter drier is required on every unit Do not use an R 22 TXV If indoor unit is equipped with a TXV it must be changed to an R 410A TXV Never open system to atmosphere while it is under a vacuum e When system must be opened for service break vacuum with dry nitrogen and replace filter driers Do not vent R 410A into the atmosphere Observe all warnings cautions and bold text Do not use capillary tube indoor coils Copyright 1995 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 38txalsm ooo Manufacturer reserves the right to discontinue or change at any time specifications or designs without notice and without incurring obligations Book
53. r thermistor See Fig 14 It is a resistor wired in parallel with the run capacitor As current flows through the PTC at start up it heats up As PTC heats up its resistance increases greatly until it effectively lowers the current through itself to an extremely low value This in effect removes the PTC from the circuit Capacitance mfd 12 5 22 5 OHMS 12 5 OHM BEIGE COLOR A94007 Fig 14 PTC Device 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 as shown in Fig 14 The cold resistance RT of any PTC device should be approxi mately 100 180 percent of device ohm rating 12 5 ohm PTC 12 5 22 5 ohm resistance beige color HN67ZA008 A94005 Fig 15 Cycle Protector Device If PTC resistance is appreciably less than rating or more than 200 percent higher than rating device is defective CYCLE PROTECTOR Solid state cycle protector protects unit compressor
54. rgized and pressure is applied in the direction of the flow arrow complete shutoff will occur If a piston is used and total equivalent horizontal length is 100 ft or longer indoor piston must be increased 1 full size No piston changes are required for the allowable 30 ft vertical elevation A TXV may be used instead of a piston for an indoor metering device When sizing an accessory TXV refer to unit presale literature TUBING CONFIGURATION Fig 4 through 6 will detail the proper installation of equipment and provide applications where accessories may be required Reference all notes of appropriate fig CHARGING INFORMATION Use superheat charging method for ACCURATER pistons Use subcooling charging method for TXV applications The standard charging methods can be found in refrigerant system charging section of the Service Manual Since total system charge is increased for long line application it is necessary to calculate additional refrigerant charge The rating plate charge of a given outdoor unit is for a standard application of 15 ft of interconnect ing tubing For line lengths greater than 15 ft add 0 50 oz of refrigerant per foot of additional line length The rating plate charge can be found on outdoor unit rating plate or in outdoor unit presale literature Long line applications do not require additional oil charge NOTE Charging units with long refrigerant lines must be done carefully to avoid over charging Pressur
55. rheat charging procedure SUBCOOLING CHARGING METHOD SEE CHARGING TABLE IN APPENDIX 1 Operate unit a minimum of 15 minutes before checking charge 2 Measure liquid service valve pressure by attaching an accurate gage to service port 3 Measure liquid line temperature by attaching an accurate thermistor type or electronic thermometer to liquid line near outdoor coil 4 Refer to unit information plate to find required subcooling temperature for unit Find point at which the required sub cooling temperature intersects measured liquid service valve pressure 5 To obtain required subcooling temperature at a specific liquid line pressure add refrigerant if liquid line temperature is higher than indicated or remove refrigerant if temperature is lower Allow a tolerance of 3 F CARE AND MAINTENANCE To assure high performance and minimize possible equipment malfunction it is essential that maintenance be performed periodi cally on this equipment The frequency with which maintenance is performed is dependent on such factors as hours of operation geographic location and local environmental conditions A WARNING Disconnect all electrical power to unit before performing any maintenance or service on outdoor unit Remember to dis connect power supply to air handler as this unit supplies low voltage power to the outdoor unit Failure to follow this warning can cause a fire personal injury or death The minimum mainten
56. s follows 1 With power off discharge capacitors as outlined above Disconnect capacitor from circuit Put ohmmeter on R X 10k scale Using ohmmeter check each terminal to ground use capacitor case Discard any capacitor which measures 1 2 scale deflection or less Place ohmmeter leads across capacitor and place on R X 10k scale Meter should jump to a low resistance value and slowly climb to higher 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 A WARNING Exercise extreme caution when taking readings while power is on Electrical shock can cause personal injury or death Use following formula to calculate capacitance X amps volts 3 Remove any capacitor that shows signs of bulging dents or leaking Do not apply power to a defective capacitor as it may explode PTC DEVICES Sometimes under adverse conditions a standard run capacitor in a system is inadequate to start compressor In these instances a start assist device is used to provide an extra starting boost to compres sor motor This device is called a positive temperature coefficient PTC o
57. sary 3 In off season cover with covering that allows air to circulate through but prevents sand from sifting in such as canvas material Do not use plastic because plastic will hold mois ture SECTION 3 APPENDIX Pressure vs Temperature Chart R 410A PSIG F PSIG F PSIG F PSIG F PSIG F PSIG F 12 37 7 114 37 8 216 74 3 318 100 2 420 120 7 522 137 6 14 34 7 116 38 7 218 74 9 320 100 7 422 121 0 524 137 9 16 32 0 118 39 5 220 75 5 322 101 1 424 121 4 526 138 3 18 29 4 120 40 5 222 76 1 324 101 6 426 121 7 528 138 6 20 36 9 122 41 3 224 76 7 326 102 0 428 122 1 530 138 9 22 24 5 124 422 226 77 2 328 102 4 430 122 5 532 139 2 24 22 2 126 43 0 228 77 8 330 102 9 432 122 8 534 139 5 26 20 0 128 43 8 230 78 4 332 103 3 434 123 2 536 139 8 28 17 9 130 44 7 232 78 9 334 103 7 436 123 5 538 140 1 30 15 8 132 45 5 234 79 5 336 104 2 438 123 9 540 140 4 32 13 8 134 46 3 236 80 0 338 104 6 440 124 2 544 141 0 34 11 9 136 47 1 238 80 6 340 105 1 442 124 6 548 141 6 36 10 1 138 47 9 240 81 1 342 105 4 444 124 9 552 142 1 38 8 3 140 48 7 242 81 6 344 105 8 446 125 3 556 142 7 40 6 5 142 49 5 244 82 2 346 106 3 448 125 6 560 143 3 42 4 5 144 50 3 246 82 7 348 106 6 450 126 0 564 143 9 44 3 2 146 51 1 248 83 3 350 107 1 452 126 3 568 144 5 46 1 6 148 51 8 250 83 8 352 107 5 454 126 6 572 145 0 48 0 0 150 52 5 252 84 3 354 107 9 456 127 0 576 145 6 50 1 5 152 533 254 84 8 356 108 3 458 127 3 580 146 2 52 30 154 54 0 256
58. size versus what is selected for the long line application Refer to the outdoor unit PDD to find the standard recommended vapor line diameter Calculate the linear length of vapor tube required adding any losses for the total number of elbows for the application See Table 3 Using this equivalent length select the desired vapor line size from Table 2 Subtract nominal percentage loss from outdoor unit presale literature Detailed Cooling Capaci ties for given indoor outdoor combination Reference all notes of Table 2 NOTE When specifying the vapor line insulation be aware of the following standard practice Tubing kits should meet the following recommendations to mini mize losses through the insulation 5 8 in and 3 4 in tubing kits should be supplied with 3 8 in insulation 7 8 in and 1 1 8 in tubing kits should be supplied with 1 2 in insulation For minimal capacity loss in long line application 1 2 in insulation should be specified NOTE Special consideration must be given to isolating intercon necting tubing from building structure Isolate tubing so that vibration or noise is not transmitted into the structure See Fig 2 METERING DEVICE An ACCURATER piston or an R 410A TXV can be installed for long line applications A liquid line solenoid valve can be used for certain long line applications See Fig 4 The solenoid valve has a flow arrow stamped on the body of the valve When solenoid is closed not ene
59. te recharge and observe unit through 1 complete operating cycle Final Check Out After the unit has been operating the following items should be checked 1 Check that unit operational noise is not excessive due to vibration of component tubing panels etc If present isolate problem and correct 2 Check to be sure caps are installed on service valves and are tight 3 Check to be sure tools loose parts and debris are removed from unit 4 Check to be sure all panels and screws are in place and tight Desert and Seacoast Locations Special consideration must be given to installation and mainte nance of condensing units installed in coastal or desert locations This is because salt and alkali content of sand adheres to aluminum fins of coil and can cause premature coil failure due to corrosion from salt alkali and moisture Preventive measures can be taken during installations such as 1 Locate unit on side of structure opposite prevailing winds 2 Elevate unit to height where drifting sand cannot pile up against coil Four in high mounting feet are available as accessories and can be used to elevate unit 3 Addition of coastal filter See PDD for accessory listing Maintenance in desert and seacoast locations 1 Frequent inspection of coil and basepan especially after storms and or high winds 2 Clean coil by flushing out sand from between coil fins and out of basepan as frequently as inspection determines neces
60. tem is free of air and liquid water See Fig 30 TRIPLE EVACUATION METHOD The triple evacuation method should only be used when vacuum pump is capable of pumping down to only 28 in of mercury vacuum and system does not contain any liquid water The procedure is as follows See Fig 31 1 Pump system down to 28 in of mercury vacuum and allow pump to continue to operate for additional 15 minutes 2 Close service valves and shut off vacuum pump 3 Connect a nitrogen cylinder and regulator to system and open until system pressure is 2 psig 4 Close service valve and allow system to stand for 1 hr during which time dry nitrogen will be able to diffuse throughout system absorbing moisture 5 Repeat procedure 3 times System will then be free of any contaminants and water vapor R 410A REFRIGERANT CHARGING Refer to unit information plate for superheat charging procedure R 410A refrigerant cylinders contain a dip tube which allows liquid refrigerant to flow from cylinder in upright position v BREAK VACUUM WITH DRY NITROGEN WAIT v v EVACUATE v BREAK VACUUM WITH DRY NITROGEN v v EVACUATE v CHECK FOR TIGHT DRY SYSTEM IF IT HOLDS DEEP VACUUM v CHARGE SYSTEM Fig 31 Triple Evacuation Method A95425 Charge R 410A units with cylinder in upright position and a commercial type metering device in the manifold hose Charge refrigerant into suction line For all approved combinations syst
61. ve coil grille from unit 4 Remove screws on corner post holding coil tube sheet A WARNING Cut tubing to reduce possibility of fire and personal injury 5 Use midget tubing cutter to cut liquid and vapor lines at both sides of coil Cut in convenient location for easy reassembly with copper slip couplings 6 Lift coil vertically from basepan and carefully place aside 7 Reverse procedure to reinstall coil 8 Replace filter drier evacuate system recharge and check for normal system operation COMPRESSOR REMOVAL AND REPLACEMENT Once it is determined that compressor has failed and the reason established compressor must be replaced A CAUTION Turn off all power to unit before proceeding Wear safety glasses and gloves when handling refrigerants Acids formed as a result of motor burnout can cause burns A WARNING Wear safety glasses and gloves when handling refrigerants and when using brazing torch Failure to follow this warning can cause a fire personal injury or death 1 Shut off all power to unit 2 Remove and recover all refrigerant from system until pressure gages read 0 psi Use all service ports Never open a system under a vacuum to atmosphere Break vacuum with dry nitrogen holding charge first Do not exceed 5 psig 3 Disconnect electrical leads from compressor Disconnect or remove crankcase heater and remove compressor hold down bolts 4 Cut compressor from system with tubing cutter Do n

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