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1. BAR STOCK FRONT SEATING VALVE A91447 Fig 28 Suction Service Valve Front Seating NOTE All outdoor unit coils will hold only factory supplied amount of refrigerant Excess refrigerant such as in long line applications may cause unit to relieve pressure through internal pressure relief valve indicated by sudden rise of suction pressure before suction pressure reaches 5 psig 35kPa If this occurs shut unit off immediately front seat suction valve and recover remaining pressure Reversing Valve In heat pumps changeover between heating and cooling modes is accomplished with a valve that reverses flow of refrigerant in system This reversing valve device is easy to troubleshoot and replace The reversing valve solenoid can be checked with power off with an ohmmeter Check for continuity and shorting to ground With control circuit 24v power on check for correct voltage at solenoid coil Check for overheated solenoid With unit operating other items can be checked such as frost or condensate water on refrigerant 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 nor
2. Put system back into operation y Check system refrigerant charge amp air flow Check for restricted refrigerant flow and or high superheat Measure discharge temp within 6 of compressor Discharge temp less than250 F Normal operation monitor 22 Confirm phasing is correct to compressor yellow black red wires on drive output See Fig 23 Fig 13 Scroll Temp Troubleshooting Part 2 Confirm operation inside Adjust expansion compressor unit device to 10 20 F temperature amp superheat speed range Y If scroll temp fault still exists change compressor A11553 Start Verify motor temp fault condition at the system controller Is the system operable Disconnect yellow black and red wires from output connections on drive See Fig 23 Verify motor winding continuity from the yellow black and red lead ends Check each leg yellow black and red wires to ground If any of the above Q readings Measure Disconnect 4 pin resistance m gt plug from drive m gt between red A See Fig 18 white wires in the 4 pin plug Measure resistance between unit Is resistance ground and black white amp red wires in the plug Is there continuity to ground
3. In an air conditioning and heat pump system refrigerant transfers heat from one replace to another The condenser is the outdoor coil in the cooling mode and the evaporator is the indoor coil In a heat pump the condenser is the indoor coil in the heating mode and the evaporator is the outdoor coil In the typical air conditioning mode compressed hot gas leaves the compressor and enters the condensing coil As gas passes through the condenser coil it rejects heat and condenses into liquid The liquid leaves condensing unit through liquid line and enters metering device at evaporator coil As it passes through metering device it becomes a gas liquid mixture As it passes through indoor coil it absorbs heat and the refrigerant moves to the compressor and is again compressed to hot gas and cycle repeats Compressor Oil A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation 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 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 im
4. A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation To avoid performance loss and compressor failure installation of filter drier in liquid line is required 4 CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation To avoid filter drier damage while brazing filter drier must be wrapped in a heat sinking material such as a wet cloth Install Liquid line Filter Drier Indoor HP Refer to Fig 31 and install filter drier as follows 1 Braze 5 in liquid tube to the indoor coil 2 Wrap filter drier with damp cloth 3 Braze filter drier to 5 in long liquid tube from step 1 4 Connect and braze liquid refrigerant tube to the filter drier 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 A05227 Fig 31 Liquid Line Filter Drier HP Thermostatic Expansion Valve TXV All fan coils and furnace coils will have a factory installed thermostatic expansion valve TXV
5. The TXV will be a bi flow hard shutoff with an external equalizer and a balance port pin A hard shut off TXV does not have a bleed port Therefore minimal equalization takes place after shutdown TXVs are specifically designed to operate with Puron or R 22 refrigerant use only factory authorized TXV s Do not interchange Puron and R 22 TXVs TXV Operation The TXV is a metering device that is used in air conditioning and heat pump systems to adjust to changing load conditions by maintaining a preset superheat temperature at the outlet of the evaporator coil The volume of refrigerant metered through the valve seat is dependent upon the following 1 Superheat temperature is sensed by cap tube sensing bulb on suction tube at outlet of evaporator coil This temperature is converted into pressure by refrigerant in the bulb pushing downward on the diaphragm which opens the valve via the push rods 2 The suction pressure at the outlet of the evaporator coil is transferred via the external equalizer tube to the underside of the diaphragm This is needed to account for the indoor coil pressure drop Residential coils typically have a high pressure drop which requires this valve feature 3 The pin is spring loaded which exerts pressure on the underside of the diaphragm Therefore the bulb pressure works against the spring pressure and evaporator suction pressure to open the valve If the load increases the temperature increases at th
6. 4 of Invert er pin out connection on ODU control if absent board is damaged Possible damage to Inverter Drive Change out ODU control before Inverter Drive if this does not help then change out the Inverter drive 13 25VNA EVENT FAULT CONT FLASH CODE Heat or Cool 7 OPERATION Amber LED Mode Possible Causes ACTION Verify contactor harness from ODU con trol CC harness check for loose con Contactor dropping out momentar nection stripped wires short to ground ily or short between wires confirm good connection is made at control board and Event 49 Both at contactor Voltage glitches and low line r voltages if persistent contact power provider Change out ODU control before Inverter Damaged Inverter Drive Drive if this does not help then change out the Inverter drive Sensor Harness not connected to Ensure plug is connected to ODU con ODU control trol Check harness for continuity resistance should measure 10k at 77 20 F Broken or loose harness wire Refer to thermistor 10 k thermistor curve If bad replace OAT OCT thermistor Fault 53 Both sensor assembly Check harness for continuity resistance should measure 10k at 77 20 F Broken or Damaged Sensor Refer to thermistor 10 k thermistor curve If bad replace OAT OCT thermistor sensor assembly Hardware damage to ODU control Replace ODU control Se
7. DC voltage between ground and supply input terminal Ensure that the input voltage is 5 VDC Next read the DC voltage across the ground and output terminal Record the output voltage The suction pressure that the pressure transducer is reading can be calculated by taking the output voltage and subtracting 0 5 from it then taking that difference and multiplying it by 50 Pressure psig 50 0 x DCV out 0 5 For example if the measured voltage is 3 0 VDC 50 X 3 0 0 5 50 X 2 5 125 psig See Fig 11 Output Voltage V o 25 50 75 100 125 150 175 200 225 Pressure Sealed Gauge psi A12035 Fig 11 Suction Pressure Transducer SPT Output Funtion Graph This can then be compared to the actual suction pressure from the gage manifold In the event of a low pressure trip or low pressure lockout check the refrigerant for an under charge If the charge is found to be correct check for low indoor airflow in cooling and the outdoor fan for proper operation in heating and outdoor coil in heating for airflow restrictions Keep in mind that the outdoor fan motor may run normally until it heats up Cool PSUCT lt 55 psig for 3 minutes Heat PSUCT lt 23 psig for 3 minutes PSUCT lt 13 psig instantaneous A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage or improper operation In order to minimize the ambient influence make
8. Reversing Valve Stuck in Cooling troubleshoot reversing valve of d Clean System refer to application Restriction due to debris guideline and replace filter drier 18 25VNA EVENT FAULT CONT FLASH CODE Heat or Cool i OPERATION Amber LED Mode Possible Causes ACTION System will try to ride through current Multiple Error 59 Compressor spikes and self recover in trip condition Scroll Temp Out of Range within two persistent Error 59 Compressor Scroll hours of run time Temp Out of Range trips will lead to Error 88 Refer to Error 59 troubleshooting tem Malfuncti Both System Malfunction Ge S System will try to ride through current Multiple Error 71 Compressor Mo spikes and self recover in trip condition tor Temp Out of Range within two persistent Error 71 Compressor Motor hours of run time Temp Out of Range trips will lead to Error 88 Refer to Error 71 troubleshooting Sensor Harness not connected to In Ensure plug is connected to Inverter Drive verter Drive control control Serea 3 GE SESCH Reattach sensor plug to compressor Check harness for continuity on the sensor fusite resistance should be in 10 Brokeno loose Harness wire kOhm between scroll and common termin System Malfunction 86 Both als and 5 kOhm between motor and com mon terminals at 70 20 F See com pressor troubleshooting guidelin
9. control board The DC voltage and PWM option al measured must be as shown in Table 4 Table 4 DC Voltage and PWM Measurement Unit Size Voltage PWM 024 036 8 9 VDC 52 048 060 11 1 VDC 84 11 Table 5 Fault Codes FAULT DESCRIPTION SENT TO UI FLASH CODE AMBER LED RESET TIME minutes Standby ON no flash SCH Variable ariel Si Emergency 1 pause Variable Speed Range Cutback EE Se Zei i Communications Loss 16 NA Invalid Model 25 NA High Pressure Switch Open 31 15 Low Pressure Trip 32 15 Control Fault 45 NA Brownout 46 Revert to 5 min cycle delay Lost Inverter Communications 48 Revert to 5 min cycle delay 230VAC Dropout Reset Event 49 Revert to 5 min cycle delay Outdoor Air Temp Sensor Fault 53 NA Suction Temp Sensor Fault 54 15 Coil Temp Sensor Fault 55 NA OAT OCT Thermistor Out of range 56 NA Suction Pressure Sensor Fault 57 15 OAT OST Thermistor Out of range 58 5 Compressor Scroll Temp Out of Range 59 15 Compressor Sump Heating Active 68 2 HOURS Inverter Compressor Internal Fault 69 15 Compressor Motor Temp Out of Range 71 15 Suction Over Temperature 72 15 Inverter Temp Out of Range Event 75 15 Inverter Over Current 77 15 Compressor No Pump Event 79 15 Suction Over Temp Lockout 82 4 Hours Low Pressure Lockout for 4 hours 83 4 HOURS High Pressure Lockout for 4 hours 8
10. nsure Service Valves are open Check system charge using Cooling Char Overcharged System ging Mode follow proper charging proced ures Check Outdoor Coil for clogging ice or debris and clean or de ice if necessary Outdoor Airflow too low or off Troubleshoot Outdoor fan motor and make Cool sure it is working follow Outdoor Airflow troubleshooting instruction Restriction in Filter Drier plus Long Ma d Ge g Clean System refer to application Line Application and filter drier on Out SE A door Unit guideline and replace filter drier Restriction in EXV plus Overcharge troubleshoot EXV ee Check kinks and straighten or replace cir System Malfunction 99 Restriction in Circuits or Tubing cuits Electric Heater plus Heat pump applic eege not eas Electric ation Electric Heater stuck on eat check tOr neater Telays ion troubleshoot Electric Heater SE If not in Defrost and Furnace is running Furnace plus Heat pump application 3 Furnace stuck on nav time as heat pump troubleshoot Fur Restriction in Filter Drier plus Long GE GE d Clean System refer to application Line Application and filter drier on In EA door Unit guideline and replace filter drier Expansion Orifice Restriction Troubleshoot TXV see guide below Troubleshoot EXV see guide below Service Valve left closed Vapor Ser vice Valve Ensure Vapor Service Valve is open Heat Check Indoor for clogging ice or debris and clean or de ice if ne
11. outdoor coil temperature OCT gt 40 F 4 4 C Or 10 minutes has passed At the defrost termination the outdoor fan output ODF will turn on 15 seconds before the reversing valve switching NOTE Compressor speed during defrost varies based on outdoor conditions CONNECTION DIAGRAM SCHEMATIC DIAGRAM LADDER FORM cone G BLK X St RED R gn WHT a COMPONENT ARRANGEMENT 23 2 TRAN 24V Bees H P pou CHOKE BRN AT RED Q 1 i L S INVERTER 1 i em GRN 1 Es CHOKE g Z i i ae g YEL RED T
12. persistent con High Pressure Trips occurred in ditions will lead to lockout refer to Error past 2 hours Code 84 High Load Cut back 2 or more System will try to self mitigate persist Both Torque Limit Trips occurred in the ent conditions will lead to lockout refer Q past 2 hours to Error Code 99 g S 1 1 sec ON Variable Capacity Range i Cutback longer pause 2 Flank Loading Guba ck Flank Eoad System will try to self mitigate persist second OFF is too high ODU raising speed NW g SC ent conditions will lead to lockout refer shrinking capacity range to im to Error Code 99 prove reliability o e 99 Oil Circulation cutback Suction Pressure too high for current com 5 PA Heat pressor speed ODU reducing check for Indoor airflow restrictions speed to improve oil circulation Regular T Stat used in Emergency Emergency Mode Continuous Flash Both mode Nominal Capacity only fixed install Infinity User Interface speed operation Verify communications wiring ABCD L 7 horted lead check for loose connection stripped EE wires short to ground or short between wires Wrong Model Plug Installed Verify correct model plug installed Event 16 Both 7 Check model plug for corrosion or Damaged Model Plug breakage replace if necessary Data Bus locked up by power loss brownout or glitch Cycle Power to system Damaged ODU control Replace ODU control Wrong Model Plug Installed Verify correct model plug installed Check model plug for co
13. see Fig 3 indicates successful communication with the other system products The green LED will remain OFF until communication is established Once a valid command is received the green LED will turn ON continuously If no communication is received within 2 minutes the LED will be turned OFF until the next valid communication Amber Status Light Amber colored STATUS light indicates operation and error status See Table 5 and Table 6 for definitions e Two minute time delay to return to standby operation from last valid communication One minute time delay of outdoor fan at termination of cooling mode when outdoor ambient is greater than or equal to 100 F 37 8 C Fifteen second delay at termination of defrost before the auxiliary heat is de energized 1 e RED A ens Beoeeee ou ee d IW 4 a app SEC EXV a e SOs 8 PWM2 P a2 PL4 e GC SPT le HPS e CB PL11 PL2 OST le RVS bd e PL1 PL6 HIE oct ie e ejim oe OAT le COMM STATUS UTIL CLSY O Ree meee eessen Pl eeen FORCED 7 ABC NO MODEL DEFROS A11139 Fig 3 Variable Speed Control Board Defrost This user interface UI offers 5 possible defrost interval times 30 60 90 120 minutes or AUTO The default is AUTO Defrost interval times 30 60 90 and 120 mi
14. size The wire size selected must have a current capacity not less than that of the copper wire specified and must not create a voltage drop between service panel and unit in excess of 2 of unit rated voltage To prepare wire before installing connector all aluminum wire must be brush scratched and coated with a corrosion inhibitor such as Pentrox A When it is suspected that connection will be exposed to moisture it is very important to cover entire connection completely to prevent an electrochemical action that will cause connection to fail very quickly Do not reduce effective size of wire such as cutting off strands so that wire will fit a connector Proper size connectors should be used Check all factory and field electrical connections for tightness This should also be done after unit has reached operating temperatures especially if aluminum conductors are used Contactor The contactor provides a means of applying power to unit using low voltage 24v from transformer in order to power contactor coil Depending on unit model you may encounter single or double pole contactors Exercise extreme caution when troubleshooting as 1 side of line may be electrically energized The contactor coil is powered by 24vac If contactor does not operate 1 With power off check whether contacts are free to move Check for severe burning or arcing on contact points 2 With power off use ohmmeter to check for continuity of coil Disconn
15. sure the thermistor curved surface hugs the pipe surface and is secured tight using the wire tie fished through the original slot insulating polymer body Variable Speed Compressor Sensor Output Terminals This compressor has a motor thermistor and a scroll thermistor Correct resistance between scroll thermistor terminal and common is 10k at 77 F 25 C Correct resistance between motor thermistor terminal and common is 5k at 77 F 25 C See Table qs Variable Speed Compressor Power Input Terminals This compressor operates with a 3 phase variable frequency PWM variable voltage to the three fusite terminals Table 3 Variable Speed Compressor Resistances winding resistance at 70 F 20 F 25VNA024 25VNA048 WINDING 25VNA036 25VNA060 Between terminals T1 T2 and T3 ES 08 Between terminal amp ground j gt 1 mega OHM gt 1 mega OHM A CAUTION UNIT DAMAGE HAZARD Failure to follow this caution may result in equipment damage and or improper operation Do not use Meggar for measuring the winding resistance ECM Fan Motor If verification of proper operation is required for the ECM motor used in this unit follow these steps 1 Verify that the 230v input to the transformer is present 2 Verify that the control board is powered 18 volts to 30 volts from the transformer 3 With the UI in charging mode in cooling measure the DC voltage between the PWM 1 and PWM 2 terminals on the outdoor
16. try to ride through voltage dro 5 pouts and self recover in trip condition Event 93 Both KE GE EE drive persistent over current trips will lead to Er 9 y ror 96 Low Voltage Lockout Refer to Er ror 96 troubleshooting System will try to ride through voltage s i spikes and self recover in trip condition Event 94 Both Mom AA AOE Be LA volage persistent over current trips will lead to Er y ror 97 High Voltage Lockout Refer to Er ror 97 troubleshooting r k Check supply voltage to Outdoor Unit if High supply line voltage gt 257 VAC high contact utility provider K When adverse weather subsides unit Stormy weather causng ntermittent should self recover cycle ODU power if voltage spikes necessary Loose wire in control box area Check for loose wire in ODU 8 Ground lead from Compressor at Ensure compressor ground and other System Malfunction 95 Both tached to winding power connection leads are correctly installed Troubleshoot compressor windings For the 2 and 3T the resistance should be 681 Compressor Winding dam ohm and for 4 and 5T the resistance DEST an oe should be 203 ohm at 70F 20F See compressor troubleshooting guidelines If confirmed replace compressor Inverter internal damage Replace Inverter 19 25VNA EVENT FAULT CONT FLASH CODE Heat or Cool r OPERATION Amber LED Mode Possible Caus
17. which the caps are tightened to attain a metal to metal seal The service valve cannot be field repaired therefore only a complete valve or valve stem and service port caps are available for replacement If the service valve is to be replaced a metal barrier must be inserted between the valve and the unit to prevent damaging the unit exterior from the heat of the brazing operations A CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant Pumpdown amp Evacuation If this system requires either a Pump Down or Evacuation for any reason the procedures below must be followed Pump Down Because this system has an inverter controlled compressor suction pressure transducer and EXV conventional procedure cannot be used to pump down and isolate the refrigerant into the outdoor unit The UI User Interface has provisions to assist in performing this function 1 Connect gages to 25VNA liquid and vapor or suction capil lary service ports to monitor operating pressures during and at completion of the procedure 2 In the advanced menu of the UI go to Checkout gt Heat Pump gt Pumpdown 3 Select mode to pump down in COOL or HEAT COOL mode allows refrigerant to be isolated in outdoor unit HEAT mode allows the refrigerant to be isolated in indoor coil and lineset Set desired time period Default
18. 0 15 35 55 75 95 115 135 155 175 195 215 235 Temperature F 255 275 295 Fig 16 Scroll Thermistor Resistance 204800 102400 51200 25600 12800 6400 3200 Paralled Thermistor Resistance Ohms 1600 800 400 Low Temp Trip Motor Thermistor Resistance High Temp Trip 5 15 35 55 75 95 115 135 155 Temperature F 175 195 Fig 17 Motor Thermistor Resistance 25 A12038 A12039 Remove This Plug A11556 A11557 Fig 19 Removing NTC Thermistor Plug 26 A11558 A11559 Fig 20 Measuring Scroll NTC Resistance Fig 21 Measuring Motor NTC Resistance A11560 Fig 22 Checking NTC Circuit for Grounded Condition 27 A11561 Fig 23 High Voltage Input Output Connections on Drive Table 7 Thermistor Resistance Values Scroll Thermistors Motor Thermistors Q Value Temp CG Temp E Q Value Temp CG Temp E 412314 43 00 45 40 HW Trip 206108 43 00 45 40 HW Trip 336936 40 00 40 00 SW Trip 168433 40 00 40 00 SW Trip 177072 30 00 22 00 88526 30 00 22 00 97088 20 00 4 00 48538 20 00 4 00 55325 10 00 14 00 27663 10 00 14 00 32654 0 32 00 16327 0 32 00 19903 10 50 00 9951 10 50 00 12492 20 68 00 6246 20 68 00 10000 25 77 00 Calibration Pt 5000 25 77 00 C
19. 25VNA Infinity Variable Speed Heat Pump with Greenspeed Intelligence 2 to 5 Nominal Tons Service Manual TABLE OF CONTENTS PAGE UNIT IDENTIFICATION e NEE EEN KE EEN EAE A EE AE EE bea A REE bea deh 2 SAFETY CONSIDERATIONS besne EEN Ae oe LNA ea dE er ce E EE EN EEE ie rd ey aaa eS 3 GENERAL INFORMATION EE ENEE ELH EEN AE AE EEE S E be REA RO E SE EEDA E d 3 ELECTRICAL eee i ee tna sin E E E E TREE EE E E EE ERR EA EEA AE 4 6 ELECTRONIC EXPANSION VALVPOESNW ER EESE bene nent e net e EERE 5 6 Controller s sis id sudan case Gis cubed mepe piane Ehe Bee dng E a E a aa pcesdnece tulad 5 Crankcase Heatef 2 SEENEN EE bare die nd ewer bee yee EE eds ane bee es 5 Outdoor Fan Mot isis ieee Be iene bee EES ane De ee eae EE Mabe pees Sg ENEE bee eS Alas 5 IMM OTIC EE 5 Infinity Controlled Low Ambient Cooling 1 0 0 ce eee EEEE EEE eee eee 6 Utility Interface with Infinity Control 6 64 25 cena os ne cece ii un Sons TERE Keine beng ENER NEESS Ee OS Ee a NEE Sele eb 6 COMMUNICATION AND STATUS FUNCTION LIGHTS 0 0 ccc cee eee ee eens 6 7 REFRIGERANT PIPING LENGTH LIMITATIONS 0 0c cece eee e eens 8 LONG LINE APPLICATIONS eer tore ten baw wars EE EE VER EROR E Seige mies Hear EES 8 9 TROUBLESHOOTING rg geg EE EES EE gee EE e Ke 10 30 REFRIGERATION SYSTEM ee dE d ee Ee Eege EE eae 33 37 Refrigerant cece cee stit ee OEE Re Kee CESS ER ERE CREE REE SERRE SOON Che EE Oe MEE LE E eas WERE aE 33 Compressor Qil ue ergeet Beree
20. 4 4 HOURS Compressor Temp Lockout 85 4 HOURS Compressor Temp Sensor Fault 86 15 Inverter Temp Lockout 88 4 HOURS Inverter VDC Out Over Voltage 91 15 Inverter VDC Out Under Voltage 92 15 230VAC Under Voltage 93 15 230VAC Over Voltage 94 15 High Current Lockout 95 2 HOURS VDC Under Voltage Lockout 96 2 HOURS VDC Over Voltage Lockout 97 2 HOURS High Torque Event 98 10 High Torque Lockout 99 2 HOURS OFF NA Status Codes Most system problems can be diagnosed by reading the status code as flashed by the amber status light on the control board The codes are flashed by a series of short and long flashes of the status light The short flashes indicate the first digit in the status code followed by long flashes indicating the second digit of the error code The short flash is 0 25 seconds ON and the long flash is 1 0 second ON Time between flashes is 0 25 seconds Time between short flash and first long flash is 1 0 second Time between code repeating is 2 5 seconds with LED OFF Codes are easily read from user interface UI EXAMPLE 3 short flashes followed by 2 long flashes indicates a 32 code 12 Table 6 25VNA EVENT FAULT FLASH CODE Heat or Cool 3 OPERATION Amber LED Mode Possible Causes ACTION Standby Charging ON no flash Variable Capacity 1 pause Pressure Trip Cutback 2 or more System will self mitigate
21. CAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label ae 430 FUSE ELEMENT A88410 Fig 32 Accumulator 37 Copyright 2012 Carrier Corp e 7310 W Morris St e Indianapolis IN 46231 REFRIGERATION SYSTEM REPAIR Leak Detection New installations should be checked for leaks prior to complete charging If a system has lost all or most of its charge system must be pressurized again to approximately 150 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 refrigerants Nitrogen cannot however be detected by an electronic leak detector See Fig 33 A95422 Fig 33 Electronic Leak Detection A WARNING PERSONAL HAZARD Failure to follow this warning could result in personal injury or death INJURY AND UNIT DAMAGE Due to the high pressure of nitrogen it should never be used without a pressure regulator on the tank Assuming that a system is pressurized with either all refrigerant or a mixture of nitrogen and refrigerant leaks in the system can be found with an electronic leak detector that is cap
22. Lubrication management and e EXV control Type 10K Q negative temperature coefficient temperature sensor Therm O Disc part number HH79NZ092 used for EXV control Electronic Expansion Valve Fig 2 Electronic Expansion Valve EXV An EXV is used for accurate refrigerant metering in the heating mode It enables the system to achieve high HSPF rating The outdoor board senses suction pressure and temperature to control EXV movement The EXV has a stepper motor with 600 steps from fully open to fully closed Cooling Valve is wide open Heating At start of each cycle valve controls to a fixed position depending on speed and ambient temperature for 120 seconds This allows the refrigerant system to stabilize After this pre set period control board controls valve as needed to control suction superheat and or compressor load Defrost Valve is wide open Controller The variable speed Heat Pump VS HP controller is a serially communicating device that receives capacity demands from the Infinity User Interface and communicates corresponding speed request to the Inverter Drive which controls compressor to the speed demanded The VS HP Control also controls the EXV to either provide superheat or act as a load shedding tool The VS HP Control also proactively tries to prevent fault trip events by using sensors and Inverter feedback Sensors include a suction pressure transducer SPT an outdoor suction thermistor OST the outdoor ai
23. Min Capacity Dehum or Zoning 24 726 651 398 36 1168 651 398 48 1394 1186 693 60 1650 1186 693 Cooling Efficiency Mode Size Max Capacity Min Capacity 24 949 830 36 1334 830 48 1593 1355 60 1885 1355 Heating Comfort Mode Size Max Capacity Min Capacity 24 698 440 36 1140 451 48 1354 751 60 1354 751 Heating Efficiency Mode Size Max Capacity Min Capacity 24 900 750 36 1350 518 48 1600 890 60 1750 901 TROUBLESHOOTING Systems Communication Failure If communication with the Infinity control is lost with the User Interface UD the control will flash the appropriate fault code see Table 5 and Table 6 Check the wiring to the User Interface and the indoor and outdoor units and power Model Plug Each control board contains a model plug The correct model plug must be installed for the system to operate properly see Table 2 Table 2 Model Plug Information PIN RESISTANCE MODEL MODEL PLUG K ohms NUMBER NUMBER Pins 1 4 Pins 2 3 25VNA024 HK70EZ001 5 1K 11K 25VNA036 HK70EZ002 5 1K 18K 25VNA048 HK70EZ003 5 1K 24K 25VNA060 HK70EZ004 5 1K 33K The model plug is used to identify the type and size of unit to the control On new units the model and serial numbers are input into the board s memory at the factory If a model plug is lost or missing at initial installation the unit will operate according to the information input at the factory and the appropriate error cod
24. NCTION OFM OUTDOOR FAN MOTOR UTIL UTILITY CURTAILMENT Selected Has Elapsed And The Coil Temperature Is Less Than 32 F 2 F It Will Terminate At 65 F 50 F or 45 F 5 F Q FIELD SPLICE oer THERMISTOR SUCTION As Needed Based On OAT At Defrost Termination The Outdoor Fan Will Turn On 15 Seconds Before Switching The CB CONTROL BOARD Reversing Valve CC CONTACTOR COIL I e FIELD INITIATED FORCED DEFROST Shown As Forced Defrost On Board By Placing A Jumper Across The Forced Defrost COMM SYSTEM COMMUNICATION Terminals For 5 Seconds Or Longer And Then Removing The Jumper The Unit Will Initate A Defrost Cycle Regardless Of Coil COMP COMPRESSOR Temperature The Defrost Cycle Will Terminate At 65 F 5 F If Coil Termperature Is Above 32 F Or Outdoor Ambient CONT CONTACTOR 338633 101 REV A Temperature Is Above 50 F Defrost Mode Will Terminate After 30 Seconds Of Active Mode EXV ELECTRONIC EXPANSION VALVE e Fig 4 Wiring Diagram 25VNA Model sizes 2 5 tons 208 230 1 User Interface UI Humidifier 24vac c Furnace or Fan Coil Cand D not required on VS Heat Pump Fig 5 Infinity Furnace or Fan Coil Wiring with Communicating Variable Speed HP A12055 REFRIGERANT PIPING LENGTH LIMITATIONS Maximum Line Lengths The maximum allowable total equivalent length for heat pumps varies depending on the vertical separation See the tables below for allowable lengths depending on w
25. RAN a1 El 5 BLK 230V 208v COM YEL IK l CONT Set K corr Ea 2 5 5 be CONTROL GND T A lt BOARD 5 d CNY A CHOKE i CONT be r CHOKE INVERTER TRAN HDN THA SET MODEL PLUG CHART 200 C Em POWER 1o 9 YEL MODEL MODEL ey RESISTANCE K Q SUPPLY ora fe SI Kalb Zeen CH 3 EXV EQUIP GND ean BLK OFM E 001 51 TT TRAN 24V BRN 36 002 5 1 18 48 003 51 24 d H iosa J RED WHT GRNIYEL BLU 60 004 5 1 33 amp SS E Ps BRN YEL YEL SEC1 SEC2 PWM2 PWM1 cc ot S e 9 RED Dan E aes eee ou YEL b D cB Pla SPT SEC1 SEC2 si E ER g D s HPS J ce PWM2 PWM1 HES SC gt RVS SE oer s PL4 SPT e OST Je g RED Rvs a PL3 SPT Je L BLUIPNK elle SST 5 D BLUIPNK t BLK z PL1 PL6 OCT HPS CB PL11 OST Z oct 7_ PL2 D ots el ORG D OST e BLK Z RVS RVS m e ORG e BLK C Zi OAT o OAT oct CHOKE o PLI PL6 COMM STATUS BARE ene e BRN mr r lt E zs OT Ve ele BLK el BRN 4 CONT lees UTILCisy O PL8 eees FORCED LS WHT BLK ABCNO eede ou e MODEL DEFROST L ee GRN s OAT S USE e BLK OAT A T CHOKE Wm Wm NOTES Ka COMM STATUS E 1 Compressor Furnished With Inherent Thermal Protection Wale 2 To Be Wired In Accordance With National Electric Code N E C And Local Codes PL8 eee FORCED N Ls 3 Use Copper Conductors Only Use Conductors Suitable For At Least 70 C 167 F MODEL DEFROST L S 4 Two Wire A and B Required For Communication Unit Contains 24 Volt Transformer To Powe
26. Restriction in Filter Drier plus Long Clean System refer to application Line Application and filter drier on Zar e Indoor Unit guideline and replace filter drier ES hs 5 Clean System refer to application Restriction due to debris guideline and replace filter drier Restriction in Circuits or Tubing Check kinks andistraighten r replace circuits Restriction in Filter Drier plus filter Clean System refer to application drier on Outdoor Unit guideline and replace filter drier Both If short lineset less than 15 ft Expansion Orifice Restriction Troubleshoot TXV see guide below re place if necessary Troubleshoot EXV see guide below Outside Normal Operating Range e g improper load calculation sys TEN 3 tem match issue outside heating Consult Application Guidelines range etc Service Valve left closed Liquid KE Service Valve Ensure Liquid Service Valve is open Check Outdoor for clogging ice or debris and clean or de ice if neces Outdoor Airflow too low or off sary Troubleshoot Outdoor fan motor and make sure it is working follow Out Heat door Airflow troubleshooting instruction Check charge in cooling if in Cooling Charge Mode Ambient Range if low add charge using Charging Mode follow Undercharged System proper charging procedures if outside cooling charge mode range pull out charge weigh in using heating charge mode R ing Valve B Reversing Valve Stuck halfway eversing valve BYPASS troubleshoot reversing valv
27. able of detecting specific refrigerants If system has been operating for some time first check for a leak visually Since refrigerant carries a small quantity of oil traces of oil at any joint or connection is an indication that refrigerant is leaking at that point A simple and inexpensive method of testing for leaks is to use soap bubbles See Fig 34 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 DETECTOR SOLUTION A95423 Fig 34 Bubble Leak Detection Manufacturer reserves the right to change at any time specifications and designs without notice and without obligations Printed in U S A You may use an electronic leak detector designed for specific refrigerant to check for leaks See Fig 33 This unquestionably is the most efficient and easiest method for checking leaks There are various types of electronic leak detectors Check with manufacturer of equipment for suitability Generally speaking they are portable lightweight and consist of a box with several switches and a pr
28. alibration Pt 6531 35 95 00 3266 35 95 00 4368 45 113 00 2184 45 113 00 2987 55 131 00 1494 55 131 00 2084 65 149 00 1042 65 149 00 1482 75 167 00 741 75 167 00 1072 85 185 00 536 85 185 00 788 95 203 00 459 90 194 00 SW Trip 589 105 221 00 394 95 203 00 HW Trip 446 115 239 00 342 125 257 00 265 135 275 00 SW Trip 235 140 284 00 185 150 302 00 HW Trip 28 Observe user interface for system faults is UI displaying inverter communications lost or inverter internal fault Adjust user interface to call for cooling or heating operation Proceed to outdoor unit Measure Input voltage to the drive See Fig 25 Is input voltage 187 253 VAC No Yes If other faults are instructions disconnect for blown fuses tripped breaker Verify outdoor unit contactor is energized Is input voltage 187 253 VAC Refer to unit troubleshooting instructions Observe COMs LEDs See Fig 26 Is red LED blinking Remove RS485 6 pin plug from drive refer to picture 3 Measure voltage between red amp black wires in the plug Check 5VDC on outdoor board measured Drive is Check indoor user interface for system faults Correct any faults not related to communications or Inverter Consult with Carrier Problem Resolution if problem still exists Is 5VDC Fig 24 Variable Sp
29. ance to change 60 minutes Is resistance 265 Q 337KQ Refer to thermistor resistance temperature data Figure 14 Is Q moving towards Q corresponding to ambient temp Power down the entire system for 2 minutes to reboot the drive v If problem still exists change the compressor Fig 12 Scroll Temp Troubleshooting Part 1 21 Thermistor circuit is shorted Remove the molded plug from the thermistor fusite on the compressor See Fig 19 d Measure resistance in scroll thermistor circuit pins See Fig 20 Is resistance 0Q Inspect molded plug assembly for lead to lead shorting Install new molded plug assembly and carefully route wires Scroll thermistor circuit is shorted internally replace compressor A12036 Remove the molded plug from the thermistor fusite on the compressor See Fig 19 Measure resistance between each of the three fusite pins and ground See Fig 22 s there continuity between any of the ins and ground The molded plug harness is grounded replace it Install new molded plug assembly and route wires carefully Yes Change the compressor Reset scroll temp fault at system controller amp remove power to drive to reboot y
30. at pump unit must be evacuated for service reasons If the EXV is not open when pulling a vacuum or recovering refrigerant from the heat pump unit extended evacuation time may be required and or inadequate vacuum obtained The UI User Interface has provisions to open the EXV for refrigerant recovery and or evacuation 1 Connect gages to 25VNA liquid and vapor or suction capil lary service ports to monitor operating pressures during and at completion of the procedure Attach recovery system or vacuum pump to gage set as needed for the service proced ure The service valves must be open to evacuate the unit through the line set service ports The suction capillary ser vice port is a direct connection to the suction port of the compressor 2 In the advanced menu of the UI go to Checkout gt Heat Pump gt gt Evacuation 3 Set desired time period Default time period for the proced ure is 120 minutes 4 Select START on UI to open the valve 5 Begin evacuation or refrigerant recovery as required for the procedure after UI indicates the EXV is open Power may be removed from heat pump after the UI indicates READY TO EVACUATE 34 6 Remove power from indoor and heat pump unit prior to ser vicing unit The EXV will retain the open position NOTE See service training materials for troubleshooting the EXV using EXV CHECK mode FIELD SIDE SEAT STEM SERVICE PORT W SCHRADER CORE
31. cessary Indoor Airflow too low or off Troubleshoot Indoor fan motor and make sure it is working follow Indoor Airflow troubleshooting instruction Check charge in cooling if in Cooling Charge Mode Ambient Range if low add charge using Charging Mode follow prop STEE EE er charging procedures if out side cool ing charge mode range pull out charge weigh in using heating charge mode Reversing Valve Stuck in Cooling troubleshoot reversing valve dn Clean System refer to application Restriction due to debris guideline and replace filter drier 20 Verify scroll temp fault condition at the system controller Is the system operable Disconnect 4 pin plug from drive See Fig 18 Measure resistance between unit ground and black white amp red wires in the plug Is there continuity to ground A good reading is equal to infinite Q Measure resistance gt between black A white wires in the 4 pin plug Is resistance Is compressor hot Allow time for compressor to m gt cool amp resistance to change 60 minutes Resistance is in the range that will allow operation Refer to thermistor resistance temperature data See Fig 14 Is resistance 0Q Measure resistance between black amp white wires in the 4 pin plug Allow time for resist
32. cumulator 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 221 C and vent the refrigerant if this temperature is reached either internal or external to the system If fuse melts the accumulator must be replaced To change accumulator 1 Shut off all power to unit 2 Recover all refrigerant from system 3 Break vacuum with dry nitrogen Do not exceed 5 psig NOTE Coil may be removed for access to accumulator Refer to appropriate sections of Service Manual for instructions A CAUTION PERSONAL INJURY HAZARD Failure to follow this caution may result in personal injury Wear safety glasses protective clothing and gloves when handling refrigerant 4 Remove accumulator from system with tubing cutter 5 Tape ends of open tubing 6 Scratch matching marks on tubing studs and old accumulator Scratch matching marks on new accumulator Unbraze stubs from old accumulator and braze into new accumulator 7 Thoroughly rinse any flux residue from joints and paint with corrosion resistant coating such as zinc rich paint 8 Install factory authorized accumulator into system with copper slip couplings 9 Evacuate and charge system Pour and measure oil quantity if any from old accumulator If more than 20 percent of oil charge is trapped in accumulator add new POE oil to compressor to make up for this loss A WARNING ELECTRI
33. e Ze Clean System refer to application Geesen guideline and replace filter drier 17 25VNA EVENT FAULT CONT FLASH CODE Heat or Cool r OPERATION Amber LED Mode Possible Causes ACTION Outside Normal Operating Range e g improper load calculation sys dE CA tem match issue outside cooling Consult Application Guidelines range outside heating range etc loose High Pressure Switch harness Check HPS harness leads Pressure Switch disconnected from ODU Control Board Check HPS connection on ODU control Check Discharge pressure with gauge if gt less than 610 20 psig and switch is Bonn Faulty Pressure Switch open measure resistance then replace pressure switch Restriction due to debris leading to one SR Clean System refer to application Overcharge when charging in Cool Har S i ing mode guideline and replace filter drier Restriction in EXV plus Long Line Application leading to Overcharge If long line troubleshoot EXV when charging in Cooling mode None condensible leading to high Clean System refer to application load guideline and replace filter drier Service Valve left closed Liquid or E Service Val Vapor nsure Service Valves are open Check system charge using Cooling Overcharged System Charging Mode follow proper charging procedures Check Outdoor Coil for clogging ice or debris and clean or de ice if neces Outdoor Airfl
34. e sensor improperly installed sensor e body may be in contact with sheet Properly install OAT sensor metal Sensor Harness not connected to Ensure plug is connected to ODU con ODU control trol Check harness for stripped wires shot to EES ground or short between wires Compare transducer voltage reading to Fault 57 Both S gauge reading at service valve see Ge short destroyediIrans Transducer Output Function graph ucer electronics Check system for electrical shorts and correct replace transducer Compare transducer reading to gauge Heat damage during brazing reading at service valve see transducer measurement chart replace transducer Suction Thermistor not properly at Ensure plug is properly attached to suc tached or in wrong location tion tube Check harness for continuity resistance Event 58 Both should measure 10k at 77 20 F Broken or loose harness wire Refer to thermistor 10 k thermistor curve If bad replace OST thermistor sensor assembly 14 25VNA EVENT FAULT CONT FLASH CODE Heat or Cool d OPERATION Amber LED Mode Possible Causes ACTION Event 58 Both Outdoor Air Thermistor Issue See Error 53 and or Error 56 Outside Normal Operating Range e g improper load calculation sys d CA tem match issue outside cooling Consult Application Guidelines range etc Service Valve left closed L
35. e bulb which increases the pressure on the top side of the diaphragm This opens the valve and increases the flow of refrigerant The increased refrigerant flow causes the leaving evaporator temperature to decrease This lowers the pressure on the diaphragm and closes the pin The refrigerant flow is effectively stabilized to the load demand with negligible change in superheat 36 Accumulator The accumulator is specifically designed to operate with Puron or R22 respectfully use only factory authorized components Under some light load conditions on indoor coils liquid refrigerant is present in suction gas returning to compressor The accumulator stores liquid and allows it to boil off into a vapor so it can be safely returned to compressor Since a compressor is designed to pump refrigerant in its gaseous state introduction of liquid into it could cause severe damage or total failure of compressor The accumulator is a passive device which seldom needs replacing Occasionally its internal oil return orifice or bleed hole may become plugged Some oil is contained in refrigerant returning to compressor It cannot boil off in accumulator with liquid refrigerant The bleed hole allows a small amount of oil and refrigerant to enter the return line where velocity of refrigerant returns it to compressor If bleed hole plugs oil is trapped in accumulator and compressor will eventually fail from lack of lubrication If bleed hole is plugged ac
36. e motor to synchronize to that frequency set by the drive e Supplies the mechanical power afforded to it by the drive voltage current and frequency Motor Control Drive BPM together Through the combination of the drive and motor the system is able to operate over a wide speed range e The drive provides protection of the system to various abnormal conditions including limiting the compressor envelope of operation to appropriate boundaries e Provides many pieces of system data as feedback to the system controller e Allows operation at least than full performance in case of system faults or issues Crankcase Heater Operation This unit has an internal crankcase heater that will be energized during the off cycle and is intelligently demanded by the system to prevent the compressor from being the coldest part of the system thus enhancing the reliability The crankcase heater will function as needed any time the outdoor unit is powered The indoor unit and UI do not need to be installed for the crankcase heater to operate properly NOTE Contactor may close intermittently without the unit starting This is done to determine whether the control needs to energize the crankcase heater Closing the contactor powers the inverter and allows the system to check compressor temperature Outdoor Fan Motor Operation The outdoor unit control Fig 3 energizes outdoor fan anytime compressor is operating except for defrost and as n
37. e will flash temporarily An RCD replacement board contains no model and serial information If the factory control board fails the model plug must be transferred from the original board to the replacement board for the unit to operate NOTE The model plug takes priority over factory model information input at the factory If the model plug is removed after initial power up the unit will operate according to the last valid model plug installed and flash the appropriate fault code temporarily Pressure Switch Protection The outdoor unit is equipped with high pressure switch If the control senses the opening of a high pressure switch it will respond as follows 1 De energize the contactor 2 Keep the outdoor fan operating for 15 minutes 3 Display the appropriate fault code see Table 5 and Table 6 4 After a 15 minute delay if there is a call for cooling or heat ing and HPS is reset the contactor is energized 5 If HPS has not closed after a 15 minute delay the outdoor fan is turned off If the open switch closes anytime after the 15 minute delay then resume operation with a call for cool ing or heating at a temporary reduced capacity 6 If HPS trips 3 consecutive cycles the unit operation is locked out for 4 hours 7 In the event of a high pressure switch trip or high pressure lockout check the refrigerant charge outdoor fan operation and outdoor coil in cooling for airflow restrictions or in door airf
38. ect 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 O resistance should be read Higher readings could indicate burned or pitted contacts which may cause future failures Parts Location PRESSURE TRANSDUCER SPT ACCUMULATOR TUBE SUCTION TUBE COMPRESSOR SUCTION THERMISTOR OST ACCUMULATOR REVERSING VALVE SUCTION SERVICE VALVE Type 10k Q negative temperature coefficient Suction Thermistor used to control EXV A11103 Fig 1 Suction Thermistor OST Attachment On Suction Tube This unit uses a 5 VDC output low pressure transducer that provides a 0 SVDC data for interpretation by the control board a 0 to 200 psig range of pressure at the suction tube Signals used by control board for e Low pressure cut out e Loss of charge management e Compressor overall envelope management e Oil circulation management Sg
39. eed Drive Troubleshooting 29 communicating with outdoor board okay No troubleshooting instructions s green LED blinking Power down the entire system for 2 minutes to reboot the drive Check for loose connections disconnected COMs plugs etc Turn power on and double check user interface for faults Consult with Carrier Problem Resolution may have to replace the drive Refer to outdoor Drive is communicating internally okay Put system back into operation A11562 Measure voltage between L1 amp L2 Voltage should be 187 to 253 VAC A11563 Fig 25 Measuring Input Voltage VAC to Drive L1 amp L2 30 Ak HAZARD HIGH VOLTAGE COMPOMENTS RAY ODRA Comer trag COMs LEDs are behind gray panel LEDs can be seen by looking behind panel DO NOT ATEMPT TO REMOVE PANEL Fig 26 Location of COMs LEDs on Drive 31 A11564 RS485 6 Pin COMs Plug to outdoor board A11565 Fig 27 Location of RS485 6 Pin COMs Plug 32 REFRIGERATION SYSTEM Refrigerant AA WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in personal injury or equipment damage Puron refrigerant which has higher pressures than R 22 and other refrigerants No other refrigerant may be used in this system Gauge set hoses and recovery system must be designed to handle Puron If you are unsure consult the equipment manufacturer
40. eeded during low ambient cooling operation The outdoor fan remains energized if a pressure switch opens or compressor scroll over temperature should occur This OD fan is an ECM motor which operates at varying speeds depending on the ambient and the demand Time Delays The unit time delays include e Five minute time delay to start cooling or heating operation when there is a call from the user interface To bypass this feature momentarily short and release Forced Defrost pins e Five minute compressor re cycle delay on return from a brown out condition Infinity Controlled Low Ambient Cooling This unit is capable of low ambient cooling down to 0 F 17 8 C with Low Ambient enabled on the Infinity Control A low ambient kit is not required The only accessory that may be required is wind baffles in locations which are likely to experience cross winds in excess of 5 miles an hour This generally occurs only on roof and open area applications The Infinity Control provides an automatic evaporator freeze thermostat Low ambient cooling must be enabled in the User Interface setup Fan may not begin to cycle until about 40 F 4 4 C OAT Fan will cycle based on coil and outdoor air temperature Infinity controlled low ambient mode operates as follows Fan is OFF when outdoor coil temperature is too low 55 F 12 7 C the saturated suction pressure indicates a freezing indoor coil or outdoor fan has been ON for 30 minutes Fan
41. ent 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 FROM INDOOR COIL VIA SERVICE VALVE ON OUTDOOR COIL TO OUTDOOR COIL TO ACCUMULATOR FROM COMPRESSOR DISCHARGE LINE A88342 Fig 29 Reversing Valve Cooling Mode or Defrost Mode Solenoid Energized TO INDOOR COIL VIA SERVICE VALVE ON OUTDOOR COIL TO FROM ACCUMULATOR OUTDOOR SE COIL P TP 4 INSULATE FOR ACCURATE ON READING INSULATE FOR TP 3 ACCURATE READING FROM COMPRESSOR DISCHARGE LINE ELECTRONIC THERMOMETER A88341 Fig 30 Reversing Valve Heating Mode Solenoid De Energized amp WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label 35 Liquid Line Filter Drier Filter driers are specifically designed for R 22 or Puron refrigerant Only operate with the appropriate drier using factory authorized components It is recommended that the liquid line drier be installed at the indoor unit Placing the drier near the TXV allows additional protection to the TXV as the liquid line drier also acts as a strainer
42. es Check harness for continuity on the sensor fusite resistance should be in 10 Failed Open Close Compressor Intern kOhm between scroll and common termin al Thermistor als and 5 kOhm between motor and com mon terminals at 70 20 F See com pressor troubleshooting guidelines Check Inverter fins for debris and clean if Blocked Inverter Heat Exchanger fins necessary Check Evaporator IDU in cooling ODU in 3 heating for clogging ice or debris and Both Outdoor Airflow too low or off clean if necessary Troubleshoot Evaporat or fan motor and make sure it is working Outdoor Unit airflow blocked improp et da System Malfunction 88 er installation Consult Application Guidelines Outside Normal Operating Range e g Cool outside cooling ambient temperature Consult Application Guidelines range etc Outside Normal Operating Range e g Heat outside heating ambient temperature Consult Application Guidelines range etc Both Inverter internal damage Replace Inverter System will try to ride through voltage P spikes and self recover in trip condition Event 91 Both EE E Ge persistent over current trips will lead to Er y ror 97 High Voltage Lockout Refer to Er ror 97 troubleshooting System will try to ride through voltage dro R pouts and self recover in trip condition Event 92 Both SE GE drive persistent over current trips will lead to Er g y ror 96 Low Voltage Lockout Refer to Er ror 96 troubleshooting System will
43. es ACTION Check supply voltage to ODU if low con Low supply line voltage lt 180 VAC tact utility provider 9 ae i When adverse weather subsides unit System Malfunction 96 Both SC e intermittent should self recover cycle ODU power if necessary Loose wire in control box area Loose wire check for loose wire in ODU Inverter internal damage Replace Inverter i A Check supply voltage to ODU if high con High supply line voltage gt 257 VAC Get utility provid GE 9 j dag i When adverse weather subsides unit System Malfunction 97 Both Stormy weather causing intermittent should self recover cycle ODU power if voltage spikes necessary Inverter internal damage Replace Inverter System will try to self mitigate persistent Event 98 Both High Torque or Flank Loading Event conditions will lead to lockout refer to Er ror Code 99 Outside Normal Operating Range e g improper load calculation system d SH match issue outside cooling range Consult Application Guidelines outside heating range etc Restriction due to debris leading to Clean System refer to application Both SE when charging in Cooling guideline and replace filter drier Restriction in EXV plus Long Line Ap plication leading to Overcharge when If long line troubleshoot EXV charging in Cooling mode None condensibles leading to high Clean System refer to application load guideline and replace filter drier Service Valve left closed Liquid or Va E por
44. h 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 A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label A WARNING ELECTRICAL HAZARD HIGH VOLTAGE Failure to follow this warning could result in personal injury or death Electrical components may hold charge DO NOT remove control box cover for 2 minutes after power has been removed from unit PRIOR TO TOUCHING ELECTRICAL COMPONENTS Verify less than 20 vdc voltage at inverter connections shown on inverter cover AA CAUTION CUT HAZARD Failure to follow this caution may result in personal injury Sheet metal parts may have sharp edges or burrs Use care and wear appropriate protective clothing and gloves when handling parts AA WARNING UNIT OPERATION AND SAFETY HAZARD Failure to follow this warning could result in personal injury or equipment damage Puron R 410A systems operate at highe
45. hether the outdoor unit is on the same level above or below the outdoor unit MAXIMUM LINE LENGTHS FOR HEAT PUMP APPLICATIONS MAXIMUM ACTUAL LENGTH MAXIMUM EQUIVALENT LENGTHT MAXIMUM VERTICAL SEPARA ft m ft m TION ft m Units on equal level 200 61 250 76 2 N A Outdoor unit ABOVE indoor unit 200 61 250 76 2 200 61 RECH See Table Maximum Total Equivalent Length Outdoor Unit BELOW Indoor Unit T Total equivalent length accounts for losses due to elbows or fitting See the Long Line Guideline for details Maximum Total Equivalent Lengtht Outdoor Unit BELOW Indoor Unit Liquid Li HP with Puron Refrigerant Maximum Total Equivalent Lengtht Si ee Vertical Separation ft m Outdoor unit BELOW indoor unit ize w TXV 0 20 21 30 31 40 41 50 51 60 61 70 71 80 0 6 1 6 4 9 1 9 4 12 2 12 5 15 2 15 5 18 3 18 6 21 3 21 6 24 4 024 HP with 3 8 250 250 250 250 250 250 250 Puron 036 HP with 3 8 250 250 250 250 250 250 250 Puron 048 HP with 3 8 250 250 250 250 230 160 Puron 060 HP with 3 8 250 225 190 150 110 EE Puron Maximum actual length not to exceed 200 ft 61 m T Total equivalent length accounts for losses due to elbows or fitting See the Long Line Guideline for details outside acceptable range LONG LINE APPLICATIONS An application is considered Long Line when the refrigeran
46. iquid or E Service Val Vapor nsure Service Valves are open Check system subcooling to determine charge status if low add charge using Undercharged System Charging Mode follow proper charging procedures Check Indoor for clogging ice or debris Cool d and clean or de ice if necessary Indoor Airflow too low or off Troubleshoot Indoor fan motor and make sure it is working follow Indoor Airflow troubleshooting instruction Restriction in Filter Drier plus Long Clean System refer to application Line Application and filter drier on Grat X Indoor Unit guideline and replace filter drier are d Clean System refer to application Restriction due to debris guideline and replace filter drier EE EE Check kinks and straighten or replace Restriction in Circuits or Tubing circuits Restriction in Filter Drier plus filter Clean System refer to application Both drier on Outdoor Unit guideline and replace filter drier Event 59 If short lineset less than 15 ft Both Expansion Orifice Restriction Troubleshoot TXV see guide below re place if necessary Troubleshoot EXV see guide below Outside Normal Operating Range e g improper load calculation sys eM Sham tem match issue outside heating Consult Application Guidelines range etc Service Valve left closed Liquid ZE Service Valve Ensure Liquid Service Valve is open Check Outdoor for clogging ice or debris and clean or de ice if neces Outdoor Airflow too low or off sary Troublesh
47. is turned off to allow refrigerant system to stabilize e Fan is ON when outdoor coil temperature is too high 80 F 26 7 C the high side pressure is too high or if outdoor fan has been OFF for 30 minutes Fan is turned on to allow refrigerant system to stabilize Low pressure indication by the suction pressure transducer is ignored for first 3 minutes during low ambient start up After 3 minutes if low pressure trip occurs then outdoor fan motor is turned off for 10 minutes with the compressor running If pressure condition is satisfied within 10 minutes then cooling continues with the outdoor fan cycling per the coil temperature routine listed above for the remainder of the cooling cycle Ifthe suction pressure condition is not satisfied within 10 minutes then the normal trip response shut down cooling operation and generate LP trip error will occur Utility Interface With Infinity Control The utility curtailment relay should be wired between the two UTIL connections on the control board for this Infinity Communicating System This input allows a power utility device to interrupt compressor operation during peak load periods When the utility sends a signal to shut the system down the User Interface will display Curtailment Active See UI installation instructions for setup details Communication and Status Function Lights Infinity Control Green Communications COMM Light A green LED COMM light on the outdoor board
48. low in heating 8 In the event of a low pressure trip or low pressure lockout check the refrigerant charge and indoor airflow cooling and outdoor fan operation and outdoor coil in heating Control Fault If the outdoor unit control board has failed the control will flash the appropriate fault code The control board should be replaced If the sensors are out of range the control will flash the appropriate fault code The thermistor comparisons are not performed during low ambient cooling or defrost operation Failed Thermistor Default Operation Factory defaults have been provided in the event of failure of outdoor air thermistor OAT and or outdoor coil thermistor OCT If the OAT sensor should fail low ambient cooling will not be allowed and the one minute outdoor fan off delay will not occur Defrost will be initiated based on coil temperature and time If the OCT sensor should fail low ambient cooling will not be allowed Defrost will occur at each time interval during heating operation but will terminate after 5 minutes If there is a thermistor out of range error defrost will occur at each time interval during heating operation but will terminate after 5 minutes Count the number of short and long flashes to determine the appropriate flash code Outdoor Coil Thermistor The outdoor coil thermistor is a 10Kohm resistor used for multiple system operations It provides the coil liquid line temperature to the hea
49. lution applied to tubing or wire before it is brazed Flux improves the strength of the brazed connection When brazing is required in the refrigeration system certain basics should be remembered The following are a few of the basic rules 1 Clean joints make the best joints To clean Remove all oxidation from surfaces to a shiny finish before brazing Remove all flux residue with brush and water while material is still hot 2 Silver brazing alloy is used on _ copper to brass copper to steel or copper to copper Flux is required when using silver brazing alloy Do not use low temperature solder 3 Fluxes should be used carefully Avoid excessive application and do not allow fluxes to enter into the system 4 Brazing temperature of copper is proper when it is heated to a minimum temperature of 800 F and it is a dull red color in appearance 33 Service Valves and Pumpdown AA WARNING PERSONAL INJURY AND UNIT DAMAGE HAZARD Failure to follow this warning could result in personal injury or equipment damage 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 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 gauge port
50. mally inlet and outlet temperatures on appropriate lines should be close to each other Any difference would be due to heat loss or gain across valve body Temperatures are best checked with a remote reading electronic type thermometer with multiple probes Route thermocouple leads to inside of coil area through service valve mounting plate area underneath coil Fig 29 and Fig 30 show test points TP on reversing valve for recording temperatures Insulate points for more accurate reading If valve is defective 1 Shut off all power to unit and remove charge from system 2 Remove solenoid coil from valve body Remove valve by cutting it from system with tubing cutter Repair person should cut in such a way that stubs can be easily re brazed back into system Do not use hacksaw This introduces chips into system that cause failure After defective valve is removed wrap it in wet rag and carefully unbraze stubs Save stubs for future use Because defective valve is not overheated it can be analyzed for cause of failure when it is returned 3 Braze new valve onto used stubs Keep stubs oriented correctly Scratch corresponding matching marks on old valve and stubs and on new valve body to aid in lining up new valve properly When brazing stubs into valve protect valve body with wet rag to prevent overheating 4 Use slip couplings to install new valve with stubs back into system Even if stubs are long wrap valve with a wet rag to prev
51. mediately cleaned up may cause embrittlement leading to cracking to occur in one year or more When performing any service which may risk exposure of compressor oil to the roof take appropriate precautions to protect roofing Procedures which risk oil leakage include but are not limited to compressor replacement repairing 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 polyethylene plastic drop cloth or tarp Cover an approximate 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 Brazing This section on brazing is not intended to teach a technician how to braze There are books and classes which teach and refine brazing techniques The basic points below are listed only as a reminder Definition The joining and sealing of metals using a nonferrous metal having a melting point over 800 F 426 6 C Flux A cleaning so
52. n the compressor See Fig 19 y Measure resistance between each of the three fusite pins and ground See Fig 20 amp 21 s there continuity between any of the pins and ground Yes Change the compressor The molded plug harness is grounded replace it n Install new molded plug assembly and route wires carefully Reset motor temp fault at system controller Check and verify correct drive part number Confirm phasing is correct to compressor yellow black red wires on drive output See Fig 23 t Put system back into operation t Check system refrigerant charge amp air flow D Check for restricted refrigerant flow m compressor unit and or high superheat Confirm operation inside temperature amp speed range Is input current to drive less than unit full load amp rating System still faulting on motor temp Normal operation monitor Fig 15 Motor Temp Fault Troubleshooting Part 2 24 Replace compressor Troubleshoot the thermistor circuit A11555 Thermistor Resistance Ohms 307200 4 153600 76800 4 38400 4 19200 9600 4 4800 4 2400 4 1200 4 600 4 300 4 Low Temp Trip Scroll Thermistor Resistance High Temp Trip 15
53. ndings For the 2 and 3T the resistance should be 681 ohm and for 4 and 5T the resist Compressor Winding damage ance should be 203 ohm at 70F 20F See compressor troubleshoot ing guidelines If confirmed replace compressor Overcharge Attic run lineset and Verify charge by putting in cooling char High Load conditions ging mode System Malfunction 82 Cool Outside Normal Operating Range e g improper load calculation sys SA DE tem match issue outside cooling Consult Application Guidelines range etc 16 25VNA EVENT FAULT CONT OPERATION FLASH CODE Amber LED System Malfunction 83 Heat or Cool 2 Mode Possible Causes ACTION Cooling in Low Ambient region 55 we Cool F and below with Low Ambient SE SE HE EE Cooling Control disabled Outside Normal Operating Range e g improper load calculation sys the GER Cool tem match issue outside cooling Consult Application Guidelines range etc Cool EE closed Liduid or Ensure Service Valves are open Vapor Check system subcooling to determine charge status if low add charge using Undercharged System Charging Mode follow proper charging procedures Check Indoor for clogging ice or debris and clean or de ice if necessary Indoor Airflow too low or off Troubleshoot Indoor fan motor and make sure it is working follow Indoor Cool Airflow troubleshooting instruction
54. nsor Harness not connected to Ensure plug is connected to ODU con ODU control trol Check harness for continuity resistance Brok h should measure 10k at 77 20 F TORE QE QOS We Refer to thermistor 10 k thermistor curve If bad replace OST sensor Fault 54 Both Suction Thermistor not properly at Ensure Sensor is properly attached to tached or in wrong location the accumulator entry tube Check harness for continuity resistance Brok D ds should measure 10k at 77 20 F ET EE Refer to thermistor 10 k thermistor curve If bad replace OST sensor Hardware damage to ODU control Replace ODU control Sensor Harness not connected to Ensure plug is connected to ODU con ODU control trol Check harness for continuity resistance should measure 10k at 77 20 F Broken or loose harness wire Refer to thermistor 10 k thermistor curve If bad replace OAT OCT thermistor sensor assembly Fault 55 Both Coil Thermistor not properly at Ensure Sensor is properly clipped to the tached or in wrong location distributor entry tube Check harness for continuity resistance should measure 10k at 77 20 F Broken or Damaged Sensor Refer to thermistor 10 k thermistor curve If bad replace OAT OCT thermistor sensor assembly Hardware damage to ODU control Replace ODU control Coil Thermistor not properly at Ensure Sensor is properly clipped to the tached or in wrong location distributor entry tube Event 56 Both Outdoor Ambient Temperatur
55. nutes or AUTO are selected by the Infinity Control User Interface dip switches are not used AUTO defrost adjusts the defrost interval time based on the last defrost time as follows When defrost time lt 3 minutes the next defrost interval 120 minutes e When defrost time 3 5 minutes the next defrost interval 90 minutes When defrost time 5 7 minutes the next defrost interval 60 minutes When defrost time gt 7 minutes the next defrost interval 30 minutes The control board accumulates compressor run time As the accumulated run time approaches the selected defrost interval time the control board monitors the coil temperature sensor for a defrost demand If a defrost demand exists a defrost cycle will be initiated at the end of the selected time interval A defrost demand exists when the coil temperature is at or below 32 F 0 C for 4 minutes during the interval If the coil temperature does not reach 32 F 0 C within the interval the interval timer will be reset and start over Upon initial power up the first defrost interval is defaulted to 30 minutes Remaining intervals are at selected times Defrost is only allowed to occur below 50 F 10 C outdoor ambient temperature The defrost cycle is terminated as described below When OAT is gt 30 F 1 1 C defrost terminates if outdoor coil temperature OCT gt 50 F 10 C When OAT is lt 30 F 1 1 C defrost terminates if
56. nvenient 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 Edition Date 01 12 Catalog No 25VNA 1SM Replaces NEW 38
57. obe or sniffer Detector is turned on and probe is passed around all fittings and connections in system Leak is detected by either the movement of a pointer on detector dial a buzzing sound or a light In all instances when a leak is found system charge must be recovered and leak repaired before final charging and operation After leak testing or leak is repaired replace liquid line filter drier evacuate system and recharge with correct refrigerant quantity amp WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Before installing modifying or servicing system main electrical disconnect switch must be in the OFF position There may be more than 1 disconnect switch Lock out and tag switch with a suitable warning label Coil Removal Coils are easy to remove if required for compressor removal or to replace coil 1 Shut off all power to unit Recover refrigerant from system through service valves Break vacuum with nitrogen Remove top cover Remove screws in base pan to coil grille Remove coil grille from unit Remove screws on corner post holding coil tube sheet AA WARNING FIRE HAZARD 2 3 4 5 6 7 Failure to follow this warning could result in personal injury or equipment damage Cut tubing to reduce possibility of personal injury and fire 8 Use midget tubing cutter to cut liquid and vapor lines at both sides of coil Cut in co
58. oot Outdoor fan motor and make sure it is working follow Out Heat door Airflow troubleshooting instruction Check charge in cooling if in Cooling Charge Mode Ambient Range if low add charge using Charging Mode follow Undercharged System proper charging procedures if out side cooling charge mode range pull out charge weigh in using heating charge mode R ing Valve B Reversing Valve Stuck halfway eversing valve ENKE troubleshoot reversing valve rare 7 Clean System refer to application Deiere guideline and replace filter drier z F Nothing system is warming up com nae ot Sieg E S Se pressor sump temperature Might take Sg SE 9 Si SEHR SE up to 2 hours thus secondary heat might pressor sump be requested if necessary EXV harness not connected to ODU Check harness connection to ODU con Even P GE control trol ven o i SS EXV coil not connected to EXV Check EXV coil and ensure it is well seated g Check TXV operation and replace if ne TXV failed open cessary Inverter PFC Thermistor sensor failed open Replace Inverter d Check line wiring and ensure proper Noisy Line Voltage contacts disconnects etc Zeg Check for system short circuit loose Short Circuit in system wire damaged contacts etc System Malfunction 69 Both el Check compressor winding resistances press namg vamage See Compressor Troubleshooting Check for system short circuit loose Inverter Damaged wire damaged contacts etc Replace Inverter Troubleshoot the compressor m
59. otor Ke thermistor Compressor sensor fusite Event 71 Cool Shorted sensor circuit should measure 5 kohm between motor and common terminals 15 25VNA EVENT FAULT CONT FLASH CODE Heat or Cool 7 OPERATION Amber LED Mode Possible Causes ACTION System will try to ride through current spikes and self recover in trip condition Event 72 Cool High Suction Gas Temperature persistent over current trips will lead to Error 82 Suction Over Temp Lockout Refer to Error 82 troubleshooting Check ODU coil for clogging ice or d debris and clean if necessary Outdoor Airflow too low or off Troubleshoot ODU fan motor and make sure it is working Event H Boin Blocked Inverter Heat Exchanger Check Inverter fins for debris and clean if fins necessary Application violates guideline ZONEN Application Guideline for compli System will try to ride through current spikes and self recover in trip condition Event 77 Both Sa t aeres H care persistent over current trips will lead to y Error 95 High Current Lockout Refer to Error 95 troubleshooting Inverter Output to Compressor leads miswired leading to com check wiring at Inverter outputs pressor running backwards Inverter Output to Compressor SR leads not attached check wiring at Inverter outputs Reversing Valve Bypa Reversing Valve Stuck halfway Event 79 Both eversing vave ENEE troubleshoot reversing valve Troubleshoot compressor wi
60. ow too low or off sary Troubleshoot Outdoor fan motor Coo and make sure it is working follow Out door Airflow troubleshooting instruction Line Applicaton and fiter drier on Clean System refer to application System Malfunction 84 Outdoor Unit guideline and replace filter drier Restriction in EXV plus Overcharge troubleshoot EXV Restriction in Circuits or Tubing E SSES circuits Electric Heater plus Heat pump ap peepee ere eae E plication Electric Heater stuck on troubleshoot Electric Heater d If not in Defrost and Furnace is running Furnace plus Heat pump applica tion Furnace stuck on same time as heat pump troubleshoot Furnace Restriction in Filter Drier plus Long SA GE g Clean System refer to application ee andfiterdrier on guideline and replace filter drier Expansion Orifice Restriction Troubleshoot TXV see guide below Troubleshoot EXV see guide below Service Valve left closed Vapor E V Service Valve i Service Valve nsure Vapor Service Valve is open Heat Check Indoor for clogging ice or debris and clean or de ice if necessary Indoor Airflow too low or off Troubleshoot Indoor fan motor and make sure it is working follow Indoor Airflow troubleshooting instruction Check charge in cooling if in Cooling Charge Mode Ambient Range if low add charge using Charging Mode follow Overcharged System proper charging procedures if out side cooling charge mode range pull out charge weigh in using heating charge mode
61. pipe length to the muffler shell inlet and from the outlet stubs e To prevent rusting provide sufficient clearance between the muffler and the ground surface Also position the muffler such that accidental abuse such as by a weed trimmer lawn mower etc of the painted surface is avoided e Insulating the muffler with Armaflex tape is recommended EXTERIOR p WALL MUFFLER H SI k 1 TO DWELLING VAPOR LINE A11543 Fig 7 Muffler Installation Table 1 MIN MAX AIRFLOW The indoor airflow delivered by this system varies significantly based on outdoor temperature indoor unit combination and system demand The air flows on these tables are for duct design considerations Duct systems capable of these ranges will ensure the system will deliver full capacity at all outdoor temperatures Minimum and maximum air flows can be adjusted from these numbers in the Infinity Control Heat Pump Setup screen Cooling Comfort Mode Minimum Cooling Size Max Capacity
62. r Control I Board If Outdoor Unit Improperly Grounded Connect Indoor Ground To C Terminal i I 5 If Any Of The Original Wire As Supplied Must Be Replaced Use The Same Or Equivalent Wire be eae eat one ee Ee el ee S 6 Check All Electrical Ggs e Control Box For Tignitness 7 Do Not Attempt To Operate Unit Until Service Valves Have Been Opened UNIT OPERATION 8 Must Use With Infinity User Interface Listed In Pre sale Literature Only This Control Board Contains A Five Minute Short Cycle Protector A Five Minute Delay Will Occur Between Compressor Offfon Cycles To Bypass Delay Short Forced Defrost Pins For 1 Second Then Release The Crankcase Heater Is Energized During LEGEND Off Cycle Below 75 F As Needed FACTORY POWER WIRING HPS HIGH PRESSURE SWITCH RVS REVERSING VALVE SOLENOID e DEFROST TIME SELECTION The Defrost Interval Time Can Be Field Selected Dependent Upon Local Georgraphic te HE ONES WIRING INVERTER INVERTER DRIVE SPT SUCTION PRESSURE Requirements It Is Factory Set At 90 Minutes And Can Be Changed To Either 30 60 Or 120 Minutes Via The User Interface FACTORY CONTROL WIRING LS LIQUID LINE SOLENOID TRANSDUCER User Interface Defaults to AUTO FIELD CONTROL WIRING OAT THERMISTOR OUTDOOR AIR STATUS SYSTEM FUNCTION LIGHT il m O COMPONENT CONNECTION OT THERMISTOR COIL TRAN TRANSFORMER e DEFROST Defrost Will Only Be Performed At Outdoor Temperatures Less Than 50 F Defrost Will Initiate When Time e JU
63. r 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 If you do not understand any of the warnings contact your product distributor for better interpretation of the warnings GENERAL INFORMATION The 25VNA Greenspeed Intelligence heat pump features a new outdoor cabinet design that uses a four sided coil design to minimize the unit foot print and provide the best heat exchange taking full advantage of the latest variable speed technology The heart of the system is the Copeland variable speed compressor powered through the use of the Emerson variable speed drive VSD inverter control Through the use of Puron refrigerant ECM outdoor fan Emerson VSD and Copeland variable speed compressor along with the new outdoor cabinet the unit achieves a Seasonal Energy Efficiency Ratio SEER up to 20 5 and up to 13 Heating Seasonal Performance Factor HSPF To ensure all of the above technology provides the ultimate in comfor
64. r thermistor OAT outdoor coil thermistor OCT high pressure switch HPS etc Features Serially Communicating 2or3 Wire DX DX Ground optional Capacity Feedback Ambient Optimized Speed Ranges Proactive Fault Prevention Automatic Load Shedding Heating Superheat Control with EXV Intelligent Defrost Low Ambient Cooling Hold at compressor speed on start up User Interface holds demand to minimum for 5 minutes Motor Control Drive Inverter e Converts the sinusoidal AC input mains voltage into a variable frequency AC output generated used PWM modulation of the output e Drive adjusts the output voltage to run the compressor at the correct speed at any load point in the envelope e The drive actively controls the motor current to insure the proper torque is provided for the given loading condition e The drive control algorithms insure the magnetic field set up in the motor is synchronized with the rotor insuring smooth efficiency operation e The drive actively controls the input current at heavy loading conditions to insure the input power factor to the drive is gt 0 95 Compressor Brushless Permanent Magnet Motor BPM e The motor inductance reacts to the drive current and a sinusoidal current is induced through the motor windings e The sinusoidal current sets a rotating magnetic field at the frequency set by the drive e The magnets enable th
65. rrosion or Event 25 Both Damaged Model Plug breakage replace if necessary Damaged ODU control Replace ODU control System will self mitigate persistent con Event 31 Both High Pressure Event ditions will lead to lockout refer to Error Code 84 System will self mitigate persistent con Event 32 Both Low Pressure Event ditions will lead to lockout refer to Error Code 83 System Malfunction 45 Both Damaged ODU control Replace ODU control Event 46 Both low line voltages if persistent contact power provider Loose or disconnected harness CC HP control CC contactor IN 3 7 VERTER HP control INVERTER Verify good harness connection inverter drive Verify communications wiring Inverter harness check for loose connection Loose wire or shorted leads stripped wires short to ground or short between wires confirm good connection is made at control board and at Inverter Verify contactor harness from ODU con trol CC harness check for loose con nection stripped wires short to ground Contactor not pulled in Sege i System Malfunction 48 Both or short between wires confirm good connection is made at control board and at contactor Damaged Contactor Coil if wiring is ok measure across the con tactor coil for 18VAC 32VAC if voltage is present measure across contactor ter minals 21 amp 23 for line voltage if absent then contactor is damaged Damaged ODU Control confirm 5VDC on pins 3 amp
66. s for measuring system pressures and provide shutoff convenience for certain types of repairs See Fig 28 The service valve 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 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 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 valve 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 the 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 evaporator coil have been evacuated the valve stem can be turned counterclockwise until back seats which releases refrigerant into tubing and evaporator coil The system can now be operated 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
67. show open or short to ground replace the plug Is compressor hot Allow time for compressor to to change 60 minutes m gt cool amp resistance l Resistance is in range that will allow operation temperature data See Fig 15 Refer to thermistor resistance Is resistance 00 Yes Measure resistance between red amp white wires in the 4 pin plug Allow time for resistance to change 60 minutes Is resistance 4590 168KQ Refer to thermistor resistance temperature data Is Q moving towards Q corresponding to ambient temp Power down the entire system for 2 minutes to reboot the drive If problem still exists change the compressor Fig 14 Motor Temp Fault Troubleshooting Part 1 23 Thermistor circuit is shorted Remove the molded plug from the thermistor fusite on the compressor See Fig 19 e Measure resistance in motor thermistor circuit pins See Fig 20 amp 21 Is resistance 00 Inspect molded plug assembly for lead to lead shorting Install new molded plug assembly and carefully route wires Motor thermistor circuit is shorted internally replace compressor A11554 Remove the molded plug from the thermistor fusite o
68. t Ee e EE 33 Servicing Systems on Roofs With Synthetic Materials 33 Brazing i34 cett tees ile a ied bees Peds bet dew Rid ded ed Ed a EE 33 service Valves and Pumpd0wn ee SE EE EE bas Obie pire bie nea cbt oir ised E 34 35 Liquid Line Filter D Lea dE EE EE ee Rane AONE AM GREE SMO RUE AERTS Le RR SEE EE 36 Suction Line Filter Ee EE 36 Thermostatic Expansion Valve TXV ee AER cece cdc ed ees Cech eS EEN NEEN SEER EEN EES KERR EES ES 36 Accumulator seerne iaa sien EE EE 37 REFRIGERATION SYSTEM REPAIR UNIT IDENTIFICATION The unit is identified using a 16 digit model number structure It is recommended providing the complete 16 digit model number when ordering replacement parts to insure receiving the correct parts MODEL NUMBER NOMENCLATURE Product Series Heat Pump SEER Undefined 20 SEER Product Available Available Family Sizes Voltage Variable 24 2 Ton 208 230 1 Speed Tier 36 3 Ton Infinity AS Se Undefined Series i Variation Major A Std Series SERIAL NUMBER NOMENCLATURE 01 06 00001 Week of Manufacture Serial Number Manufacturing Site E Collierville TN X Monterrey Mexico Year of Manufacture SAFETY CONSIDERATIONS Installation service and repair of these units should be attempted only by trained service technicians familiar with standard service instruction and training material All equipment should be installed in accordance wit
69. t it is combined with either the FE fan coil or Variable Speed Gas furnace controlled with a two wire communication Infinity User Interface GSYSTXCCUIDO1 V or the Infinity Zone User Interface SYSTXCCUIZO1 V Ensuring achievement of comfort with the consciences of finger tip trouble shooting and diagnostic capability ELECTRICAL A WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death Exercise extreme caution when working on any electrical components Shut off all power to system prior to troubleshooting Some troubleshooting techniques require power to remain on In these instances exercise extreme caution to avoid danger of electrical shock ONLY TRAINED SERVICE PERSONNEL SHOULD PERFORM ELECTRICAL TROUBLESHOOTING Aluminum Wire A CAUTION UNIT OPERATION AND SAFETY HAZARD Failure to follow this caution may result in equipment damage or improper operation Aluminum wire may be used in the branch circuit such as the circuit between the main and unit disconnect but only copper wire may be used between the unit disconnect and the unit Whenever aluminum wire is used in branch circuit wiring with this unit adhere to the following recommendations Connections must be made in accordance with the National Electrical Code NEC using connectors approved for aluminum wire The connectors must be UL approved marked Al Cu with the UL symbol for the application and wire
70. t level in the system requires the use of accessories to maintain acceptable refrigerant management for systems reliability Defining a system as long line depends on the liquid line diameter actual length of the tubing and vertical separation between the indoor and outdoor units For Heat Pump systems the chart below shows when an application is considered Long Line Beyond these lengths long line accessories are required HP WITH PURON REFRIGERANT LONG LINE DESCRIPTION ft m Beyond these lengths long line accessories are required Outdoor Above Indoor 80 24 4 Outdoor Below Indoor 20 6 1 vertical or 80 24 4 total Units On Same Level 80 24 4 Liquid Line Size 3 8 Note See Long Line Guideline for details IF B EXCEEDS 20 LIQUID LINE SOLENOID VALVE REQUIRED IF A B C EXCEEDS 80 LIQUID LINE SOLENOID B VALVE REQUIRED REFER TO INSTALLATION INSTRUCTIONS FOR GUIDELINES A11265 Fig 6 Long Line Application External Muffler Factory Supplied Muffler part LM10KK003 Installation is Required On Every Installation e A muffler is required to reduce noise transmitted to indoor through the line set Muffler must be installed outside the dwelling Muffler can also be installed in vertical configuration for space consideration maintaining a minimum of 12 in 304 8 mm straight pipe section to the closest bend Maintain at least 12 in 304 8 mm straight
71. t pump board and user interface Low ambient operation defrost initiation defrost termination and assistance with OAT temperature measurement of some of the functions The sensor must be securely mounted to the tube connecting the EXV and distributor See Fig 9 for proper placement OAT Thermistor must be locked in place with spherical nib end facing towards the front of the ontrol box A11142 Fig 8 OAT Thermistor Location Bottom of Control Box OCT SENSOR LOCATION A11143 Fig 9 Outdoor Coil Thermistor OCT Attachment On Distributor Tube 10 PRESSURE TRANSDUCER SPT ACCUMULATOR TUBE SUCTION TUBE SUCTION THERMISTOR OST ACCUMULATOR REVERSING VALVE SUCTION SERVICE VALVE A11103 Fig 10 Suction Thermistor OST Attachment On Suction Tube Suction Thermistor OST Suction Thermistor is used for assisting in EXV control and must be secured on the suction tube and aligned longitudinally to the vertical surface of the tube axis see Fig 10 Suction Pressure Transducer SPT If the accuracy of the transducer is questioned the technician can check it while it is attached to the VSHP board Connect a gage manifold to the suction valve gage port fitting At the VSHP board with the wire harness receptacle exposing a portion of the three pins on the VSHP board a DC voltmeter can read the
72. time peri od for the procedure is 120 minutes 4 Select Start on UI to begin the pumpdown process Unit will begin running in selected mode after a brief delay 5 Close the liquid service valve 6 The unit will run in selected mode with the low pressure protection set to indicate pumpdown is complete when the suction pressure drops below 0 psig Compressor protec tions are still active to prevent damage to the compressor or inverter high pressure high current high torque scroll temperature etc 7 Once system indicates pumpdown complete or failure to complete shutdown close vapor service valve 8 If pumpdown does not complete due to compressor safety shutdown a recovery system will be required to remove fi nal quantity of refrigerant from indoor coil and line set 9 Remove power from indoor and heat pump unit prior to ser vicing unit NOTE A small quantity of charge remains in the OD unit that must be manually recovered if isolating refrigerant to indoor coil and lineset via HEAT mode PUMP DOWN Evacuation and Recovery of Refrigerant from within 25VNA A CAUTION ENVIRONMENTAL HAZARD Failure to follow this caution may result in environmental damage Federal regulations require that you do not vent refrigerant to the atmosphere Recover during system repair or final unit disposal Because this system has an EXV for the heating expansion device additional steps must be taken to open the EXV if the he

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