Home

Application Guideline and Service Manual

1. 8 Cycle Protector AAA 8 Crankcase Heater iecit a zwi 9 Time Delay Relay reiten ERES 10 Pressure SwitCheS ucc EE 10 Low Pressure Switch A C Only ees 10 High Pressure Switch potro 11 Loss Of Charge Switch H P Only 11 Pressureguard Heating Vapor Pressure Switch H P Only ettet an 13 Discharge Temperature Switch sss 14 Check Defrost Thermostat eee 14 Defrost Thermostats enia a 14 Detrost Control Board eere 15 CES0110063 Defrost Control sess 15 CES0130076 Defrost Control esses 16 Fan MO OE zie O A e a ak 18 Compressor PLUG trente tetto idee n 18 Low Voltage Terminals eerte tn ERES 18 COPELAND SCROLL COMPRESSOR W PURONQ 18 Compressor Failut s 5 erento ttiv 18 Mechanical Fail res eee 18 REFRIGERATION SYSTEM s eeeeeeeeeeetett tette 21 R frIgerant zero 21 Compressor Oll sse eere RERO a i IR SEEN 21 Servicing Systems on Roofs With Synthetic Materials 21 Synthetic Roof Precautionary Procedure 22 ROREM 22 Service Valves and Pumpdown esee 22 Reversing Valve ue a O GA dps 23 Liquid Line Filter Diet eode 24 Suction Line Filter DIE ueteres 24 venuto e 24
2. NOTE 1 Tube diameters are for lengths up to 50ft For tubing lengths greater than 50 ft consult the Long Line section of this manual 2 Refrigerant tubes and indoor coils must be evacuated to 500 microns to minimize contamination and moisture in the system ELECTRICAL 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 A WARNING Exercise extreme caution when working on any electrical components Shut off all power to system prior to trouble shooting Some troubleshooting techniques require power to remain on In these instances exercise extreme caution to avoid danger of electrical shock ONLY TRAINED SER VICE PERSONNEL SHOULD PERFORM ELECTRICAL TROUBLESHOOTING Failure to follow this warning can cause a fire personal injury or death Step 1 Aluminum Wire CAUTION Aluminum wire may be used in the branch circuit such as the circuit between the main and unit disconnect but only copper wire may be used between the unit disconnect and the unit Whenever aluminum wire is used in branch circuit wiring with this unit adhere to the following recommenda
3. a a aA t ben EL estes 24 Thermostatic Expansion Valve TXV sss 25 Shutoff HSO ette nettement 25 Replacing R 22 Expansion Device with Puron TXV 25 REFRIGERATION SYSTEM Leak Detection ya O RANA EE Coi REMOVAL A Compressor Removal and Replacement System Clean Up After Burnout EV aCu ation RE bein te Bai Deep Vacuum Method cerneret Puron Refrigerant Charging ee Checking Charge oie a na iniecit Galia Superheat Charging Method Subcooling Charging Method TWOSSPBED n rre Application Guidelines siressa Safety REVIEW cnet piti ER RE UH Major Components eire GA pereo Led Function Malfunction Lights ssssss Sequence Of Operation Troubleshooting CARE AND nennen 34 34 Cleanimg COU rer Ee OUI R ia 34 Cleaning Outdoor Fan Motor And Blade 35 Electrical Controls And Wiring eess 35 Refrigerant CIE CIL etre tror erp Revo pedo 35 Final ien enaa 35 Desert and Seacoast Locations 35 APPENDIX een eniro re ER UH Las 36 SAFETY CONSIDERATIONS Installation service and repai
4. 2650 X amps volts 3 Remove any capacitor that shows signs of bulging dents or leaking Do not apply power to a defective capacitor as it may explode Sometimes under adverse conditions a standard run capacitor in a system is inadequate to start compressor In these instances a start assist device is used to provide an extra starting boost to compres sor motor This device is called a positive temperature coefficient PTC or start thermistor See Fig 15 It is a resistor wired in parallel with the run capacitor As current flows through the PTC at start up it heats up As PTC heats up its resistance increases greatly until it effectively lowers the current through itself to an extremely low value This in effect removes the PTC from the circuit After system shutdown resistor cools 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 15 The cold resistance RT of any PTC device should be approxi mately 100 180 percent of device ohm rating 12 5 ohm PTC
5. 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 7 Install a new retainer O ring retainer assembly or Teflon washer before reassembling AccuRater Step 11 Thermostatic Expansion Valve TXV The thermostatic expansion valve is specifically designed to operate with Puron use only factory authorized TXV Do not use an R 22 Step 12 Hard Shutoff HSO Has no bleed port and allows no bleed through after system shutdown No pressure equalization occurs The TXV is a metering device that is used in air conditioning and heat pump systems to adjust to changing load conditions by maintaining a preset superheat temperature at the outlet of the evaporator coil The volume of refrigerant metered through the valve seat is dependent upon the following See Fig 37 1 Superheat temperature sensed by cap tube sensing bulb on suction tube at outlet of evaporator coil As long as this bulb and cap tube contains some liquid refrigerant this temperature is converted into suction pressure pushing downward on the diaphragm which tends to open the valve via the pushrods 2
6. HEATING 8 COOLING Air Conditioners and Heat Pumps Using Puron Refrigerant Visit www carrier com Application Guideline and Service Manual NOTE Read the entire instruction manual before starting the installation TABLE OF CONTENTS SAFETY CONSIDERATIONS INTRODUCTION cyz diaz rer EE eret EHE AED 2 INSTALLATION GUIDELINE certe eene Residential New Construction Add On Replacement Retrofit Seacoast For Air Conditioners Only sess 2 ACCESSORY DESCRIPTIONS erri 2 LOW AMBIENT GUIDELINE iscissi 3 t ed 4 Interconnecting Tubing esee 4 Metering Device Long Line Set sss 4 Tubing Configuration Charging Information UNIT IDENTIFICATION ehem heredes ed 4 Model Number Nomenclature eee 4 Serial Number Nomenclature eee 4 CABINET ASSEMBLY rri nicer 4 Remove Top Covet eei need 4 Remove Fan Motor Assembly eene d Information Plate irre rre canon ed 4 Control Box Cover Cube Products sss 6 Remove Top Cover Cube Products sss 6 Remove Fan Motor Assembly Cube Products 6 ELECTRICAL i zdac in Aluminum Wire COMLACEON iss Capacitor O W O W A
7. TXV Operation under a vacuum to atmosphere Break vacuum with dry nitrogen holding charge first Do not exceed 5 psig 3 Disconnect electrical leads from compressor Disconnect or remove crankcase heater and remove compressor hold down bolts 4 Cut compressor from system with tubing cutter Do not use brazing torch for compressor removal Oil vapor may ignite when compressor is disconnected 5 Scratch matching marks on stubs in old compressor Make corresponding marks on replacement compressor 6 Use torch to remove stubs from old compressor and to reinstall them in replacement compressor 7 Use copper couplings to tie compressor back into system 8 Replace filter drier evacuate system recharge and check for normal system operation CAUTION Do not leave system open to atmosphere Product damage could occur Compressor oil is highly susceptible to moisture absorption Step 4 System Clean Up After Burnout Some compressor electrical failures can cause motor to burn When this occurs 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 com pressor is installed The 2 types of motor burnout are classified as mild or severe In mild burnout there is little or no detectable odor Compressor oil is clear or slightly discolored An
8. 12 5 22 5 ohm resistance beige color If PTC resistance is appreciably less than rating or more than 200 percent higher than rating device is defective Step 4 Cycle Protector Solid state cycle protector protects unit compressor by preventing short cycling After a system shutdown cycle protector provides Table 6 Estimated Percentage of Nominal Cooling Capacity Losses UNIT STANDARD LONG LINE NOMINAL VAPOR VAPOR PERCENTAGE OF COOLING CAPACITY LOSS BTU VERSUS EQUIVALENT LENGTH TU NT 25 Ft 50 Ft 75 Ft 100 Ft 125 Ft 150 Ft 175 Ft 1 2 1 1 2 2 3 4 5 18000 5 8 5 8 0 1 2 2 3 4 5 5 8 0 1 2 3 4 6 7 24 000 5 8 3 4 0 0 0 1 1 2 2 7 8 0 0 0 0 0 1 1 5 8 1 2 3 4 5 6 7 30 000 3 4 3 4 0 0 1 1 2 2 2 7 8 0 0 0 0 1 1 1 5 8 1 3 5 6 8 9 11 36 000 3 4 3 4 0 1 1 2 3 3 4 7 8 0 0 0 0 1 1 2 3 4 0 1 2 2 3 4 5 42 000 7 8 7 8 0 0 0 1 1 1 2 1 1 8 0 0 0 0 0 0 0 3 4 1 1 2 3 2 4 T 48 000 7 8 7 8 0 0 1 1 2 3 3 1 1 8 0 0 0 0 0 0 1 3 4 2 3 5 7 8 10 11 60 000 1 1 8 7 8 1 2 2 3 4 5 6 1 1 8 0 0 1 1 1 1 2 C 90 STD 90 LONG RAD 45 STD A01058 Fig 4 Tube Bend Losses Table 7 Fitting Losses in Equivalent Ft TUBE SIZE OD REFERENCE DIAGRAM IN FIG 4 IN A B C 1 2 1 2 0 8 0 6 5 8 1 6 1 0 0 8 3 4 1 8 1 2 0 9 7 8 2 0 1 4 1 0 1 1 8 2 6 1 7 1 8 for a 5 2 minute delay before compressor restarts On norma
9. APPENDIX WITH PURONG QUICK REFERENCE GUIDE Puron R 410A refrigerant operates at 50 percent to 70 percent higher pressures than R 22 Be sure that servicing equipment and replacement components are designed to oper ate with Puron Puron refrigerant cylinders are rose colored Recovery cylinder service pressure rating must be 400 psig DOT 4BA400 or DOT BW400 Puron 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 PuronG as with other HFCS is only compatible with POE oils Vacuum pumps will not remove moisture from oil Only use factory specified liquid line filter driers with rated working pressures less than 600 psig Do not install a suction line filter drier in liquid line 36 POE oils absorb moisture rapidly Do not expose oil to atmosphere POE oils may cause damage to certain plastics and roofing materials Wrap all filter driers and service valves with wet cloth when brazing A factory approved liquid line filter drier is required on every unit Do not use an R 22 TXV If indoor unit is equipped with a TXV it must be changed to a Puron Never open system
10. remaining 10 KW you can now stage the strip heat and provide the customer with a more comfortable and efficient heating mode As per in the last example W2 was wired to 10 of the 15 KW available in the strip heater second stage strip heat is achieved when W2 initiates 24 volt control power to the fan coil heater the 10 KW element power up 33 Board failure Highest Priority 5th Stage High Capacity Heating H P Only Fifth stage heating is high capacity heating with three stage strip heat This is achieved when a call from the indoor thermostat is initiated and 24 volt control power is applied to Y1 Y2 W1 and W2 Y2 will tell the control to start the compressor for high capacity operation Because there is no O signal telling the control to shift the reversing valve the reversing valve remains in the heating position Again using the 15 KW heater as an example third stage strip heat is achieved when W1 and W2 initiates 24 volt control power to the fan coil heater the W1 5 KW and W2 10 KW elements are power up giving you the full 15 KW the heat package can achieve TROUBLESHOOTING NOTE The wiring diagrams shown in the following paragraphs are simplified versions of actual wiring diagrams found in air conditioners and heat pumps The first operation sequence shown is for the air conditioning followed by the heat pump operating sequence Both wiring diagra
11. 6 90 26 4 192 67 0 294 94 8 396 116 2 498 133 9 660 157 1 92 27 4 194 67 7 296 95 2 398 116 6 500 134 0 664 157 7 94 28 5 196 68 3 298 95 7 400 117 0 502 134 5 668 158 2 96 29 5 198 68 9 300 96 2 402 117 3 504 134 8 672 158 7 98 30 5 200 69 5 302 96 6 404 117 7 506 135 2 676 159 2 100 31 2 202 70 1 304 97 1 406 118 1 508 135 5 680 159 8 102 32 2 204 70 7 306 97 5 408 118 5 510 135 8 684 160 3 104 33 2 206 71 4 308 98 0 410 118 8 512 136 1 688 160 8 106 34 1 208 72 0 310 98 4 412 119 2 514 136 4 692 161 3 108 35 1 210 72 6 312 98 9 414 119 6 516 136 7 696 161 8 110 35 5 212 73 2 314 99 3 416 119 9 518 137 0 112 36 9 214 73 8 316 99 7 418 120 3 520 137 3 37 Table 16 Subcooling Charging Table REQUIRED LIQUID LINE TEMPERATURE LIQUID PRESSURE REQUIRED SUBCOOLING TEMPERATURE F AT SERVICE VALVE PSIG do 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 58 56 54 215 64 62 60 58 56 222 66 64 62 60 58 229 68 66 64 62 60 236 70 68 66 64 62 243 72 70 68 66 64 251 74 72 70 68 66 259 76 74 72 70 68 266 78 76 74 72 70 274 80 78 76 74 72 283 82 80 78 76 74 291 84 82 80 78 76 299 86 84 82 80 78 308 88 86 84 82 80 317 90 88 86 84 82 326 92 90 88 86 84 335 94 92 90 88 86 345 96 94 92 90 88 354 98 96 94 92 90 364 100 98 96 94 92 374 102 100 98 96 94 384 104 102 100 98 96 395 106 104 102 100 98 406 108 106 104 102 100 416 110 108 427 112 110 439 114 112 110 45
12. 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 OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING DAMAGED OR STUCK REVERSING VALVE RESTRICTED DISCHARGE TUBE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT LOOSE LEAD AT FAN MOTOR DEFROST RELAY N C CONTACTS OPEN MOTOR DEFECTIVE INCORRECT OFM CAPACITOR DEFECTIVE DEFROST THERMOSTAT 41 DIRTY AIR FILTERS DUCT RESTRICTED DAMPERS PARTLY CLOSED INDOOR COIL FROSTED SLIGHTLY LOW ON REFRIGERANT LIQUID LINE SLIGHTLY RESTRICTED PISTON RESTRICTED INCORRECT SIZE PISTON INDOOR COIL STRAINER RESTRICTED INDOOR BLOWER MOTOR DEFECTIVE OR CYCLING ON OL HIGH SUCTION LOW HEAD PRESSURE REVERSING VALVE HUNG UP OR INTERNAL LEAK DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON A90207 42 43 Copyright 2005 CARRIER Corp 7310 W Morris St Indianapolis IN 46231 3812sm Manufacturer reserves the right to discontinue
13. If it takes 2 sec to remove speed up jumper after unit has switched to defrost the unit will switch back to heat mode 12 After a few minutes in defrost cooling operation liquid line should be warm enough to have caused defrost thermostat contacts to open Check resistance across defrost thermostat Ohmmeter should read infinite resistance indicating defrost thermostat has opened at approximately 80 F 13 Shut off unit power and reconnect fan lead 14 Remove jumper between DFT and R terminals Reconnect defrost thermostat leads Failure to remove jumper causes unit to switch to defrost every 30 50 or 90 minutes and remain in defrost for full 10 minutes 15 Replace control box cover Restore power to unit If defrost thermostat does not check out following above items or incorrect calibration is suspected check for defective thermostat as follows 1 Follow items 1 5 above 2 Route sensor or probe underneath coil or other convenient location using thermocouple temperature measuring device Attach to liquid line near defrost thermostat Insulate for more accurate reading 3 Turn on power to outdoor unit 4 Restart unit in heating 5 Within a few minutes liquid line temperature drops within a range causing defrost thermostat contacts to close Tempera ture range is from 33 F to 27 F Notice temperature at which ohmmeter reading goes from to zero ohms Thermostat contacts close at this point FIELD POWER
14. OR CYCLING ON OL HIGH SUCTION LOW HEAD PRESSURE DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON A90208 TROUBLESHOOTINGDHEATING CYCLE NO HEATING OR INSUFFICIENT HEATING COMPRESSOR COMPRESSOR RUNS BUT RUNS CYCLES ON INSUFFICIENT INTERNAL HEATING OVERLOAD COMPRESSOR WILL NOT RUN CONTACT OPEN DEFECTIVE LOW VOLTAGE TRANSFORMER REMOTE CONTROL CENTER DEFECTIVE CONTACTOR COIL OPEN OR SHORTED OPEN INDOOR THERMOSTAT LIQUID LINE PRESSURE SWITCH OPEN LOSS OF CHARGE OPEN CONTROL CIRCUIT CONTACTOR CLOSED COMPRESSOR POWER SUPPLY LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH COMPRESSOR STUCK COMPRESSOR INTERNAL OVERLOAD OPEN OPEN SHORTED OR GROUNDED COMPRESSOR WINDINGS DEFECTIVE RUN CAPACITOR DIRTY FILTERS OR INDOOR COIL INDOOR FAN STOPPED OR CYCLING ON OVERLOAD DAMAGED REVERSING VALVE RESTRICTION IN DISCHARGE LINE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR 1 PH COMPRESSOR BEARINGS HIGH LOAD CONDITION REVERSING VALVE JAMMED IN MIDPOSITION HIGH SUPERHEAT DEFECTIVE FAN MOTOR CAPACITOR LOOSE LEADS AT FAN MOTOR FAN MOTOR BURNED OUT 40 OUTDOOR FAN STOPPED LOOSE LEADS AT
15. 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 PROPERLY CHARGED OUTDOOR FAN RUNNING REVERSING VALVE STUCK RESTRICTED LIQUID LINE PISTON RESTRICTED OR IS CLOGGED UNDER CHARGED OUTDOOR COIL DIRTY STRIP HEATERS NOT OPERATING OUTDOOR THERMOSTAT DEFECTIVE ODT SETTING TOO LOW CAP TUBE PINCHED OR BULB NOT SENSING TRUE ODT STRIP HEATER RELAY OR CONTACTOR DEFECTIVE OPENING IN POWER CIRCUIT TO HEATER ELEMENTS BROKEN FUSE LINK STRAINER RESTRICTED OUTDOOR COIL HEAVILY FROSTED DEFECTIVE DEFROST THERMOSTAT DEFROST THERMOSTAT IN POOR PHYSICAL CONTACT WITH TUBE DEFECTIVE CIRCUIT BOARD BAD ELECTRICAL CONNECTION ANYWHERE IN DEFROST CIRCUIT BROKEN HEATER ELEMENT OPEN KLIXON OVER TEMPERATURE THERMOSTAT DEFECTIVE ROOM THERMOSTAT 2ND STAGE A90206 HEAT PUMP TROUBLESHOOTINGDCOOLING CYCLE NO COOLING OR INSUFFICIENT COOLING COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD COMPRESSOR RUNS BUT INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN CONTACTOR OPEN POWER SUPPLY DEFECTIVE LOW VOLTAGE TRANSFORMER OPEN THERMOSTAT OPEN CONTROL CIRCUIT LOSS OF CHARGE CONTACTOR OR COIL DEFECTIVE LOOSE ELECTRICAL
16. SUPPLY Start capacitor SC temporarily connected Capacitance boosting A00195 Fig 16 Capacitance Boosting HN67ZA008 A94005 Fig 17 Cycle Protector Device 3 OPERATING eek TIME SEP Men EM T2 BLK DENOTES CLOSED CONTACTS HN67ZA008 A94009 Fig 18 Cycle Protector Sequence 6 Short between the speed up terminals using a small slotted screwdriver 7 Unit changes over to defrost within 21 sec depending on timing cycle setting Liquid line temperature rises to range where defrost thermostat contacts open Temperature range is from 75 F to 85 F Resistance goes from zero to 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 CES0130076 DEFROST CONTROL This defrost control is the same size as the CESO130063 control but is not backwards compatible To upgrade to the new control you must have replacement defrost thermostat and harness kit See your replacement component representative for kit part number Defrost Settings The defrost control is a time temperature control which includes a field selectable time period DIP switch 1 and 2 on board see Table 8 between defrost cycles of 30 60 90 and 120 minutes factory set at 90 min
17. Table 1 for an Accessory Usage Guide for Puron Air Conditioners and Table 2 for Puron Heat Pumps Refer to the appropriate section below for a description of each accessory and its use Compressor Crankcase Heater An electric heater which mounts to base of compressor to keep lubricant warm during off cycles Improves compressor lubrication on restart and minimizes chance of refrigerant slugging and oil pumpout The crankcase heater may or may not include a thermostat control For units equipped with crankcase heaters apply power for 24 hr before starting compressor Crankcase Heater Switch Some models may contain a crankcase heater switch CHS The switch is used to control the crankcase heater It closes on a temperature fall and completes the circuit to the compressor crankcase heater The CHS closes at 65 F and opens at 85 F ambient temperature Evaporator Freeze Thermostat An SPST temperature 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 Compressor Start Assist PTC Solid state electrical device which gives a soft boost to the compressor each start Compressor Start Assist Capacitor Relay Start capacitor and start relay gives hard boost to compressor motor at each start Required with Li
18. 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 27 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 Puron filter driers NOTE On heat pumps install suction line drier between com pressor and accumulator 5 Operate system for 10 hr Monitor pressure drop across drier If pressure drop exceeds 3 psig replace suction line and liquid line filter driers Be sure to purge system with dry nitrogen when replacing filter driers If suction line driers must be replaced retest pressure drop after additional 10 hours run time Continue to monitor pressure drop across suction line filter drier After 10 hr of run time remove suction line filter drier and replace liquid line filter drier Never leave suction line filter drier in system longer than 72 hr actual time 6 Charge system See unit information plate Step 5 Evacuation Proper evacuation of the system will remove non condensibl
19. 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 3MA POE 32 cSt oil This is the only oil allowed for oil recharge See Table 10 Step 1 Compressor Failures Compressor failures are classified in 2 broad failure categories mechanical and electrical Both types are discussed below Step 2 Mechanical Failures A compressor is a mechanical pump driven by an electric motor contained in a welded or hermetic shell In a mechanical failure motor or electrical circuit appears normal but compressor does not function normally o gt gl 2 RA gt Co X ojla gt I CD U m m U c U gt 4 2 5 E m 2 o 3 Speedup Pins Shift j C_ gt CESO 130076 00 Defrost interval DIP switches A99442 Fig 24 Defrost Control Table 10 Oil Charging RECHARGE COMPRESSOR MODEL FL OZ OIL TYPE COPELAND ZP16 26 38 3MA POE 32 cSt ZP32 41 42 3MA POE 32 cSt ZP54 53 3
20. changeover or if the pressure switches should open After the termination of a defrost cycle on the heat pump models the outdoor fan motor delays coming on for 20 seconds This allows the refrigerant system to recover the outdoor coil heat and minimize the steam cloud effect Compressor Although the Bristol reciprocating compressor may look like any other reciprocating compressor the compressor is specifically designed for Puron higher operating pressures and two speed operation This model of compressor uses a required oil known as MCP 2134 POE a polyolester lubricating oil with additive that is compatible with the new refrigerant Should the compressor require replacement use only the manufacturer specified replace ment The Bristol two speed compressor relies on the reverse rotation of the hermetic motor to idle one of the two pistons to provide reduced capacity The Bristol two speed reciprocating compressor while running in the clockwise rotation activates both pistons When the motor is running in the counterclockwise rotation the cam and clutch mechanism idles one of the pistons thus reducing the capacity of the compressor The motor RPM does not change appreciably between single or two piston operation Compressor Vc Vh The two speed Puron units have a Vc Vh thermal trip device The control board monitors the compressor capacitor voltage and when voltage is below 90vac or above 600vac the control board will cutoff cur
21. controls The Tennessee Valley Authority TVA requires that the electric strip heat have a lockout feature This is achieved through the corporate thermostat or zone control and must be used on all TVA approved units The new control board in the Puron two speed air conditioner and heat pump units does not contain or require the high speed latching balance point or defrost time potentiometers The bal ance point was for dual fuel application which can now be done using the Thermidistat or Dual Fuel Thermostat The defrost timer is now activated using two dip switches The two speed heat pump units cannot use the fan coil Super Comfort Heat mode in conjunction with the use of PressureGuard The pressure guard is designed to insure that the head pressure during heating mode operation does not exceed the pressure limits of standard line sets Enabling Super Comfort Heat mode on the fan coil slows the indoor fan down and increases the head pressure Super Comfort Heat operation at high ambient temperatures may cause the PressureGuard switch to cycle Cycling PressureGuard defeats the functionality of Super Comfort Heat operation The Puron two speed units are not approved for low ambient applications Long line application requirements are similar to those on the single speed Puron refrigerant units See the Long Line Guideline in Table of Contents SAFETY REVIEW Only qualified technicians should inst
22. 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 3 Be sure all power is off 4 Discharge all capacitors 5 Remove wires from terminals C S and R e EXAMPLE e e POWER OFF DEDUCTION O OHMMETER 0 100 SCALE O 06 TO DETERMINE INTERNAL CONNECTIONS OF SINGLE PHASE MOTORS C S R EXCEPT SHADED POLE GREATEST RESISTANCE 5 8Q OHM SMALLEST RESISTANCE REMAINING RESISTANCE 5 20 RUN WINDING R START WINDING 5 2 is COMMON 0 62 BY ELIMINATION 2 Is common THEREFORE 0 IS START WINDING 5 3 IS RUN WINDING R A88344 Fig 26 Identifying Internal Connections 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 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
23. for leaks is to use soap bubbles See Fig 39 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 You may use an electronic leak detector designed for HFCs to check for leaks See Fig 38 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 Puron HFC refrigerant Check with manufacturer of equipment for suitability Generally speaking they are portable lightweight and consist of a box with several switches and a probe or sniffer Detector is turned on and probe is passed around all fittings and connections in system Leak is detected by either the movement of a pointer on detector dial a buzzing sound or a light In all instances when 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 rechar
24. or change at any time specifications or designs without notice and without incurring obligations Book 1 1 2 101 Catalog No Printed in U S A Form 38 12SM Pg 44 4 05 Replaces 38 11SM Tab 3a 5a
25. power off and heater leads disconnected check across leads with ohmmeter Do not look for a specific resistance reading Check for resistance or an open circuit Change heater if an open circuit is detected Step 6 Time Delay Relay The TDR is a solid state control recycle delay timer which keeps indoor blower operating for 90 sec after thermostat is satisfied This delay enables blower to remove residual cooling in coil after compression shutdown thereby improving efficiency of system The sequence of operation is that on closure of wall thermostat and at end of a fixed on delay of 1 sec fan relay is energized When 10 thermostat is satisfied an off delay is initiated When fixed delay of 90 20 sec is completed fan relay is de energized and fan motor stops If wall thermostat closes during this delay TDR is reset and fan relay remains energized TDR is a 24v 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 the fan switch is set to AUTO the TDR is probably defective and must be replaced Step 7 Pressure Switches Pressure switches are protective devices wired into control circuit low voltage They shut off compressor if abnormally high low pressures are present in the refrigeration circuit These pressure switches are specifically designed to operate with Puron systems R 22 pressure switches must not be used as replacements for the Puro
26. problems are not attributed to the defrost control board CES0110063 DEFROST CONTROL AII heat pumps in this line use the CES0110063 defrost control This control board has a connector plug with stripped wire leads It also contains a feature that allows the heat pump to restart in defrost if the room thermostat is satisfied during defrost The board also contains a 5 minute cycle protector that prevents the unit from short cycling after it cycles off or after a power interruption To troubleshoot the board perform the following items 1 Turn thermostat to OFF Shut off all power to outdoor unit 2 Remove control box cover for access to electrical components and 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 co for open thermostat depending on outdoor temperature 4 Jumper between DFT and R terminals on control board as shown in Fig 20 5 Disconnect outdoor fan motor lead from OF2 Tape lead to prevent grounding 6 Turn on power to outdoor unit 7 Restart unit in heating mode allowing frost to accumulate on outdoor coil 8 After a few minutes in heating mode liquid line temperature at defrost thermostat should drop below closing set point of defrost thermostat of approximately 30
27. recharge the unit by the weigh in method if ambient temperature does not allow checking the charge by subcooling method in cooling mode Check to ensure the proper outdoor AccuRater is installed according to the rating plate or the Long Line Guideline NOTE Due to the presence of a vapor pressure switch in outdoor unit fan circuit and the possibility of fan cycling this unit may go into brief defrost at high ambient heating conditions Step 8 Discharge Temperature Switch Heat pump units are equipped with a Discharge Temperature Switch DTS located on the compressor discharge line The DTS is a temperature limiting device which will cycle the compressor contactor This device protects the compressor in the event of a loss of indoor air when used in combination with a TXV and an accumulator The DTS is wired in series with the low and high pressure switches and opens at 275 F and closes at 225 F A95507 A95508 Fig 12 Information Plate Removed Installed Below Control Box A88350 Fig 13 Contactor Step 9 Check Defrost Thermostat There is a liquid header with a brass distributor and feeder tube 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 21 The defrost thermostat should be located on stub tube Note that there is only 1 stub tube used with a liquid header and o
28. the standard single speed defrost controls The unit will defrost for 30 seconds and then check the defrost thermistor if the defrost thermistor is indicating a need to defrost the unit will continue until the defrost cycle is completed If the defrost thermistor indicates no defrost is necessary the defrost cycle will be terminated 120 30 60 60 30 90 Fig 43 Defrost Timer Table 13 Switch Settings for Defrost Intervals A00429 DEFROST TIME 2 AWZ MINUTES On Off 30 Off On 60 Off Off 90 On On 120 Defrost Time Temperature The unit will initiate a defrost cycle if the coil temperature is below 30 F the outdoor temperature is less than 50 F and the time function is met The unit will complete the defrost cycle using the standard time temperature method used on all single speed pump units Defrost will terminate if the coil temperature exceeds 85 F or if a ten minute defrost time is achieved which ever occurs first When the defrost cycle is terminated the unit will shift back into the heating mode The outdoor fan motor will have a delayed start time of twenty seconds This feature allows moisture to drain away from the unit so it will not refreeze on the coil surface and helps to maximize the heat transfer for heating mode restart It may also minimize the fogging or misting that occurs as the unit comes out of defrost and returns to the heating mode LED FUNCTION MALFUNCTION LIGHTS
29. to atmosphere while it is under a vacuum When system must be opened for service recover refrigerant break vacuum with dry nitrogen before opening system Always replace filter drier after opening system for service Do not vent Puron into the atmosphere Do not use capillary tube coils Observe all warnings cautions and bold text Puron heat pumps must have indoor Do not leave Puron suction line driers in place for more than 72 hr Table 15 Pressure vs Temperature Chart Puron R 410A PSIG F PSIG E PSIG 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 26 9 122 41 3 224 76 7 326 102 0 428 122 1 530 138 9 22 24 5 124 42 2 226 77 2 328 102 4 430 122 5 532 139 2 24 22 2 126 43 0 228 77 8 330 102 9 432 122 8 534 139 5 26 20 0 128 43 8 230 78 4 332 103 3 434 123 2 536 139 8 28 17 9 130 44 7 232 78 9 334 103 7 436 123 5 538 140 1 30 15 8 132 45 5 234 79 5 336 104 2 438 123 9 540 140 4 32 13 8 134 46 3 236 80 0 338 104 6 440 124 2 544 141 0 34 11 9 136 47 1 238 80 6 340 105 1 442 124 6 548 141 6 36 10 1 138 47 9 240 81 1 342 105
30. 0 116 114 112 110 118 116 114 112 110 118 116 114 112 118 116 114 118 116 120 118 95617 38 AIR CONDITIONER TROUBLESHOOTING CHART NO COOLING OR INSUFFICIENT COOLING COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD COMPRESSOR RUNS BUT INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN CONTACTOR OPEN POWER SUPPLY DEFECTIVE LOW VOLTAGE TRANSFORMER OPEN THERMOSTAT OPEN CONTROL CIRCUIT LOSS OF CHARGE CONTACTOR OR COIL DEFECTIVE LOOSE ELECTRICAL CONNECTION CONTACTOR CLOSED COMPRESSOR POWER SUPPLY OPEN LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH OPEN SHORTED OR GROUNDED COMPRESSOR MOTOR WINDINGS COMPRESSOR STUCK COMPRESSOR INTERNAL PROTECTION OPEN DEFECTIVE RUN CAPACITOR OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING RESTRICTED DISCHARGE TUBE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT LOOSE LEAD AT FAN MOTOR MOTOR DEFECTIVE INCORRECT OFM CAPACITOR 39 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
31. 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 53 3 254 84 8 356 108 3 458 127 3 580 146 2 52 3 0 154 54 0 256 85 4 358 108 8 460 127 7 584 146 7 54 4 5 156 54 8 258 85 9 360 109 2 462 128 0 588 147 3 56 5 9 158 55 5 260 86 4 362 109 6 464 128 3 592 147 9 58 7 3 160 56 2 262 86 9 364 110 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 1147 490 132 6 644 155 0 84 23 2 186 65 1 288 93 3 390 115 0 492 132 9 648 155 5 86 24 3 188 65 8 290 93 8 392 115 5 494 133 3 652 156 1 88 25 4 190 66 4 292 94 3 394 115 8 496 133 6 656 156
32. 5 16 32 5 8 10 11 16 24 3 4 16 3 16 8 1 4 35 13 16 33 13 16 25 15 16 23 7 8 25 3 4 40 1 8 10 11 16 32 1 4 23 11 16 15 13 16 23 13 16 21 13 16 27 15 16 25 7 8 25 3 4 40 1 8 10 11 16 32 1 4 23 11 16 15 13 16 25 13 16 23 13 16 29 15 16 27 7 8 25 3 4 40 1 8 10 11 16 32 1 4 23 11 16 15 13 16 27 13 16 25 13 16 31 15 16 29 7 8 25 3 4 40 1 8 10 11 16 32 1 4 23 11 16 15 13 16 29 13 16 27 13 16 33 15 16 31 7 8 25 3 4 40 1 8 10 11 16 32 1 4 23 11 16 15 13 16 31 13 16 29 13 16 35 15 16 33 7 8 25 3 4 40 1 8 10 11 16 32 1 4 23 11 16 15 13 16 33 13 16 31 13 16 37 15 16 35 7 8 25 3 4 40 1 8 10 11 16 32 1 4 23 11 16 15 13 16 35 13 16 33 13 16 39 15 16 37 7 8 25 3 4 40 1 8 10 11 16 32 1 4 23 11 16 15 13 16 37 13 16 35 13 16 UNIT SIZE AA Large 30 Table 5 Refrigerant Connections and Recommended Liquid and Vapor Tube Diameters Heat Pumps CONNECTION DIAMETER IN TUBE DIAMETER IN TUBE DIAMETER ST SEE UNIT SIZE ALTERNATE IN PERMITTED Liquid Vapor Liquid Vapor Vapor Vapor 018 3 8 5 8 3 8 5 8 1 2 3 4 7 8 and 1 1 8 024 3 8 5 8 3 8 5 8 3 4 ACR 3 4 030 3 8 3 4 3 8 3 4 7 8 1 1 8 036 3 8 3 4 3 8 3 4 7 8 1 1 8 042 048 3 8 7 8 3 8 7 8 7 8 3 4 and 1 1 8 060 3 8 7 8 3 8 1 1 8 7 8 3 4
33. 6 i W W w n i UA A Xn VN OK LY AA E BULB INSULATION TAPE A01193 Fig 34 Puron TXV Kit Components 7 V M x O M RY SENSING BULB X 4 O CLOCK A00399 8 O CLOCK Fig 35 Position of Sensing Bulb SENSING BULB EQUALIZER TUBE THERMOSTATIC EXPANSION VALVE A91277 Fig 36 Typical TXV Installation 4 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 DIAPHRAGM PUSHRODS ZF FEEDER TUBES PZ gt gt INLET 2 U NEEDLE VALVE SPRING DISTRIBUTOR CAPILLARY TUBE M me COIL BULB EXTERNAL EQUALIZER TUBE A94056 Fig 37
34. 9 13 16 21 30 5 8 36 1 2 42 35 5 8 36 3 8 35 5 8 17 1 8 17 7 8 Large 42 1 16 33 13 16 25 5 16 39 3 4 30 1 2 50 9 16 29 5 8 30 3 8 29 5 8 21 11 16 14 7 8 39 13 16 25 5 16 39 3 4 36 1 2 50 9 16 35 5 8 36 3 8 35 5 8 21 11 16 17 7 8 Fig 1 Wind Baffle Construction Tech 2000 5 7 Jg 3 16 200 0 4 6 E 1 Va gt 12 7 6 4 a Y H l 5 3 128 0 Yo pU B BAFFLE LEFT MAT L 20 GA STEEL 199 9 AE pex 10 0 R 1 4 5 56 DIA A 2 REQ D E 24 WI 63 5 Y i Bj 18 3 45 DIA 57 4 H H 21 0 Y 63 5 Z La 21 32 42 1 1 4 x 3 8 5 56 x 9 53 SLOT 6 REQ D 4 9 64 105 2 23 64 9 2 gt J gt 2 5 64 52 6 4 57 64 124 2 ME 12 7 8 e4 205 3 gt mj TYP 28 9 2 6 4 SUPPORT m A MAT L 18 GA STEEL 1 8 3 45 DIA JH 4 REQ D Lr Y i M 1 4 5 56 DIA FP F a 5 3 64 4 128 0 yt 13 64 Y 5 4 M 2 L 7 29 32 200 al 12 7 32 200 8 TYP 1 21 30 42 1 BAFFLE RIGHT MAT L 20 GA STEEL 1 4 x 3 8 5 56 x 9 53 SLOT t 6 REQ D 1 4 5 56 DIA l 4 REQD 25 4 10 0 LEFT SIDE RIGHT SIDE SCREW 14 REQ D 2 REQ D SU
35. An LED indicator light informs the service technician of the current status of the unit There are nine 9 codes that indicate faults as well as operational modes and a board failure mode Led Function Light Codes A constant flash with no pause indicates the unit is in the standby mode That is the thermostat is satisfied and the unit is ready to respond to call for heating or cooling One flash with a pause between indicates the unit is in low speed mode Two flashes with a pause between indicates the unit is in high speed mode Three flashes with a pause between indicates a failure of the outdoor air temperature thermistor Four flashes with a pause between indicates a failure of the outdoor coil thermistor Three Four flashes with a pause between indicates that the thermistors are out of range We will review the out of range settings on the next slide 32 Five flashes a momentary pause plus one additional flash with a pause between indicates the low pressure switch is open Five flashes a momentary pause plus two additional flashes with a pause between indicates the high pressure switch is open Six flashes with a pause between indicates the Vc Vh has shut the compressor down If the light is on constantly with no flashes or no pauses it indicates the board has failed and must be replaced 3 4 Fault In Cooling If the outdoor thermistor indicates greater than 10 F or more than the coil the
36. F Check resistance across defrost thermostat leads using ohmmeter Resistance of zero indicates defrost thermostat is closed and operating properly 15 9 Short between the speed up terminals using a thermostat screwdriver This reduces the timing sequence to 1 256 of original time See Fig 22 and Table 8 NOTE Since Fig 22 shows timing cycle set at 90 minutes unit initiates defrost within approximately 21 sec When you hear the reversing valve changing position remove screwdriver immedi ately Otherwise control will terminate normal 10 minute defrost cycle in approximately 2 sec Table 8 Defrost Control Speed Up Timing Sequence MINIMUM MAXIMUM SPEED UP PARAMETER MINUTES MINUTES NOMINAL 30 minute cycle 27 33 7 sec 50 minute cycle 45 55 12 sec 90 minute cycle 81 99 21 sec 10 minute cycle 9 11 2 sec 5 minutes 4 5 5 5 1 sec A CAUTION Exercise extreme caution when shorting speed up pins If pins are accidentally shorted to other terminals damage to the control board will occur 10 Unit is now operating in defrost mode Check between C and W2 using voltmeter as shown in Fig 23 Reading on voltmeter should indicate 24v This step ensures defrost relay contacts have closed energizing supplemental heat W2 and reversing valve solenoid 11 Unit should remain in defrost no longer than 10 minutes Actual time in defrost depends on how quickly speed up jumper is removed
37. MA POE 32 cSt BRISTOL T89B19 38 37 Mobil MCP2134 T89A51 62 Mobil MCP2134 H29B16 30 37 3MA POE 32 cSt A WARNING Do not supply power to unit with compressor terminal box cover removed Failure to follow this warning can cause a fire personal injury or death A WARNING Exercise extreme caution when reading compressor currents when high voltage power is on Correct any of the problems described below before installing and running a replacement compressor Wear safety glasses and gloves when handling refrigerants Failure to follow this warning can cause a fire personal injury or death Locked Rotor In this type of failure compressor motor and all starting compo nents are normal When compressor attempts to start it draws locked rotor current and cycles off on internal protection Locked rotor current is measured by applying a clamp on ammeter around common blk lead of compressor Current drawn when it attempts to start is then measured Locked rotor amp LRA value is stamped on compressor nameplate If compressor draws locked rotor amps and all other external sources of problems have been eliminated compressor must be replaced Because compressor is a sealed unit it is impossible to determine exact mechanical failure However complete system should be checked for abnormalities such as incorrect refrigerant charge restrictions insufficient airflow across indoor or outdoor coil etc which could be co
38. PPORT 3 REQ D OUTDOOR UNIT BAFFLE ASSEMBLY A95446 Fig 2 Wind Baffle Construction Cube Units covers opening below the control box On larger models informa tion plate may not cover entire opening In this instance access panel can be removed and placed on its side to cover additional space Step 4 Control Box Cover Cube Products This panel contains much of the same information as the informa tion plate mentioned previously but is designed only to cover the control box Step 5 Remove Top Cover Cube Products 1 Turn off all power to outdoor an indoor units 2 Remove 5 screws holding top cover to coil grille and coil tube sheet 3 Remove 2 screws holding control box cover 4 Remove 2 screws holding information plate 5 Disconnect fan motor wires cut any wire ties and move wires out of control box and through tube clamp on back of control box 6 Lift top cover from unit 7 Reverse sequence for reassembly Step 6 Remove Fan Motor Assembly Cube Products 1 Perform items 1 3 4 and 5 above Note item 2 is not required Remove 4 screws holding wire basket to top cover Lift wire basket from unit Remove nuts holding fan motor to wire basket Remove motor and fan blade assembly Pull wires through wire raceway to change motor Reverse sequence for reassembly JO U A Prior to applying power check that fan rotates freely Table 4 Wind Baffle f
39. RODUCTION Section 1 of this Application Guideline and Service Manual provides the required system information necessary to install Puron equipment in all applications Section 2 provides the necessary information to service repair and maintain the family of Puron air conditioners and heat pumps Section 3 of this manual is an appendix Use the Table of Contents to locate desired topics INSTALLATION GUIDELINE Step 1 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 DO NOT DEVIATE FROM PDD Consult unit Installa tion Instructions for detailed information Step 2 Add On Replacement Retrofit Specifications for this unit in the add on replacement retrofit market require change out of outdoor unit metering device and all capillary tube coils Change out of indoor coil is recommended There can be no deviation 1 If system is being replaced due to compressor electrical failure assume acid is in system If system is being replaced for any other reason use approved acid test kit to determine acid level If even low levels of acid are detected install factory approved 100 percent activated alumina suction line filter drier in addition to the factory supplied liquid line filter drier Remove the suction line filter drier as soon as possible with a
40. The suction pressure at the outlet of the evaporator coil is transferred via the external equalizer tube to the underside of the diaphragm 3 The needle valve on the pin carrier is spring loaded which exerts pressure on the underside of the diaphragm via the pushrods and tends to close the valve Therefore bulb pressure equals evaporator pressure at outlet of coil plus spring pressure If the load increases the temperature increases at the bulb which increases the pressure on the top side of the diaphragm which pushes the carrier away from the seat opening the valve and increasing the flow of refrigerant The increased refrigerant flow causes increased leaving evaporator pressure which is transferred via the equalizer tube to the underside of the diaphragm This tends to cause the pin carrier 25 spring pressure to close the valve The refrigerant flow is effectively stabilized to the load demand with negligible change in superheat Step 13 Replacing R 22 Expansion Device with Puron TXV An existing R 22 TXV must be replaced with a factory approved specifically designed for Puron NOTE Puron Heat Pumps require a Puron hard shutoff TXV For existing R 22 TXV Fan Coils and Furnace Coils the TXV must be replaced with a factory approved specifically designed for Puron Fan Coils with internal TXV s may have directly replaced with from kit Fan coils and furnace coils with pistons TX
41. V must be located external to cabinet as shown in Fig 36 See Fig 35 for proper sensing bulb position and Fig 36 for proper sensing bulb location Follow instructions included with Puron kit for specific details See Fig 34 REFRIGERATION SYSTEM REPAIR Step 1 Leak Detection New installations should be checked for leaks prior to complete charging If a system has lost all or most of its charge system must be pressurized again to approximately 150 psi minimum and 375 psi maximum This can be done by adding refrigerant using normal charging procedures or by pressurizing system with nitrogen less expensive than refrigerant Nitrogen also leaks faster than Puron Nitrogen cannot however be detected by an electronic leak detector See Fig 38 A WARNING Due to the high pressure of nitrogen it should never be used without a pressure regulator on the tank Failure to follow this warning can cause a fire personal injury or death Assuming that a system is pressurized with either all refrigerant or a mixture of nitrogen and refrigerant leaks in the system can be found with an electronic leak detector that is capable of detecting HFC refrigerant If system has been operating for some time first check for a leak visually Since refrigerant carries a small quantity of oil traces of oil at any joint or connection is an indication that refrigerant is leaking at that point A simple and inexpensive method of testing
42. a shiny finish before brazing b 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 and it is a dull red color in appearance This section on brazing is not intended to teach a technician how to braze There are books and classes which teach and refine brazing techniques The basic points above are listed only as a reminder Step 5 Service Valves and Pumpdown A WARNING Never attempt to make repairs to existing service valves Unit operates under high pressure Damaged seats and o rings should not be replaced Replacement of entire service valve is required Tampering with damaged valves can cause personal injury or death Service valve must be replaced by properly trained service technician 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 shutoff convenience for certain types of repairs See Fig 27 and 28 Two types of service valves are used in outdoor residential equipment The
43. ack Thermistor Outdoor Ambient The Puron two speed air conditioner and heat pump units have an outdoor ambient air thermistor The control board must know the outdoor air temperature so it can activate various functions These functions include Activating the compressor crankcase heater when ever the outdoor unit is in the off cycle The fan motor speed changes for both air conditioner and heat pump on the 037 unit Outdoor Coil Thermistor OCT The coil or defrost thermistor is the same thermistor used to monitor outdoor air temperature The control board must know the coil temperature so it can activate various functions These functions include Frost sensing on heat pumps e Coil vs Ambient temperature relationship Thermistor Curve The resistance vs temperature chart enables the service techni cians to check thermistor resistance regardless of the temperature For example at a 60 F temperature thermistor resistance should be around 16 000 Ohms See Fig 41 We will talk about the thermistor in more detail when we review the control board fault codes Control Box Contactor And Capacitor THERMISTOR CURVE 90 80 gt 70 60 50 40 30 20 RESISTANCE KOHMS 10 0 20 40 60 80 100 120 TEMPERATURE DEG F A91431 Fig 41 Resistance Values Versus Temperature Removal of the information plate exposes the control components Both air cond
44. actor does not operate 1 With power off check whether contacts are free to move Check for severe burning or arcing on contact points 2 With power off use ohmmeter to check for continuity of coil Disconnect leads before checking A low resistance reading is normal Do not look for a specific value as different part numbers will have different resistance values 3 Reconnect leads and apply low voltage power to contactor coil This may be done by leaving high voltage power to outdoor unit off and turning thermostat to cooling Check voltage at coil with voltmeter Reading should be between 20v and 30v Contactor should pull in if voltage is correct and coil is good If contactor does not pull in replace contactor 4 With high voltage power off and contacts pulled in check for continuity across contacts with ohmmeter A very low or 0 resistance should be read Higher readings could indicate burned or pitted contacts which may cause future failures Step 3 Capacitor CAUTION 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 NOTE If bleed resistor is wired across start capacitor it must be disconnected to avoid erroneous readings when ohmme
45. acuum with dry nitrogen A WARNING Wear safety glasses and gloves when working with refriger ants To replace switch 1 Apply heat with torch to solder joint and remove switch A CAUTION Wear safety glasses when using torch have quenching cloth available Oil vapor in line may ignite when switch is removed 2 Braze in 1 4 in flare fitting and replace pressure switch LOSS OF CHARGE SWITCH H P 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 LSV HEAT PUMP ONLY M M IA DA f 150 MAX M M fof LA A98328 A crankcase heater must be installed on compressor The above requirements provide protection against refrigerant migration to compressor when outdoor temperature is lower than indoor temperature Maximum elevation between units is 150 ft Maximum equivalent total line length is 175 ft Heat Pump Only Bi flow liquid line solenoid must be installed within 2 ft of outdoor unit with arrow pointing toward outdoor unit Fig 7 Application with Air Conditio
46. air flow Support Feet Four adhesive plastic feet which raise unit 4 in above mounting pad This allows sand dirt and other debris to be flushed from unit base minimizes corrosion Liquid Line Solenoid Valve An electrically operated shutoff valve to be installed at outdoor or indoor unit depending on tubing configuration which stops and starts refrigerant liquid flow in response to compressor operation Maintains a column refrigerant liquid ready for action at next compressor operation cycle Thermostatic Expansion Valve A modulating flow control device which meters refrigerant flow rate into the evaporator in response to the superheat of the refrigerant gas leaving the evaporator Puron amp TXVs are hard shutoff only Only use factory specified TXVs LOW AMBIENT GUIDELINE The minimum operating temperature for these units in cooling mode is 55 F outdoor ambient without additional accessories This equipment may be operated in cooling mode at ambient tempera tures below 55 F when the accessories listed in Table 1 or 2 are installed Wind baffles are required when operating in cooling mode at ambients below 55 F Refer to Fig 1 and 2 and Tables 3 and 4 for wind baffle construction details Puron amp Two Speed units are not approved for low ambient operation LONG LINE GUIDELINE This guideline provides the required system changes for the Puron air conditioners and heat pumps having piping require ments greater than 50
47. all or service this product Whenever possible shut off all power before working on electrical equipment If you must work on energized electrical equipment remove all watches and rings to minimize shock hazards Wear Safety glasses and gloves when handling refrigerants or brazing Never vent refrigerant to the atmosphere Recover or reclaim refrigerant using approved recovery equipment for use on Puron refrigerant 29 These are some general safety procedures Always read and follow specific procedures in the manufacturers installation and service literature MAJOR COMPONENTS Filter Drier All Puron two speed air conditioners and heat pumps are shipped with a filter drier designed for Puron The air conditioners use a single flow filter drier while the heat pumps use a bi flow drier The drier MUST be installed in the liquid line Thermal Expansion Valve TXV For Puron two speed air conditioners and heat pumps a hard shutoff bi flow TXV specifically designed for Puron and two speed operation must be used as the indoor coil metering device If a 40FKA or FV4A fan coil is used the must also be changed Although these two families of fan coils are designed for Puron applications currently the factory installed does not have the capability to meet the capacity ranges required for the two speed unit See the product literature for TXV requirements Fan Motor Fan motor rotates the fan blade that either d
48. alled for This will quickly clear any liquid that may have accumulated in the compressor 2nd Stage High Capacity Cooling Second stage cooling or high capacity cooling is achieved when a call from the indoor thermostat is initiated and 24 volt control power is applied to Y1 Y2 and heat pump only Y2 will tell the control to start the compressor for high capacity operation while tells the control to shift the reversing valve on the heat pump models to the cooling position Note that the system can start in low or high capacity cooling If the unit is running and a change in capacity is called for the compressor will shutdown for one minute between cycles The outdoor fan motor will continue to operate between these one minute shutdown cycles The 037 size model with its variable speed outdoor fan motor will continue to operate and will change to the desired speed at the beginning of the one minute shutdown cycle 1st Stage Low Capacity Heating H P Only The unit sequence of operation for the first stage heating for the Puron two speed heat pumps begins with a call from the indoor thermostat then 24 volt control power is applied to Y1 Y1 will tell the control to start the compressor for low capacity Table 14 Function Light Codes FUNCTION LIGHT LED CODE DEFINITION Constant Flash No Pause No demand stand by Lowest Priority 1 Flash with Pause Low capac
49. an air conditioning and heat pump system refrigerant transfers heat from on replace to another The condenser is the outdoor coil in the cooling mode and the evaporator is the indoor coil The condenser is the indoor coil in the heating mode and the evaporator is the outdoor coil Compressed hot gas leaves the compressor and enters the condensing coil As gas passes through the condenser coil it rejects heat and condenses into liquid The liquid leaves condensing unit through liquid line and enters metering device at 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 Step 2 Compressor Oil A CAUTION The compressor in a Puron system uses a polyol ester POE oil 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 See Table 10 Step 3 Servicing Systems on Roofs With Synthetic Materials POE polyol ester compressor lubricants are known to cause long term damage to some synthetic roofing materials Exposure even if immediately cleaned up may cause embrittlement leading to cracking to occur in one year or more When performing any service which may risk ex
50. at pump W1 signal is required Check thermostat literature for more information Troubleshooting the Two Speed Compressor Start Assist Start the compressor in Low Speed The starting amperage should fall below 12 amps within 5 sec If after 5 sec the amperage exceeds 12 amps and the start relay does not release the compressor will open the thermal overload and will be locked out by the control board The control board display will show Vc Vh When this occurs replace the start assist components CARE AND MAINTENANCE To assure high performance and minimize possible equipment malfunction it is essential that maintenance be performed periodi cally on this equipment The frequency with which maintenance is performed is dependent on such factors as hours of operation geographic location and local environmental conditions A WARNING Disconnect all electrical power to unit before performing any maintenance or service on outdoor unit Remember to dis connect power supply to air handler as this unit supplies low voltage power to the outdoor unit Failure to follow this warning can cause a fire personal injury or death The minimum maintenance that should be performed on this equipment is as follows 1 Check outdoor coil for cleanliness each 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 connect
51. c If present isolate problem and correct Check to be sure caps are installed on service valves and are tight Check to be sure tools loose parts and debris are removed from unit Check to be sure all panels and screws are in place and tight Step 2 Desert and Seacoast Locations Special consideration must be given to installation and mainte nance of condensing units installed in coastal or desert locations This is because salt and alkali content of sand adheres to aluminum fins of coil and can cause premature coil failure due to corrosion Preventive measures can be taken during installations such as 1 2 Locate unit on side of structure opposite prevailing winds Elevate unit to height where drifting sand cannot pile up against coil Mounting feet 4 in high are available as accessories and can be used to elevate unit Addition of coastal filter See Product Data Digest for accessory listing Maintenance in desert and seacoast locations i Frequent inspection of coil and basepan especially after storms and or high winds Clean coil by flushing out sand from between coil fins and out of basepan as frequently as inspection determines necessary In off season cover with covering that allows air to circulate through but prevents sand from sifting in such as canvas material Do not use plastic as plastic will hold moisture possibly causing corrosion AIR CONDITIONER AND HEAT PUMP
52. 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 5 6 alignment Reinstall top cover and position blade Reconnect electrical power and check for proper operation ELECTRICAL CONTROLS AND WIRING 1 2 Disconnect power to both outdoor and indoor units Check all electrical connections for tightness Tighten all screws on electrical connections If any connections appear to be burned or 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 reconnect electrical power to indoor and outdoor units and observe unit through 1 complete operating cycle If there are any discrepancies in operating cycle troubleshoot to find cause and correct REFRIGERANT CIRCUIT 1 2 Check refrigerant charge using the superheat method and if low on charge check unit for leaks using an electronic leak detector If any leaks are found remove and reclaim or isolate charge pumpdown if applicable Make necessary repairs 35 Evacuate recharge observe unit through 1 complete operating cycle FINAL CHECK OUT After the unit has been operating the following items should be checked 1 4 Check that unit operational noise is not excessive due to vibration of component tubing panels et
53. ccomplished with a valve that reverses flow of refrigerant in system See Fig 28 This reversing valve device is easy to 23 NEW SOLENOID COIL 4TH PORT 4 PORT DESIGN A91456 Fig 29 Reversing Valve troubleshoot and replace The reversing valve solenoid can be checked with power off with an ohmmeter Check for continuity and shorting to ground With control circuit 24v power on check for correct voltage at solenoid coil Check for overheated solenoid With unit operating other items can be checked such as frost or condensate water on refrigerant lines The sound made by a reversing valve as it begins or ends defrost is a whooshing sound as the valve reverses and pressures in system equalize An experienced service technician detects this sound and uses it as a valuable troubleshooting tool Using a remote measuring device check inlet and outlet line temperatures DO NOT touch lines If reversing valve is operating normally inlet and outlet temperatures on appropriate lines should be close Any difference would be due to heat loss or gain across valve body Temperatures are best checked with a remote reading electronic type thermometer with multiple probes Route thermo couple leads to inside of coil area through service valve mounting plate area underneath coil Fig 30 and 31 show test points TP on reversing valve for recording temperatures Insulate points for more accurate reading If valve is defect
54. d a 24 volt signal out to the LOW capacity contactor coil CL Step 3 This will close the contactor which will send a signal to the compressor S terminal and eventually to the terminal via the start components Step 4 The Hard Start Capacitor and Relay will only be in the circuit for a short time and will be the power to keep the compressor running Compressor NOTE The S and terminals on the compressor are NOT your traditional START and RUN terminals This type of compressor acts as a Balanced Wind ing type motor similar to reversible rotation blower motor HIGH capacity will cause the compressor to run in one direction while LOW will cause the motor to run in the opposite direction thus reversing the traditional sense of the S and terminals This sequence shows the compressor ready to shift to HIGH capacity operation NOTE the condenser fan motor will be running during the switch form LOW to HIGH operation There is a one minute delay between LOW and HIGH capacity Step 1 The signal comes from the indoor thermostat to the second stage cooling terminal Y2 This will send a 24 volt signal to the HIGH capacity contactor coil CH and close the contactor Step 2 With the contactor closed high voltage will be sent to the R terminal and eventually to the S terminal via the start components Step 3 The Hard Start Capacitor and Relay will only be the circuit for a sh
55. due to temperature or slight elevation differences between indoor and outdoor units Maximum equivalent line length is 175 ft between indoor and outdoor units Heat Pump Only Bi flow liquid line solenoid must be installed within 2 ft of outdoor unit with arrow pointing toward outdoor unit Fig 5 Application with Air Conditioner or Heat Pump Installed in a Horizontal Configuration 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 20 When contacts open a circuit is completed from line side of contactor through crankcase heater through run windings of compressor and to other side of line When contacts are closed there is no circuit through crankcase heater because both leads are connected to same side of line This allows heater to operate when system is not calling for cooling The heater does not operate when system is calling for cooling The crankcase heater is powered by high voltage power of unit Use extreme caution troubleshooting this device with power on The easiest method of troubleshooting is to apply voltmeter across crankcase heater leads to see if heater has power Do not touch heater Carefully feel area around crankcase heater If warm crankcase heater is probably functioning Do not rely on this method as absolute evidence heater is functioning If compressor has been running the area will still be warm With
56. e valve before brazing To prevent damage to the unit use a metal barrier between brazing area and unit After the brazing operation and the refrigerant tubing and evapo rator coil have been evacuated the valve stem can be turned counterclockwise until it opens or back seats which releases refrigerant into tubing and evaporator coil The system can now be operated Back seating service valves must be back seated turned counter clockwise until seated before the service port caps can be re moved and hoses of gage manifold connected In this position refrigerant has access from and through outdoor and indoor unit The service valve stem cap is tightened to 20 2 ft lb torque and the service port caps to 9 2 ft lb torque The seating surface of the valve stem has a knife set edge against which the caps are tightened to attain a metal to metal seal If accessory pressure switches are used the service valve must be cracked Then the knife set stem cap becomes the primary seal The service valve cannot be field repaired therefore only a complete valve or valve stem and service port caps are available for replacement If the service valve is to be replaced a metal barrier must be inserted between the valve and the unit to prevent damaging the unit exterior from the heat of the brazing operations A WARNING Wear safety glasses and gloves when handling refrigerants Failure to follow this warning can cause a fire personal inj
57. ed 20 Open Circuit 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 of the spirals orbits N g y Ww y W gt 2 M m 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 gg d WM ao nisi By the time the gas arrives at the center port discharge pressure has been reached Actually during operation all six gas passages are in various stages of compression at all times resulting in nearly con tinuous suction and discharge A90198 Fig 25 Scroll Compressor Refrigerant Flow 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
58. eft The correct plug can be connected easily to compressor terminals and plug wires routed easily through slot terminal cover Step 14 Low Voltage Terminals The low voltage terminal designations and their description and function are used on all split system condensers W Energizes first stage supplemental heat through defrost relay wht L Energizes light on thermostat with service alarm W3 Energizes second or third stage supplemental heat R Energizes 24 v power from transformer red Y Energizes contactor for first stage cooling or first stage heat ing for heat pumps yel O Energizes reversing valve on heat pumps orn C Common side of transformer blk COPELAND SCROLL COMPRESSOR W PURON The compressor used in this product is specifically designed to operate with Puron 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 niques Refrigerants present additional safety hazards A WARNING Wear safety glasses and gloves when handling refrigerants Failure to follow this warning can cause a fire personal injury or death The scroll compressor pumps refrigerant through the system by the interaction of a stationary and an orbiting scroll See Fig 25 The scroll compressor has no dynamic suction or discharge valves
59. emperature is higher than indicated Remove refrigerant if temperature is lower Allow a tolerance of 3 F 28 Step 8 TWO SPEED APPLICATION GUIDELINES Carrier designed and tested Puron two speed air conditioner and heat pump products operate in a range of 55 to 125 F ambient for cooling and 30 to 66 F ambient for heating Hot gas by pass and 100 percent outdoor air applications are not approved on this or any Carrier split system residential product The Puron two speed products like all Puron products are shipped with a filter drier to be installed in the field liquid line two speed air conditioners and heat pumps require a Balance Port Thermal Expansion Valve TXV be used as the metering device on the indoor coil for cooling applications The TXV is not shipped with the outdoor unit it is field supplied Consult the presale literature for proper sizing of the TXV The indoor coil fan coil may have to be replaced to an approved combination listed in the product literature or ARI directory Line sets for the Puron two speed air conditioners are similar to those used on existing R 22 and Puron units Line sets for the Puron two speed heat pumps are similar to the Puron single speed heat pump units Carrier thermidistat thermostats and zone controls are recom mended control devices the logic for sequence control of the Puron two speed products are contained within the thermostats and zoning
60. entering compressor reaches a prescribed value Small variations of charge affect suction gas superheat temperatures greatly Therefore this method of charging is very accurate This method can be used with fixed restrictor type metering devices such as AccuRater For units using a TXV the subcooling method must be used To charge by superheat a service technician will need an accurate superheat thermocouple or thermistor type thermometer a sling psychrom eter and a gage manifold Do not use mercury or small dial type thermometers as they are not adequate for this type of measure ment Refer to unit information plate for superheat charging procedure A95422 5000 4500 4000 e 2500 o z 2000 1500 1000 500 LEAK IN SYSTEM VACUUM TIGHT TOO WET TIGHT DRY SYSTEM 0 1 2 3 4 5 6 7 MINUTES A95424 Fig 40 Deep Vacuum Graph SUBCOOLING CHARGING METHOD See Charging Tables 15 amp 16 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 required subcooling temperature intersects measured liquid service valve pressure 5 Add refrigerant if liquid line t
61. es and assure a tight dry system before charging The 2 methods used to evacuate a system are the deep vacuum method and the triple evacuation method DEEP VACUUM METHOD The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gage capable of accurately measuring this vacuum depth The deep vacuum method is the most positive way of assuring a system is free of air and moisture See Fig 40 LEAK DETECTOR SOLUTION A95423 Fig 39 Bubble Leak Detection Step 6 Puron Refrigerant Charging Refer to unit information plate for superheat charging procedure Charge Puron units with cylinder in upright position and a commercial type metering device in manifold hose Charge refrig erant into suction line For all approved combinations system must be charged correctly for normal system operation and reliable operation of components See Fig 41 If system has lost all charge weigh in charge using digital scales System charge should be fine tuned by using superheat method or subcooling method as defined by cooling mode metering device For charging during heating season charge must be weighed in accordance with unit rating plate 0 6 oz ft of 3 8 in liquid line above or below 15 ft respectively Step 7 Checking Charge SUPERHEAT CHARGING METHOD Superheat charging is the process of charging refrigerant in a system until the temperature superheat of suction gas
62. first type is a front seating valve which has a service port that contains a Schrader fitting The service port is always pressurized after the valve is moved off the front seat position 22 The second type is a combination front seating back seating valve which has a metal to metal seat in both the open and closed positions When it is fully back seated the service port is not pressurized To pressurize the service port this valve must be moved off the back seating position This valve does not contain a Schrader fitting Both types of service valves are designed for sweat connection to the field tubing The service valves in the outdoor unit come from the factory front seated This means that the refrigerant charge is isolated from the line set connection ports Some heat pumps are shipped with sweat adapter tube This tube must be installed on the liquid service valve After connecting the sweat adapter to the liquid service valve of a heat pump the valves are ready for brazing The interconnecting tubing line set can be brazed to the service valves using industry accepted methods and materials Consult local codes Before brazing the line set to the valves the belled ends of the sweat connections on the service valves must be cleaned so that no brass plating remains on either the inside or outside of the bell joint To prevent damage to the valve and or cap O ring use a wet cloth or other acceptable heat sinking material on th
63. ft or installations where indoor unit is located above and or below outdoor unit by more than 20 ft This guide is intended to cover applications outside Installation Instruc tions AII air conditioners and heat pumps require a hard shutoff TXV a compressor start capacitor and relay and a crankcase heater in long line installations Step 1 Interconnecting Tubing Table 4 lists the required interconnecting vapor line diameters for heat pumps Puron systems installed in long line applications must use only 3 8 in liquid lines Equivalent line lengths equal the linear length measured of the interconnecting vapor tubing plus losses due to elbows See Table 7 and Fig 4 Table 6 provides estimated percentage of nominal cooling capacity losses based on standard required vapor line size versus what is selected for long line application Refer to outdoor unit presale literature for the required vapor line diameter Calculate linear length of vapor tube required adding any losses for total number of elbows for application See Table 7 Using this equivalent length select desired vapor line size from the table Subtract nominal percentage loss from outdoor unit presale litera ture Detailed Cooling Capacities for given indoor outdoor combi nation Reference all notes of Table 6 NOTE When specifying the vapor line insulation be aware of the following standard practice Tubing kits should meet the following recommendations to min
64. ge with correct refrigerant quantity Step 2 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 service valves 3 Break vacuum with nitrogen 4 Remove top cover See Remove Top Cover in Cabinet section of the manual Remove screws in base pan to coil grille 6 Remove coil grille from unit 7 Remove screws on corner post holding coil tube sheet A WARNING Cut tubing to reduce possibility of fire and personal injury 8 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 9 Lift coil vertically from basepan and carefully place aside 10 Reverse procedure to reinstall coil 11 Replace filter drier evacuate system recharge and check for normal systems operation PISTON RETAINER PISTON RING ae PISTON Y 1 Ko PISTON Bons Y e U 2 S3 Pad 2d E 2 2 4 c 2 2 2 2 2 e FIELD 2 CONNECTION 2 NC STRAINER I i FLARE T ADAPTER LIQUID LINE STRAINER lt 4 APPROX 2 LONG 3 V STRAINER LABEL AFFIX TO LIQ LINE NEAR STRAINER LOCATION A01019 Fig 33 AccuRater amp Components Step 3 Compressor Removal and Replacement Once it is determined that compressor has failed and the reason established compressor must be replaced 2
65. i mize losses through insulation 5 8 in and 3 4 in tubing kits should be supplied with 3 8 in insulation 7 8 in and 1 1 8 in tubing kits should be supplied with 1 2 in insulation For minimal capacity loss in long line application 1 2 in insulation should be specified NOTE Special consideration must be given to isolating intercon necting tubing from building structure Isolate tubing so that vibration or noise is not transmitted into structure See Fig 3 Step 2 Metering Device Long Line Set A hard shutoff TXV must be used instead of a piston for an indoor metering device When sizing an accessory TXV refer to unit presale literature NOTE With heat pumps having vertical or equivalent lengths over 100 ft the outdoor piston size MUST be increased one size A liquid line solenoid must be used for all long line heat pump applications The solenoid valve has a flow arrow stamped in the valve body This flow arrow must point toward the outdoor unit Step 3 Tubing Configuration Fig 5 through 7 detail the proper installation of equipment and provide applications where accessories may be required Reference all notes of appropriate figure Step 4 Charging Information Use subcooling charging method The standard subcooling charg ing methods can be found in refrigerant system charging section of Service Manual Since total system charge is increased for long line application it is necessary to calculate additional
66. ions for tightness and controls for proper operation each cooling season and service as necessary A CAUTION Because of possible damage to the equipment or personal injury maintenance should be performed by qualified person nel only Step 1 Cleaning CLEANING COIL 1 Remove top cover See Remove Top Cover in Cabinet section of this manual A 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 5 6 If oil deposits are present spray coil with ordinary household detergent Wait 10 minutes and proceed to next step Using garden hose spray coil vertically downward with constant stream of water at moderate pressure Keep nozzle at a 15 to 20 angle about 3 in from coil face and 18 in from tube Spray so debris is washed out of coil and basepan Reinstall top cover and position blade Reconnect electrical power and check for proper operation CLEANING OUTDOOR FAN MOTOR AND BLADE 1 Remove fan motor and blade careful not to bend dent fan blade Clean motor and blade with soft brush or cloth Be
67. itioner and heat pump control boxes will appear to be nearly identical There are two contactors two capacitors a control board and a compressor start assist device called Puron Kick Start The contactors are identical to those used in the standard single speed units One controls low capacity operation and the second controls high speed The capacitors also are similar to those used in standard single speed units You have a fan capacitor for the outdoor fan motor and a run capacitor for the compressor motor The control board and Puron Kick Start will be covered momentarily Always replace these devices with the Factory Approved Compo nents Incoming Power Incoming power is attached to the two power wire stripped leads A ground lug is also provided Outdoor 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 Kick Start The Puron Kick Start device is similar to a hard start capacitor and relay used on standard single speed units when extra starting capacitance is required to start the compressor motor What makes this start assist special is that it takes only one relay and capacitor to start the compressor in both low and high speed These components are unique to the two speed product and can not be substituted by standard hard start components for single speed units Control Board The
68. ity operation 2 Flashes with Pause High capacity operation 3 Flashes with Pause Alternate 3 amp 4 flashes Outdoor thermistor failure Thermistor out of range Alternate 5 8 1 flashes Low pressure switch trip Alternate 5 amp 2 flashes High pressure switch trip Alternate 6 flashes Compressor Vc Vh trip Constant light operation Because there is no signal telling the control to shift the reversing valve the reversing valve remains in the heating position 2nd Stage High Capacity Heating H P Only Second stage heating or high capacity heating is achieved when a call from the indoor thermostat is initiated and 24 volt control power is applied to Y1 and Y2 Y2 will tell the control to start the compressor for high capacity operation Because there is no signal telling the control to shift the reversing valve the reversing valve remains in the heating position Note that the system can start in low or high capacity heating If the unit is running and a change in capacity is called for the compressor will shutdown for one minute between cycles The outdoor fan motor will continue to operate between these one minute shutdown cycles The 037 size model with its variable speed outdoor fan motor will continue to operate and will change to the desired speed at the beginning of the one minute shutdown cycle The outdoor fan motor works in the heating mode in the sa
69. ive 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 rebrazed back into system Do not use hacksaw This introduces chips into system that cause failure After defective valve is removed wrap it in wet rag and carefully unbraze stubs Save stubs for future use Because defective valve is not overheated it can be analyzed for cause of failure when it is returned 3 Braze new valve onto used stubs Keep stubs oriented cor rectly Scratch corresponding matching marks on old valve and stubs and on new valve body to aid in lining up new valve FROM INDOOR COIL VIA SERVICE VALVE ON OUTDOOR COIL TO OUTDOOR COIL TO ACCUMULATOR FROM COMPRESSOR DISCHARGE LINE A88342 Fig 30 Reversing Valve Cooling Mode or Defrost Mode Solenoid Energized TO FROM TO INDOOR COIL OUTDOOR AM enor VIA SERVICE VALVE COIL ON OUTDOOR COIL TP 3 e ACCURATE READING i TP 4 INSULATE FOR ACCURATE READING FROM COMPRESSOR DISCHARGE LINE ELECTRONIC THERMOMETER A88341 Fig 31 Reversing Valve Heating Mode Solenoid De Energized 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
70. l start up a 5 minute delay occurs before thermostat closes After thermostat closes cycle protector device provides a 3 sec delay See Fig 17 18 and 19 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 Step 5 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 hard shutoff must be installed at indoor unit Acrankcase heater must be installed on compressor Vapor line should slope toward indoor unit A97637 The above requirements provide refrigerant migration protection during off cycle
71. lty 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 Step 13 Compressor Plug The compressor electrical plug provides a quick tight connection to compressor terminals The plug completely covers compressor terminals and mating female terminals are completely encapsu 18 lated in plug Therefore terminals are isolated from any moisture so corrosion and resultant pitted or discolored terminals are reduced The plug is oriented to relief slot in terminal box so cover cannot be secured if wires are not positioned in slot assuring correct electrical connection at the compressor The plug can be removed by simultaneously pulling while rocking plug How ever these plugs can be used on only specific compressor The configuration around the fusite terminals is outline of the terminal covers The slot through which wires of plug are routed is oriented on the bottom and slightly to the l
72. maximum of 72 hr 2 Drain oil from low points or traps in suction line and evaporator if they were not replaced 3 Change out indoor coil or verify existing coil is listed in the Product Data Digest 4 Unless indoor unit is equipped with a Puron approved metering device change out metering device to factory supplied or field accessory device specifically designed for Puron 5 Replace outdoor unit with Puron outdoor unit 6 Install factory supplied liquid line filter drier A WARNING Never install suction line filter drier in the liquid line of a Puron system Failure to follow this warning can cause a fire personal injury or death 7 If suction line filter drier was installed for system clean up operate system for 10 hr Monitor pressure drop across drier If pressure drop exceeds 3 psig replace suction line and liquid line filter driers Be sure to purge system with dry nitrogen and evacuate when replacing filter driers Continue to monitor pressure drop across suction line filter drier After 10 hr of runtime remove suction line filter drier and replace liquid line filter drier Never leave suction line filter drier in system longer than 72 hr actual time 8 Charge system See unit information plate Step 3 Seacoast For Air Conditioners Only Installation of these units in seacoast locations requires the use of a coastal filter See section on cleaning ACCESSORY DESCRIPTIONS Refer to
73. me manner as the cooling mode with the exception of the Pressure Guard cycling the fan motor during heating operation 3rd Stage High Capacity Heating H P Only Third stage heating is high capacity heating with first stage strip heat This is achieved when a call from the indoor thermostat is initiated and 24 volt control power is applied to Y1 Y2 and W1 Y2 will tell the control to start the compressor for high capacity operation Because there is no signal telling the control to shift the reversing valve the reversing valve remains in the heating position First stage strip heat is achieved when W1 initiates 24 volt control power to the fan coil heater element 4th Stage High Capacity Heating H P Only Fourth stage heating is high capacity heating with second stage strip heat This is achieved when a call from the indoor thermostat is initiated and 24 volt control power is applied to Y1 Y2 and W2 Y2 will tell the control to start the compressor for high capacity operation Because there is no signal telling the control to shift the reversing valve the reversing valve remains in the heating position Staging the strip heater can be accomplished by wiring the heater using W1 and W2 terminal and splitting the heater elements on the fan coil unit A typical 15 KW heater will have three 5 KW elements By connecting W1 to 5 KW and W2 to the
74. ms contain optional com ponents We will cover only the Heat Pump operation of the two speed unit This will cover how the air conditioning system works in the cooling mode of the heat pump This sequence shows the unit in standby or ready to start condition Step 1 Low voltage reading will be at the Common and the Power 24Vac terminals Step 2 High voltage readings should be taken at the HIGH capacity contactor terminals 23 and 21 To verify that the crankcase heater is operating check voltage at the CL terminal 11 and CCH terminals If 230 volts is present then the compres sor casing should feel warm Step 3 If a jumper is installed between HP AC and common the wiring harness is setup for Heat Pump operation If there is no jumper then the wiring harness is setup for Air Conditioning operation and the Defrost mode operation is disabled NOTE The crankcase heater CCH is energized ANYTIME the compressor is off regardless of outdoor temperature This sequence shows the compressor ready to start in LOW capacity operation NOTE Fan motor operation shown on sepa rate slide Step 1 The signal for the Reversing Valve O terminal comes from the indoor thermostat The circuit board will then send a 24 volt signal out to the reversing valve terminals RVS and C Step 2 The first stage cooling Y1 comes from the indoor thermostat The circuit board will then sen
75. n air conditioner Puron pressure switches are identified by a pink stripe down each wire LOW PRESSURE SWITCH A C ONLY The low pressure switch is located on suction line and protects against low suction pressures caused by such events as loss of charge low airflow across indoor coil dirty filters etc It opens on a pressure drop at about 50 psig If system pressure is above this switch should be closed To check switch 1 Turn off all power to unit 2 Disconnect leads on switch 3 Apply ohmmeter leads across switch You should have con tinuity on a good switch lt A crankcase heater must be installed on compressor 50 MAX LSV HEAT PUMP ONLY x A98327 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 50 ft Maximum equivalent total line length is 175 ft Heat Pump Only Bi flow liquid line solenoid must be installed within 2 ft of outdoor unit with arrow pointing toward outdoor unit Fig 6 Application with Air Conditioner or Heat Pump Installed with Indoor Unit Above Outdoor Unit NOTE Because these switches are attached to refrigera
76. n most units it is the bottom circuit Step 10 Defrost Thermostats Defrost thermostat signals heat pump that conditions are right for defrost or that conditions have changed to terminate defrost It is 14 A94006 Fig 14 Capacitors a thermally actuated switch clamped to outdoor coil to sense its temperature Normal temperature range is closed at 30 3 F and open at 80 5 F NOTE The defrost thermostat must be located on the liquid side of the outdoor coil on the bottom circuit and as close to the coil as possible Step 11 Defrost Control Board Solid state defrost boards used on heat pumps replace electrome chanical timer and defrost relay found on older defrost systems The defrost control board can be field set to check need for defrost every 30 50 or 90 minutes of operating time by connecting the jumper labeled W1 on the circuit board to the terminal for the 91455 Fig 15 PTC Device defrost time desired The board is set at factory for 90 minutes The defrost period is field selectable depending upon geographic areas and defrost demands Troubleshooting defrost control involves a series of simple steps that indicate whether or not board is defective 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
77. n 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 terminals is start S Remaining terminal will be run winding R See Fig 25 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 26 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 eliminated such as overloads improper voltage pres sure equalization defective capacitor s relays wiring etc Com pressor has internal line break overload so be certain it is clos
78. ner or Heat Pump with Indoor Unit Below Outdoor Unit SERVICE PANEL RATIN GROMMET PLATE CONTROL BOX SERVICE INFO VALVE LABEL INFO PLATE LIQ TUBE WARNING LABEL m n 9 1 _ ACCESS PANEL e is BASE PAN N BASE PAN Fig 8 Callouts for Puron Air Conditioner and Heat Pump A95410 12 38TXA 38TXA 13 SEER Air Conditioner 38TZA 12 SEER Air Conditioner 38TSA 14 SEER Air Conditioner 38EZA 12 SEER Air Conditioner 38EYA 12 SEER Heat Pump 38YXA 13 SEER Heat Pump 38YZA 12 SEER Heat Pump 38TDB Two Speed Air Conditioner 38YDB Two Speed Heat Pump Nominal Capacity 018 18 000 Btuh 024 24 000 Btuh 030 30 000 Btuh 036 36 000 Btuh 037 37 000 Btuh 042 42 000 Btuh 048 48 000 Btuh 060 60 000 Btuh 018 0 1 m Series Electrical 208 230 1 Fig 9 Model Number Nomenclature 01 96 Week of Manufacture Year of Manufacture A00427 E 00001 Serial Number Manufacturing Site A95406 Fig 10 Serial Number Nomenclature A95506 Fig 11 Information Plate cannot be installed on suction line This switch is installed in liquid line instead and acts as loss of charge protector The liquid line is the low side of the system in heating mode It operates identically to low pressure switch except it opens at 23 psi Tro
79. new two speed control board is smaller and has less compo nents than the older two speed control This control requires no configuration plug has no high speed latching pot and requires less troubleshooting Let s review some of the features of this control Jumpers and Plugs The two speed control has five 5 jumpers or plugs which are used at the factory and by the field Connections to the control by the factory are from various components within the unit such as crankcase heater low and high pressure switches air temperature and outdoor coil thermistors See Fig 42 Lets review the jumpers and their connections 31 112 M LO PL2 LPS PL3 1 2 3 4 HP AC C SEV RS FORCED DEFROST DEFROST TIME MIN Co DIP SWITCHES SSSSSO A00428 Fig 42 Control Board e PL1 Terminals 1 amp 2 are used to configure the board for air conditioner or heat pump Terminal 3 is for future use Terminals 4 amp 5 are for heat pump reversing valve coil connections PL2 Terminal 1 connection is for high capacity contactor 24 volt coil Terminal 2 connection is for low capacity contactor 24 volt coil e Low Pressure switch terminals PLA High Pressure switch terminals PLS Terminals are for the Outdoor Air OAT and Outdoor Coil and Defrost OCT the
80. ntributing to the failure Runs Does Not Pump In this type of failure compressor motor runs and turns compres sor but compressor does not pump refrigerant A clamp on ammeter on common leg shows a very low current draw much Table 11 PressureGuard Heating Vapor Pressure Switch STANDARD VAPOR CUT IN CUT OUT LINE SIZE PART NUMBER ps PSI 1 2 HK02ZB325 325 400 5 8 HK02ZB325 325 400 3 4 HK02ZB309 309 384 7 8 HK02ZB325 325 400 118 HK02ZB300 300 374 Use only factory approved Part Numbers lower than rated load amp RLA value stamped on compressor nameplate Because no refrigerant is being pumped there is no return gas to cool compressor motor It eventually overheats and shuts off on its internal protection Noisy Compressor Noise may be caused by a variety of internal or external problems such as loosened hardware System problems such as an over charged compressor especially at start up may also cause exces sive noise Electrical Failures The compressor mechanical pump is driven by an electric motor within its hermetic shell In electrical failures compressor does not although external electrical and mechanical systems appear normal Compressor must be checked electrically for abnormali ties Before troubleshooting compressor motor review this description of compressor motor terminal identification Single Phase Motors To identify terminals C S and R 1 Tur
81. or Cube Units In UNIT HEIGHT A B c D E F G H J 21 15 16 19 7 8 13 3 4 28 1 8 10 11 16 20 1 4 11 11 16 3 13 16 19 13 16 17 13 16 23 15 16 21 7 8 13 3 4 28 1 8 10 11 16 20 1 4 11 11 16 3 13 16 21 13 16 19 13 16 25 15 16 23 7 8 13 3 4 28 1 8 10 11 16 20 1 4 11 11 16 3 13 16 23 13 16 21 13 16 Small 18 27 15 16 25 7 8 13 3 4 28 1 8 10 11 16 20 1 4 11 11 16 3 13 16 25 13 16 23 13 16 29 15 16 27 7 8 13 3 4 28 1 8 10 11 16 20 1 4 11 11 16 3 13 16 27 13 16 25 13 16 31 15 16 29 7 8 13 3 4 28 1 8 10 11 16 20 1 4 11 11 16 3 13 16 29 13 16 27 13 16 33 15 16 31 7 8 13 3 4 28 1 8 10 11 16 20 1 4 11 11 16 3 13 16 31 13 16 29 13 16 21 15 16 19 7 8 18 5 16 32 5 8 10 11 16 24 3 4 16 3 16 8 1 4 19 13 16 17 13 16 23 15 16 21 7 8 18 5 16 32 5 8 10 11 16 24 3 4 16 3 16 8 1 4 21 13 16 19 13 16 25 15 16 23 7 8 18 5 16 32 5 8 10 11 16 24 3 4 16 3 16 8 1 4 23 13 16 21 13 16 27 15 16 25 7 8 18 5 16 32 5 8 10 11 16 24 3 4 16 3 16 8 1 4 25 13 16 23 13 16 Medium 22 1 2 29 15 16 27 7 8 18 5 16 32 5 8 10 11 16 24 3 4 16 3 16 8 1 4 27 13 16 25 13 16 31 15 16 29 7 8 18 5 16 32 5 8 10 11 16 24 3 4 16 3 16 8 1 4 29 13 16 27 13 16 33 15 16 31 7 8 18 5 16 32 5 8 10 11 16 24 3 4 16 3 16 8 1 4 31 13 16 29 13 16 35 15 16 33 7 8 18 5 16 32 5 8 10 11 16 24 3 4 16 3 16 8 1 4 33 18 6 31 13 16 37 15 16 35 7 8 18
82. or Start Assist PTC or t Yes Yes No Compressor Start Assist Capacitor Relay MotorMaster amp Control 32LT660004 RCD or or Yes No No Low Ambient Pressure Switch KSALA0301410 Wind Baffle N A No KAACF0201MED or Coastal Filter KAACF0701SML No Yes Support Feet KSASF0101AAA Recommended Recommended KSATX0201HSZ KSATX0301HSZ Puron Hard Shutoff TXV KSATX0401HSZ No No KSATX0501HSZ Fan motor with ball bearings required Consult Product Data Digest for appropriate ordering number Table 2 Required Field Installed Accessories for Puron Heat Pumps REQUIRED FOR REQUIRED FOR ORDERING LOW AMBIENT COOLING LONG LINE ACCESSORY NUMBER APPLICATIONS APPLICATIONS BELOW 55 F 50 175 FT Crankcase Heater KAACH1201AAA Yes Yes Evaporator Freeze Thermostat KAAFT0101AAA Yes No Compressor Start Assist Capacitor and Relay t Yes Yes MotorMaster amp Control or KSALA0301410 Yes No Puron Low Ambient Pressure Switch Wind Baffle N A Yes No Support Feet KSASF0101AAA Recommended No KSATX0201HSZ KSATX0301HSZ Puron Hard Shutoff TXV KSATX0401HSZ Yes Yes KSATX0501HSZ Puron Liquid Line Solenoid Valve for Heating KHALS0401LLS No Yes Isolation Relay KHAIRO101AAA Yes No Required for all applications Consult Product Data Digest for appropriate ordering number A mesh screen inserted under top cover and inside base pan to protect condenser coil from salt damage without restricting
83. ort time and will be the power to keep the compressor running The condenser fan motor receives power form the closing of a relay in the circuit board If the unit is calling for the condenser fan motor apply a meter across terminals CL terminal 11 and ODF The reading should be 230 volts If the LOW LPS or HIGH HPS Pressure Switch opens the condenser fan will continue to run for up to fifteen 15 minutes If the switches have NOT closed after 15 minutes the condenser fan will stop running A fault code of either alternate 5 amp 1 or alternate 5 amp 2 flashes will occur If the system is a heat pump and in the heat pump operation the condenser fan can be turned off two different ways while the compressor is running in the heating mode One scenario is if the unit goes into defrost The circuit opens the fan relay so the coil can defrost quickly The other scenario is if the Pressure Guard VPS cycles see previous VPS description and operation in the Pressure Guard VPS section During cooling operation the VPS is in the vapor line low pressure which keeps the VPS from cycling off the condenser fan NOTE The condenser fan will run during the switching from LOW to HIGH or HIGH to LOW capacity operation On Heat Pump versions there is a 20 second fan delay at the termination of the defrost mode During heating operation frost may form on the outdoor coil as part of normal operation This frost must be periodicall
84. posure of compressor oil to the roof take appropriate precautions to protect roofing Procedures which risk oil leakage include but are not limited to compressor replacement repairing refrigerants leaks replacing refrigerant components such as filter drier pressure switch metering device coil accumulator or reversing valve SYNTHETIC ROOF PRECAUTIONARY PROCEDURE 1 Cover extended roof working area with an impermeable polyehtelene plastic drop cloth or tarp Cover an approxi mate 10 x 10 ft area 2 Cover area in front of the unit service panel with a terry cloth shop towel to absorb lubricant spills and prevent run offs and protect drop cloth from tears caused by tools or components 3 Place terry cloth shop towel inside unit immediately under component s to be serviced and prevent lubricant run offs through the louvered openings in the base pan 4 Perform required service 5 Remove and dispose of any oil contaminated material per local codes Step 4 Brazing Definition The joining and sealing of metals using a nonferrous metal having a melting point over 800 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 a Remove all oxidation from surfaces to
85. quid Line Solenoid or hard shutoff TXV for all Series A equipment MotorMaster Control A fan speed control device activated by a temperature sensor It is designed to control condenser fan motor speed in response to the saturated condensing temperature during operation in cooling mode only For outdoor temperature down to 20 F it maintains condensing temperature at 100 F 10 F Requires a ball bearing fan motor Low Ambient Pressure Switch A long life pressure switch which is mounted to outdoor unit service valve It is designed to cycle the outdoor fan motor in response to condenser pressure in cooling mode in order to maintain head pressure within normal operating limits approxi mately 200 psig to 365 psig The control will maintain working head pressure at low ambient temperatures down to 0 F when properly installed Wind Baffle A field fabricated sheet metal cover used to stop prevailing winds or where outdoor ambient temperature is less than 55 F during unit operation of cooling mode Coastal Filter Table 1 Required Field Installed Accessories for Puron Air Conditioners REQUIRED FOR LOW AMBIENT REQUIRED FOR REQUIRED FOR ORDERING LONG LINE SEACOAST ACCESSORY NUMBER RELON EE APPLICATIONS APPLICATIONS 50 175 WITHIN 2 MILES Crankcase Heater KAACH1201AAA Yes Yes No Evaporator Freeze Thermostat KAAFT0101AAA Yes No No Winter Start Control KAAWS0101AAA Yes No No Compress
86. r is designed to pump refrigerant in its gaseous state introduction of liquid into it could cause severe damage or total failure of compressor The accumulator is a passive device which seldom needs replac ing Occasionally its internal oil return orifice or bleed hole may become plugged Some oil is contained in refrigerant returning to compressor It cannot boil off in accumulator with liquid refriger ant The bleed hole allows a small amount of oil and refrigerant to 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 32 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 Recover 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 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 Remove acc
87. r of these units should be attempted only by trained service technicians familiar with standard service instruction and training material 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 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 Tab 3a 5a la Catalog No Printed in U S A Form 38 12SM Pg 1 4 05 Replaces 38 11SM A CAUTION Puron R 410A systems operate at higher pressures than standard R 22 systems Do not use R 22 service equipment or components on Puron equipment Ensure service equipment is rated for Puron Refrigeration systems contain refrigerant under pressure Extreme caution should be observed when handling refrigerants Wear safety glasses and gloves to prevent personal injury During normal system operations some components are hot and can cause burns Rotating fan blades can cause personal injury Appropriate safety considerations are posted throughout this manual where potentially dangerous techniques are addressed INT
88. raws or blows air through outdoor coil to perform heat exchange Motors are totally enclosed to increase reliability This also eliminates need for rain shield 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 check for continuity between three leads Replace motors that show an open circuit in any of the windings Place 1 lead of ohmmeter on each motor lead At same time place other ohmmeter lead on motor case ground Replace any motor that shows resistance to ground signs of arcing burning or overheating Located above the compressor is a single speed fan motor and fan This is not the case on the 037 size air conditioner and heat pump models which use the ICM variable speed fan motor ICM FAN MOTOR Only the 037 size air conditioner and heat pump models have the ICM variable speed fan motor The outdoor Integral Cont
89. refrig erant charge The rating plate charge of a given outdoor unit is for a standard application of 15 ft of interconnecting tubing For line lengths greater than 15 ft add 0 60 oz of refrigerant per foot of additional line length The rating plate charge can be found on outdoor unit rating plate or in the outdoor unit presale literature Long line applications do not require additional oil charge NOTE Excessive charge will increase risk of refrigerant migra tion and compressor damage Charging units with long refrigerant lines must be done carefully to avoid over charging Pressure and temperature changes are slower with long lines Adding or removing charge must be done slowly to allow time for system to stabilize UNIT IDENTIFICATION A WARNING Improper installation adjustment alteration service mainte nance or use can cause explosion fire electrical shock or other conditions which may cause personal injury death or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified installer or agency must use factory authorized kits accessories or replacement components when modifying this product Troubleshooting Charts for Puron Air Conditioners and Heat Pumps are provided in the appendix at back of this manual They enable the service technician to use a systematic approach to locating the cause of a problem and correcting system malfunc
90. rent flow to the contactor coil and shutdown A fault light will appear on the control board Fault lights and their meanings will be covered later in this program Pressure Switches The Puron two speed air conditioner contains two pressure switches to prevent system operation if the pressures get exces sively high or low The air conditioner low pressure switch in the suction line opens at 50 PSI and closes at 95 PSI The high pressure switch opens at 610 PSI and closes at 420 PSI Both pressure switch settings are considerably higher than on compara bly sized R 22 units The high and low pressure switches can be identified by their pink stripe on the switch s electrical wires The Puron two speed heat pump contains a loss of charge switch in the liquid line which opens at 23 PSI and closes at 55 PSI Table 12 PressureGuard Control Settings UNIT SIZE PART NUMBER CUT OUT CUT IN 024 HK02ZB325 400 325 036 HK02ZB309 384 309 037 HK02ZB325 400 325 048 HK02ZB325 400 325 060 HK02ZB300 374 300 30 PressureGuard VPS The Puron two speed heat pump contains a pressure guard labeled VPS which stands for Vapor Pressure Switch in the vapor line PressureGuard or VPS keeps the system pressures from exceed ing certain values during heating operation This device allows the Puron two speed heat pump to be installed on today s indoor coils and in most cases on today s interconnecting tubing Remember only cer
91. rmistor OR the outdoor thermistor indicates lower than 20 F the coil thermistor the thermistors are out of range In Heating If the outdoor thermistor indicates greater than 30 F or more than the coil defrost thermistor OR the outdoor ther mistor indicates lower than 10 F or more than the coil defrost thermistor the thermistors are out of range Compressor Vc Vh Trip Six 6 flashes represent a compressor thermal trip This trip code monitors the voltage at the compressor capacitor to verify the compressor voltage is in the proper range If the voltage drops below 90 volts or above 600 volts a fault of 6 flashes will be generated and the compressor will lock out Compressor Thermal Trip replaces PTC trip Board Monitors Compressor Capacitor Voltage and when Voltage drops below 90VAC or Above 600VAC Fault will Occur SEQUENCE OF OPERATION 1st Stage Low Capacity Cooling With a call for first stage cooling for Puron two speed air conditioners and heat pumps following is the unit sequence A call from the indoor thermostat is initiated 24 volt control power is applied to Y1 and Y1 will tell the control to start the compressor for low capacity operation while tells the control to shift the reversing valve on the heat pump models to the cooling position If the unit has been off for more than 12 hours it will start in high capacity for five minutes regardless of the capacity being c
92. rmistors Screw Terminals There are two 2 screw terminal blocks on the control board Terminal block labeled A through D is for future use The terminal block with six 6 screw connections is for the field low voltage wiring It is labeled O Y2 Y1 W1 C R in descending order Dip Switches There are two dip switches used to set the defrost timer interval or the run time between defrost checks It is factory set at 90 minutes and can be changed to 30 60 or 120 minute intervals Defrost Timer By setting the dip switches as shown in Table 13 the time interval between defrost checks can be changed There are 4 settings and the factory setting is at 90 minutes To change the timer from 90 minutes to the new 120 minute interval move both dip switches to the position as shown in the Table 13 To change the timer from 90 to 30 minutes move dip switch 1 to the ON position while leaving dip switch 2 in the OFF position To change the timer from 90 to 60 minutes move dip switch 2 to the ON position while leaving dip switch 1 in the OFF position See Fig 43 and Table 13 Forced Defrost The defrost cycle can be initiated by shorting out the Forced Defrost terminals for five seconds with a flat bladed screw driver After the five seconds has elapsed remove the blade and the defrost cycle will start There is no need to place a jumper across the to DFT on the control board as needed on
93. rol Motor ICM is a variable speed motor which operates from 400 to 900 rpm The motor is a permanent magnet type motor with the electronic controls inte grated into its rear cover The control package includes a small diode bridge capacitors and power switching devices It converts ac to dc power and switches the dc power to the motor windings on and off at various rates to control the motor speed The speed at which the motor windings are thus commutated is determined by a pulse width modulated PWM signal which is received from the control board on the motor control lines The PWM signal is created by turning a DC signal on and off once within a given period of time The signal on time relative to the signal total period defines the percent of the PWM For example if the period is 5 sec and the control power is turned on for 1 sec then off the signal will remain off for 4 sec before turning on again to start the next cycle The PWM is called a 20 percent duty cycle signal If the on time is increased to 4 sec of the 5 sec period the PWM is called an 80 percent duty cycle The ICM reads the PWM signal and increases the motor speed linearly from minimum speed to maximum speed with the percent duty cycle value of the supplied PWM signal FAN MOTOR OPERATION The two speed control board energizes the outdoor fan motor anytime the compressor is operating The outdoor fan motor remains energized during the one minute compressor speed
94. 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 6 Subtract instrument probe and lead resistance from each reading If any reading is within 20 percent of known resistance motor is probably normal Usually a considerable difference in reading is noted if a turn to turn short is present 21 REFRIGERATION SYSTEM Step 1 Refrigerant A CAUTION This system uses Puron refrigerant which has higher pres sures than R 22 and other refrigerants No other refrigerant may be used in this system Gage set hoses and recovery system must be designed to handle Puron If you are unsure consult the equipment manufacturer In
95. sor for 30 seconds while going into and out of defrost modes This is accomplished by turning DIP switch 3 to the ON position See Fig 24 for switch position Factory default is in the OFF position c TEST 30 50 90 Fn 50110063 97641 Fig 23 Checking Between C and W2 Five Minute Time Delay This control has a 5 minute time delay on startup The speedup terminals can be used to bypass this delay Momentary shorting across the speedup terminals for more than 5 seconds or defrost mode will be initiated Troubleshooting Troubleshooting this control is done in the same manner as the CES0130063 with the exceptions listed above Step 12 Fan Motor Fan motor rotates fan blade that draws air through outdoor coil to perform heat exchange Motors are totally enclosed to increase reliability This also eliminates need for rain shield For the correct 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 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 fau
96. tain indoor coil fan coil combinations will work properly Consult the presale literature for approved combinations Cut in and cut out values for the Pressure Guard are shown in Table 12 The PressureGuard has solid black leads Here is how the Vapor Pressure Switch VPS works Under certain high ambient operating conditions during the heating operation the vapor pressure in a normally operating system may exceed the pressure setting of the device This excess pressure will open the switch The switch is in series with the outdoor fan motor and will shut the fan motor off With the outdoor fan off less heat will be absorbed in the outdoor coil and the system pressures will drop When the outdoor fan is off frost may accumulate This can cause the system to have shorter time intervals between defrost cycles CAUTION The PressureGuard device VPS is in the high voltage 230 volt circuit It is not in the low or control voltage 24 volt circuit as are other pressure switches in the unit Use caution when working near this switch in an operating unit Muffler Accumulator Reversing Valve RVS The Puron two speed air conditioners and heat pumps have a compressor discharge line muffler to dampen sound pressure pulsations The Puron two speed heat pumps have a specifically designed reversing valve for Puron application and an accumulator for storing excess liquid refrigerant during the heating mode to prevent damaging flood b
97. ter is applied across capacitor See Fig 14 A CAUTION Always check capacitors with power off Attempting to troubleshoot a capacitor with power on can be dangerous Defective capacitors may explode when power is applied Insulating fluid inside is combustible and may ignite causing burns Capacitors are used as a phase shifting device to aid in starting certain single phase motors Check capacitors as follows 1 With power off discharge capacitors as outlined above Disconnect capacitor from circuit Put ohmmeter on R X 10k scale Using an analog ohmmeter check each terminal to ground use capacitor case Discard any capacitor which measures 1 2 scale deflection or less Place ohmmeter leads 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 Capacitance mfd
98. than 90 When information plate is removed these tabs can be inserted into 2 mating slots in bottom front edge of control box and plate will hang down forming a lower front panel See Fig 12 This is convenient when access to controls is required while unit is operating The information plate on small size casing completely 7 30 x 3 8 5 56 x 9 53 SLOT 4 REQ D L c dm c 9 54 3 45 DIA HOLE dk 2 REQ D mq 3 8 9 6 MAT L 18 GA STEEL E amp SUPPORT 9 54 3 45 DIA HOLE 1REQD K B The J lt 11 6 Y d Typ 7 82 5 56 DIA HOLE 3 REQD r UA M lat A lt 6 3 6 3 TYP TYP Thag x 2 BAFFLE 5 56 x 50 8 SLOT SCREW MAT L 20 GA STEEL 10 REQD 4 REQ D OUTDOOR BAFFLE 7 UNIT 2 REQ D BAFFLE ASSEMBLY A95444 Table 3 Dimensions In UNIT SIZE AA UNIT HEIGHT E F G H J K L 23 13 16 24 516 20 1 2 34 1 2 19 5 8 20 3 8 19 5 8 0 0 Small 26 316 27 13 16 24 516 24 12 34 1 2 23 5 8 24 3 8 23 5 8 0 11 7 8 33 13 16 24 516 30 1 2 34 1 2 29 5 8 30 3 8 29 5 8 0 14 7 8 27 13 16 21 30 5 8 24 1 2 42 23 5 8 24 3 8 23 5 8 17 1 8 11 7 8 Medium 33 33 13 16 21 30 5 8 30 1 2 42 29 5 8 30 3 8 29 5 8 17 1 8 14 7 8 3
99. tion 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 CAUTION Wear safety glasses and gloves when working with refriger ants To replace switch 1 Apply heat with torch to solder joint and remove switch A CAUTION Wear safety glasses when using torch Have quenching cloth available Oil vapor in line may ignite when switch is removed 2 Braze in 1 4 in flare fitting and screw on replacement pressure switch HIGH PRESSURE SWITCH The high pressure switch is located in liquid line and protects against excessive condenser coil pressure It opens at 610 psig High pressure may be caused by a dirty condenser coil failed fan motor or condenser air recirculation To check switch 1 Turn off all power to unit 11 2 Disconnect leads on switch 3 Apply ohmmeter leads across switch You should have con tinuity on a good switch NOTE Because these switches are attached to refrigeration system under pressure it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists If switch must be removed remove and recover all system charge so that pressure gages read 0 psi Never open system without breaking v
100. tions This section explains how to obtain the model and serial number from unit rating plate These numbers are needed to service and repair the Puron air conditioner or heat pump Step 1 Model Number Nomenclature Model number is found on unit rating plate See Fig 8 and 9 Step 2 Serial Number Nomenclature Serial number is found on unit rating plate See Fig 8 and 10 CABINET ASSEMBLY Certain maintenance routines and repairs require removal of cabinet panels Step 1 Remove Top Cover 1 Turn off all power to outdoor and indoor units 2 Remove access panel 3 Remove information plate 4 Disconnect fan motor wires and cut wire ties Remove wires from control box Refer to unit wiring label 5 Remove screws holding top cover to coil grille and corner posts 6 Lift top cover from unit 7 Reverse sequence for reassembly Step 2 Remove Fan Motor Assembly 1 Perform items 1 through 6 from above 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 Step 3 Information Plate The information plate is secured to front of control box and provides the control box cover See Fig 11 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
101. tions 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 tempera tures especially if aluminum conductors are used Step 2 Contactor The contactor provides a means of applying power to unit using low voltage 24v from transformer in order to power contactor NOTE Avoid contact between tubing and structure OUTDOOR WALL INDOOR WALL CAULK F LIQUID TUBE J VAPOR TUBE INSULATION THROUGH THE WALL Pass HANGER STRAP ABO UBE ONLY INSULATION 8 VAPOR TUBE C 3 1 25 4 mm MIN a X LIQUID TUBE SUSPENSION A94028 Fig 3 Tubing Support coil See Fig 13 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 cont
102. ubleshooting and removing this switch is identical to procedures used on other switches Observe same safety precautions PRESSUREGUARD HEATING VAPOR PRESSURE SWITCH H P ONLY This outdoor unit is equipped with a heating vapor pressure limiting device which cycles the outdoor fan at high ambient heating conditions Because Puron is a high pressure refrigerant this switch pro vides maximum flexibility and minimum cost for the installer owner by not requiring special thicker wall vapor tubing 13 and indoor coils thus allowing limited retrofit The use of this switch also allows the maximum number of indoor coil choices at minimum cost for the installer owner since it can use standard refrigeration tubing The effect of outdoor fan cycling on the HSPF Heating Seasonal Performance Factor is minimal due to its occurrence at outdoor ambients where building load is very low The exact ambient which the outdoor fan cycles depends on the indoor unit size indoor airflow including restricted filter and or coil refrigerant charge and AccuRater If PressureGuard cycles at unsatisfactory low outdoor ambients check each of the following items Ensure ARI approved indoor outdoor combination is used Check for proper airflow per the Product Data Digest Airflow may be drastically affected by dirty filters dirty coils poor duct work and or poor duct design Check refrigerant charge If in doubt about the proper charge
103. uiet Shift position When Quiet Shift switch is in ON position the length of defrost is 1 minute 30 sec compressor off period followed by 30 sec of defrost with com pressor operation On return to heat operation compressor will again turn off for an additional 30 sec and the fan for 40 sec When Quiet Shift is in OFF position only a brief 30 sec cycle will be observed If it is desirable to observe a complete defrost in warmer weather the thermostat must be closed as follows 1 Turn off power to outdoor unit 2 Disconnect outdoor fan motor lead from OF2 on control board See Fig 23 Tape to prevent grounding 17 A88415 O R T2 Y TI S b theses 111111 E o R w2 c A97642 Fig 22 CES0110063 Defrost Control 3 Restart unit in heating mode allowing frost to accumulate on outdoor coil 4 After a few minutes in heating mode liquid line temperature should drop below closing point of defrost thermostat ap proximately 30 F NOTE Unit will remain in defrost until defrost thermostat reopens at approximately 80 coil temperature at liquid line or remainder of defrost cycle time 5 Turn off power to outdoor unit and reconnect fan motor lead to OF2 on control board after above forced defrost cycle Compressor Shut Down This control has the option of shutting down the compres
104. umulator from system with tubing cutter 5 Tape ends of open tubing 6 Scratch matching marks on tubing studs and old accumulator Scratch matching marks on new accumulator Unbraze stubs from old accumulator and braze into new accumulator 7 Thoroughly rinse any flux residue from joints and paint with corrosion resistant coating such as zinc rich paint 8 Install factory authorized accumulator into system with copper slip couplings 9 Evacuate and charge system Pour and measure oil quantity if any from old accumulator If more than 20 percent of oil charge is trapped in accumulator add new POE oil to compressor to make up for this loss See Table 9 Step 10 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 Puron If air conditioner is shipped with a piston ring located in piston bag be sure it is installed per Fig 33 The piston ring will ensure piston stays seated during all operating conditions For Heat Pumps piston ring not used at outdoor piston To check clean or replace piston follow these steps See Fig 33 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 Rz 430 FUSE ELEMENT A88410 Fig 32 Accumulator
105. ury or death Pumpdown Procedure Service valves provide a convenient shutoff valve useful for certain refrigeration system repairs System may be pumped down to make repairs on low side without losing complete refrigerant charge 1 Attach pressure gage to suction service valve gage port 2 Front seat liquid line valve 3 Start unit in cooling mode Run until suction pressure reaches 5 psig 35kPa Do not allow compressor to pump to a vacuum 4 Shut unit off Front seat suction valve STAINLESS STEEL NE STEM SERVICE PORT ENTRANCE SEAT FRONT SEAT POSITION FIELD SIDE FORGED BACK SEATING VALVE A91435 Fig 27 Service Valve Back Seating FIELD SIDE STEM SERVICE PORT W SCHRADER CORE BAR STOCK FRONT SEATING VALVE A91447 Fig 28 Service Valve Front Seating NOTE outdoor unit coils will hold only factory supplied amount of refrigerant Excess refrigerant such as in long line applications may cause unit to relieve pressure through internal pressure relief valve indicated by sudden rise of suction pressure before suction pressure reaches 5 psig 35kPa If this occurs shut off unit immediately front seat suction valve and recover remain ing pressure Step 6 Reversing Valve In heat pumps changeover between heating and cooling modes is a
106. utes Table 9 Defrost Timer Settings swi sw2 DEFROST TIMES IN MINUTES Off 30 Off On 60 Off Off 90 120 To initiate a forced defrost two options are available depending on the status of the defrost thermostat If defrost thermostat is closed speedup pins J1 must be shorted by placing a flathead screwdriver in between for 5 seconds and releasing to observe a complete defrost cycle When the Quiet Shift switch is selected compressor will be turned off for two 30 sec intervals during this complete defrost cycle When Quiet Shift switch is in factory default OFF position a normal and complete defrost cycle will be observed CUT YELLOW WIRE BETWEEN CONTACTOR AND LOW PRESSURE SWITCH _ sarem P TA YEL GoNTROL FL BRN TERMINAL YEL VIO TERMINAL BOARD BOARD CONNECTION CONNECTION TH Ts BLK T2 Fig 19 Cycle Protector Wiring TEMP SWITCH CRANKCASE HTR awe ANN BLK BLK BLK BLK 11 21 A97586 Fig 20 Wiring for Single Pole Contactor FEEDER TUBE STUB TUBE DEFROST THERMOSTAT A97517 Fig 21 Defrost Thermostat Location If defrost thermostat is in open position and speedup pins are shorted with a flathead screwdriver for 5 seconds and released a short defrost cycle will be observed actual length is dependent upon the selected Q
107. 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 Step 7 Liquid Line Filter Drier The filter drier is specifically designed to operate with Puron use only factory authorized components Filter drier must be replaced whenever the refrigerant system is opened When removing a filter drier use a tubing cutter to cut the drier from the system Do not unsweat a filter drier from the system Heat from unsweating will release moisture and contaminants from drier into system Step 8 Suction Line Filter Drier The suction line drier is specifically designed to operate with Puron use only factory authorized components Suction line filter drier is used in cases where acid might occur such as burnout Heat pump units must have the drier installed between the compressor and accumulator only Remove after 10 hours of operation Never leave suction line filter drier in a system longer than 72 hours actual time 24 Step 9 Accumulator The accumulator is specifically designed to operate with PuronG 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 compresso
108. y removed for efficient operation The Puron heat pump uses the reliable time temperature method Service Technicians can select a 30 60 90 or 120 minute intervals between defrosts From the factory the control is set at a 90 minute defrost interval Other conditions MUST also be met The Outdoor Air Thermistor OAT MUST read below 50 before the unit will be allowed to go into defrost The Outdoor Coil Thermistor OCT temperature must be 30 or colder to allow the unit to go into defrost The defrost sequence is initiated by time AND temperature and terminated by time OR temperature Having the right conditions of ONLY time or temperature will NOT initiate defrost both conditions must be met Termination however can take place whenever conditions of EITHER time or temperature have been met 34 Once the system has determined a defrost is needed the heat pump s circuit board energizes the reversing valve RVS and de energizes the condenser fan motor If the W1 wire is hooked up to the indoor section 24 volts will be sent to energize supplemental heat NOTE If certain thermostats are used TSTATCCPDFOI B TSTATCCPRHOI B and CZII zoning the signal generated from the heat pump board is sensed at the thermostat and will assure that the unit will complete its defrost The RH and CZII zoning also have the option option 12 to bring on W signals from the thermostat If this option is used no wire from the he

Application Guideline and Service Manual

Contents

Download Pdf Manuals

Related Search

Related Contents