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Bryant R-22 User's Manual

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1. SUCTION SERVICE PORT AT SERVICE VALVE CLG CYCLE TRAINER 4 OUTDOOR STRAINER COIL SUCTION LIQUID LINE SERVICE PRESSURE SWITCH PORT BYPASSING METERING HEAT PUMP ACCESSORY LIQUID LINE SERVICE PORT FILTER DRIER DUAL FLOW AT SERVICE VALVE CLG CYCLE A88400 Fig 42 Heat Pump Refrigerant Flow Diagrams CAUTION Due to the high pressure of nitrogen it A should never be used without a pressure regulator on the tank Leaks in a system pressurized with refrigerant can be spotted with a leak detector that detects extremely small refrigerant leaks This discussion assumes that system is pressurized with either all refrigerant or a mixture of nitrogen and refrigerant If system has been operating for some time make first check for a leak visually Since refrigerant carries a small quantity of oil traces of oil at any joint or connection are an indication that refrigerant is leaking at that point A simple and inexpensive method of testing for leaks is to use soap bubbles Any solution of water and soap may be used Soap solution is applied to all joints and connections in system A small pinhole leak is located by tracing bubbles in soap solution around leak Use electronic leak detector to check for leaks This unquestion ably is the most efficient and easiest method for checking le
2. D1 C TRANSFORMER COMMON 2 R TRANSFORMER LINE 3 4 5 W2 FIRST STAGE AUXILIARY HEAT H6 O REVERSING VALVE r17 Y2 SECOND STAGE COOLING HEAT PUMP 8 V1 FIRST STAGE COOLING HEAT PUMP 9 W3 SECOND STAGE AUXILIARY HEAT 10 L MALFUNCTION LIGHT 11 Flos Ln HOM IF NO JUMPER IS L INSTALLED DEFAULT 18 IS 3 TON 5 TON 14 15 16 17 JUMPER FOR 148 4 HEAT PUMP ONLY A93576 Fig 37 Header Pin Housing TS T8 T7 T2 T1 EXTERNAL MAIN QD QQ 00007 MAIN WINDING 4 POLE START 000 S gt S T 2 POLE START HIGH SPEED LOW SPEED L1 T1 T7 L1 T1 L2 T2 T3 L2 T7 T8 A92015 Fig 38 Energizing Windings TABLE 18 TWO SPEED COMPRESSOR WINDING RESISTANCE AT 70 F 2 WINDING 34 pressures exceeds 500 psi The compressor is also protected by 3 PTC devices attached to the motor windings The PTC s resistance is sensed by the 2 speed control board See Table 16 for resistance ranges MECHANICALLY INTERLOCKED CONTACTORS The 2 speed products are equipped with mechanically interlocked contactors Each contactor has interconnecting linkage providing independent interlocks The 2 speed control provides the electrical interlock The contac tors are supplied with 240v coils which reduce the va require ments of the low voltage 2
3. A90074 Fig 4 Application with Air Conditioner Installed in a Horizontal Configuration A90075 Fig 5 Application with Heat Pump Installed in a Horizontal Configuration mE Ns N IS 55 S ANS TRAP 1 BER M Sh x 50 MAX p HEAT PUMP ONLY H GROUNDLEVEL A90076 Fig 6 Application with Air Conditioner or Heat Pump Installed with Indoor Unit Above Outdoor Unit CABINET Certain maintenance routines and repairs require removal of cabine t panels There are 4 basic cabinet designs for air condition ers and heat pumps See Fig 8 The horizontal discharge unit will be discussed in a separate section of this manual Note that separate sections apply according to date of manufacture l REMOVE TOP COVER BEFORE 1 1 92 NOTE This section applies to all Reliant products made prior to January 1 1992 1 2 Turn off all power to outdoor and indoor units Remove screws holding top cover to coil grille and corner posts 3 Remove access panel Remove information plate 5 Disconnect fan motor wires cut wire ties and remove wire 6 ties from control box Refer to unit wiring label Lift top cover from
4. 2 Measure liquid service valve pressure by attaching an cally on this equipment The frequency with which maintenance is accurate gage to the service port performed is dependent on such factors as hours of operation 3 Measure the liquid line temperature by attaching an accu geographic location and local environmental conditions rate thermistor type or electronic thermometer to the liquid line near the outdoor coil WARNING Disconnect all electrical power to unit before performing any maintenance or service on outdoor 4 Refer to unit rating plate to find required subcooling unit Remember to disconnect power supply to air handler temperature for units produced during or after January as this unit supplies low voltage power to the outdoor 1993 For units produced through December 1992 refer to unit Electric shock can cause personal injury or death Table 23 Find the point at which the required subcooling temperature intersects the measured liquid service valve pressure on Table 24 The minimum maintenance that should be performed on this 5 To obtain the required subcooling temperature at a specific equipment is as follows liquid line pressure add refrigerant if liquid line tempera ture is higher than indicated or remove refrigerant if temperature is lower Allow a tolerance of 3 F 1 Check outdoor coil for cleanliness each month during the heating heat pump only or cooling season and clean a
5. HK32FA003 HK32FA006 A88402 ipt O O CES0110063 CES0130024 A91442 Fig 19 Jumper DFT and R Terminals 2 Using thermocouple temperature measuring device route sensor or probe underneath coil or other convenient loca tion Attach to liquid line near defrost thermostat Insulate for more accurate reading 3 Turn on power to outdoor unit 4 Restart unit in heating mode 5 Within a few minutes liquid line temperature drops within a range causing defrost thermostat contacts to close Tem perature range is from 33 F to 27 F Notice temperature at which ohmmeter reading goes from to zero ohms Thermostat contacts close at this point 6 Remove protective cover from TP1 and TP2 speed up terminals and install jumper wire on the speed up termi nals 7 Unit changes over to defrost within 90 sec depending on timing cycle setting Liquid line temperature rises to range where defrost thermostat contacts open Temperature range is from 75 F to 85 F Resistance goes from zero to o when contacts open 8 If either opening or closing temperature does not fall within above ranges or thermostat sticks in 1 position replace thermostat to ensure proper defrost operation CES0110063 DEFROST CONTROL Some heat pumps built in 1991 and later incorporate a new defrost control The screw terminals found on t
6. solenoid valve that is piped between the discharge tube and suction tube of the compressor The purpose of the solenoid valve is to PLASTIC CAP BLUE SEALANT PRONG GROMMET THERMAL GREASE THERMOSTAT A90198 Fig 30 Location of Discharge Thermostat cause a rapid pressure equalization around the compressor thus reducing the normal shutdown sound created by reverse rotation of the scroll The solenoid valve is normally closed and is wired across high voltage line 1 to load terminals of the contactor See Fig 18 The solenoid valve assembly also requires a check valve piped in the discharge tube between the solenoid valve tee and the condenser coil or reversing valve on heat pumps The purpose of the check valve is to prevent refrigerant from bypassing through the solenoid valve into the suction tube when the unit cycles off MILLENNIUM SCROLL COMPRESSOR FEATURES The scroll compressor pumps refrigerant through the system by the interaction of a stationary and an orbiting scroll See Fig 29 The scroll compressor has no dynamic suction or discharge valves and itis more tolerant of stresses caused by debris liquid slugging and flooded starts The Millennium scroll varies from the Copeland scroll in that the Millennium has a shutdown flapper valve located between the scroll plates and the discharge head whereas the Copeland has a check device at the discharge connection after the discharge head The Copeland discharge he
7. Ill DISCHARGE THERMOSTAT Some scroll compressors have a discharge thermostat that recip rocating compressors do not have This thermostat is mounted in a well in the top of the compressor shell to sense if the discharge temperature reaches 290 F and shuts down the compressor to prevent damage to it When the temperature of the thermostat reaches 140 F power is restored to the compressor To determine if the thermostat is operating properly either attach the thermocouple of an electronic thermometer to the dome of the compressor near the thermostat or remove the thermostat and place the thermocouple inside the well The electronic thermom eter must be capable of reading at least 300 F Start the unit and let it run for at least 15 minutes to obtain normal operating conditions Watch the thermometer to see if it is approaching 270 F If the thermocouple is located on the dome near the discharge thermo stat there could be a 20 difference between well and dome temperatures If the temperature approaches 270 F repair system problem such as low charge blocked condenser coil and so forth If the temperature does not approach 270 F replace discharge thermostat Replacing Discharge Thermostat To replace the discharge thermostat refer to the Installation Instructions packaged with the replacement discharge thermostat kit See Fig 30 IV DISCHARGE SOLENOID VALVE Some larger units equipped with scroll compressors contain a
8. The compressor is an electrical as well as mechanical device Exercise extreme caution when working near compressors Power should be shut off if possible for most troubleshooting techniques Refriger ants in system present other safety hazards Always wear safety glasses and gloves when handling refrigerants Compressor failures are classified in 2 broad failure categories mechanical and electrical Both types are discussed below l MECHANICAL FAILURES A compressor is a mechanical pump driven by an electric motor contained in a welded or hermetic shell In a mechanical failure motor or electrical circuit appears normal but compressor does not function normally CAUTION Exercise extreme caution when reading compressor currents when high voltage power is on A Correct any of the problems described below before installing and running a replacement compressor Wear safety glasses and gloves when handling refrigerants LOCKED ROTOR In this type of failure compressor motor and all starting compo nents are normal When compressor attempts to start it draws locked rotor current and cycles off on the internal protection Locked rotor current is measured by applying a clamp on ammeter around common blk lead of the compressor on a single phase compressor or any 1 of the leads on a 3 phase compressor Current drawn when it attempts to start is then measured LRA locked rotor amp value is stamped on compressor namepla
9. V CRANKCASE HEATER Crankcase heater is a device for keeping compressor oil warm By keeping oil warm refrigerant does not migrate to and condense in compressor shell when the compressor is off This prevents flooded starts which can damage compressor Crankcase heaters come in 2 basic types wraparound bellyband type that is wrapped externally around compressor shell and insertion type that is inserted into compressor oil well in shell of compressor Both types are used in outdoor units On units that have a single pole contactor the crankcase heater is wired parallel with the contactor contacts and in series with the compressor See Fig 18 When the contacts are open a circuit is completed from the line side of the contactor through the crankcase heater through the run windings of the compressor and to the other side of the line When the contacts are closed there is 16 no circuit through the crankcase heater because both leads are connected to the same side of the line This allows the heater to operate when the system is not calling for heating cooling The heater does not operate when the system is calling for heating cooling On units with 2 or 3 pole contactors the crank case heater is connected to the line side of the contactor and is not controlled by the contactor contacts The crankcase heater is powered by high voltage power of unit Use extreme caution troubleshooting this device with power on The easi
10. unit presale literature must be consulted to determine metering devices specified for standard applications After determining standard application piston size s refer to Tables 6 and 7 as they relate to system design outdoor unit above or below indoor unit per equivalent length of tubing 90 LONG RAD C 45 STD Fig 3 Tube Bend Losses A92498 TABLE 5 FITTING LOSSES IN EQUIVALENT FT TUBE SIZE OD REFERENCE DIAGRAM IN FIG 1 IN 5 8 3 4 7 8 1 1 8 NOTE If total equivalent horizontal length is 100 ft or longer both indoor and outdoor pistons must be increased 1 full piston size in addition to changes required by Tables 6 and 7 After finding appropriate change in piston size add or subtract the change from original piston number If piston size is decreased round new piston number down to nearest common piston number found in Table 8 If piston size is increased round new piston number up to nearest common piston number found in Table 8 uj EXAMPLE An 042 size heat pump is 75 ft above an 042 size fan coil The 042 size heat pump presale literature specifies a size 80 indoor piston and size 63 outdoor piston To establish correct indoor piston size for a 75 ft vertical separation refer to Table 6 For a 75 ft equivalent line length the piston change is 5 Therefore subtract 5 from the original indoor piston size of 80 80 5275 Table 8 provides common piston sizes
11. 7 Use copper couplings to tie compressor back into system 8 Evacuate system recharge and check for normal system operation 9 Copeland CR 6 and scroll compressors have copper plated steel suction ports Excess heat during brazing will burn off copper plating See Brazing section for additional informa tion COPELAND SCROLL COMPRESSOR FEATURES The scroll compressor pumps refrigerant through the system by the interaction of a stationary and an orbiting scroll See Fig 29 The scroll compressor has no dynamic suction or discharge valves and itis more tolerant of stresses caused by debris liquid slugging and flooded starts Due to the design of the scroll compressor the internal compression components unload equalize pressure on shutdown The white oil Sontex 200LT used in the scroll is compatible with 3GS oil which can be used if additional oil is required See Table 13 for oil recharge requirements TABLE 13 COMPRESSOR OIL RECHARGE RECHARGE COMPRESSOR MODEL FL OZ OIL TYPE Carlyle Scroll J Type Suniso 3GS SC SRD450AC SR SRH482 SRY482 SRH602 SRY602 Zerol 150 w 3 percent Syn O Ad Copeland CRG3 CRH3 CRJ3 CRK3 CRL3 CRN5 CRP5 CRT5 CTH1 CTL1 CRC4 CRZ4 CR16K6 THROUGH CR42K6 ZR18K1 ZR23K1 ZR28K1 ZR34K1 ZR40K1 ZR49K1 PFV ZR49K2 TF5 ZR49K2 TFD ZR61K2 PFV ZR61K2 TF5 ZR61K2 TFD Tecumse Suniso 3GS AV55 A
12. Expansion Valves TXV sss Thermostatic Expansion Valve Bi Flow TXV Coll Removal nre tre nte ete Ete dd Liquid Line Strainer Heat Pumps Only ACCUMULATOR 3353520086 2 A treten e rent ee Contaminant Removal sessessseseeeeeeeeeneenneenns System Charging Checking Charge CARE AND MAINTENANCE eee SAFETY CONSIDERATIONS Service and repair of these units should be attempted only by trained service technicians familiar with Bryant standard service instructions and training manual All equipment should be installed in accordance with accepted practices and unit Installation Instructions and in compliance with all national and local codes Power should be turned off when servicing or repairing electrical components Extreme caution should be observed when trouble shooting electrical components with power on Observe all warn ing notices posted on equipment Refrigeration system contains refrigerant under pressure Extreme caution should be observed when handling refrigerants Wear safety glasses and gloves to prevent personal injury During normal system operation some components are hot and can cause burns Rotating fan blades can cause personal injury Appropriate safety considerations are posted throughout this manual where potentially dangerous techniques are addressed It is important to recognize safety informati
13. Fig 1 or 2 and Table 2 or 3 for wind baffle construction details i LONG LINE GUIDELINE This Long Line Application Guideline applies to all Bryant residential air conditioner and heat pump split systems that have a nominal capacity of 18 000 to 60 000 Btuh This guideline provides required system changes and accessories necessary for any residential product having piping requirements greater than 50 ft or installations where indoor unit is located above outdoor unit This guideline is intended to cover applications outside the standard Installation Instructions This guideline is for standard single speed products For applications involving 2 speed prod ucts refer to Section VI first NOTE The presale literature for outdoor unit must be referred to in conjunction with this guideline I APPROVED SYSTEMS Any residential indoor outdoor unit combination listed in the outdoor unit presale literature is an approved system EXCEPT the following Indoor coils with capillary metering devices All equipment less than nominal 18 000 Btuh All 1 4 in and 5 16 in liquid line applications Any indoor furnace coil fan coil not listed in outdoor unit presale literature Any application which has interconnecting tubing with an equivalent length greater than 175 ft Il INTERCONNECTING TUBING SIZING Table 4 lists recommended interconnecting vapor line diameters for equivalent total line lengths All residential split systems in
14. In this instance 75 is not listed therefore round DOWN to next piston size which would be 74 To establish correct outdoor piston size for a 75 ft vertical separation refer to Table 7 For a 75 ft equivalent line length the piston change is 4 Therefore add 4 to the original outdoor piston size of 63 63 4 67 Since 67 is listed in Table 8 that is the piston which should be used If a 67 size piston were not listed it would be necessary to round UP to next piston size TXVs may be used instead of pistons for indoor metering devices Some fan coils are equipped with a hard shutoff bi flow TXV standard and no change is required When sizing an accessory TXV for long line applications TXV should be the same nominal tonnage as outdoor unit Refer to presale literature for kit part numbers TABLE 6 CALCULATION OF INDOOR PISTON NO OUTDOOR UNIT ABOVE INDOOR FT PISTON CHANGE 0 25 26 50 51 75 76 100 101 125 126 150 10 OUTDOOR UNIT BELOW INDOOR PISTON CHANGE 0 4 TABLE 7 CALCULATION OF OUTDOOR PISTON NO OUTDOOR UNIT ABOVE INDOOR FT PISTON CHANGE 0 50 0 51 75 4 76 100 6 101 125 8 126 150 10 OUTDOOR UNIT BELOW INDOOR FT PISTON CHANGE 0 50 0 IV LIQUID LINE SOLENOID AND TUBING CONFIGU RATION There are 2 types of liquid line solenoids 1 for single flow applications and the other for bi flow appli
15. Input Check thermostat Defrost Y2 W2 0 C Outdoor temperature below 50 F Output Coil temperature less than 30 F Second Stage of Y1 W2 C Input Check thermostat Auxiliary Heat W3 Y2 C Output Check balance point setting Cooling Second stage Latching Y1 Y2 0 C 37 Ambient thermistor failure Input Check second stage POT SERVICE PORT W SCHRADER CORE STEM SEAT FORGED FRONT SEATING VALVE A91448 Fig 44 Service Valves b Remove all flux residue with brush and water while material is still hot 2 Use sil fos or phos copper for copper to copper only No flux is required 3 Silver solder is used on copper to brass copper to steel or copper to copper Flux is required when using silver solder 4 Fluxes should be used carefully Avoid excessive applica tion and do not allow fluxes to enter into the system 5 Proper brazing temperature of copper is when it is heated to a dull red color This section on brazing is not intended to teach a technician how to braze There are books and classes that teach and refine brazing techniques The basic points above are listed only as a reminder IV SERVICE VALVES WARNING Never attempt to make repairs to existing service valves Unit operates under high pressure Dam aged seats and o rings should not be replaced Replace ment of entire service valve is required Tampering with
16. OUTDOOR TEMP F INDOOR COIL ENTERING AIR TEMP F WET BULB 55 60 65 70 75 80 85 90 95 Where a dash appears do not attempt to charge system under these conditions or refrigerant slugging may occur TABLE 22 REQUIRED VAPOR TEMPERATURE F SUPERHEAT TEMP CF VAPOR PRESSURE AT SERVICE PORT PSIG a TXV the subcooling method must be used Heat pumps must be operating in the cooling mode To charge by superheat a service technician needs an accurate superheat thermocouple or thermistor type thermometer a sling psychrometer and a gage manifold Do not use mercury or small dial type thermometers as they are not adequate for this type of measurement Then use 1 of the following procedures SUPERHEAT CHARGING METHOD 1 Operate a unit a minimum of 10 minutes before checking charge 2 Measure vapor pressure by attaching a gage to vapor valve service port 3 Measure vapor line temperature by attaching a service thermometer to unit vapor line near vapor valve On a heat pump attach to the suction tube between the accumulator and the compressor Insulate thermometer for accurate readings 4 Measure outdoor air dry bulb temperature with a second thermometer 44 5 Measure indoor air entering i
17. Phase 50 Hertz Position 6 Fuel and Controls Not applicable on condensing units or heat pumps so the letter X is used to signify none Positions 7 8 and 9 Nominal Cooling Capacity in thousands Btuh Example 036 36 000 Btuh or 3 ton capacity Positions 10 11 and 12 Not applicable on condensing units or heat pumps so the number zero is used to signify none Position 13 Brand Name Example A Common unit U S A Only Position 14 Unit Series New units are introduced with the letter A and subsequent major component variations such as in compressor fan motor coil circuitor size etc are identified by changing to the next letter as B then C and so forth Positions 15 and 16 Product Variations 52 Last week of a year Example Positions 3 and 4 Year of Manufacture AA Standard unit Example Other letters For product variations from standard 94 1994 Il SERIAL NUMBER IDENTIFICATION Position 5 Manufacturing Site Example The unit serial number has 10 positions containing groups of numbers and a letter that indicate specific information about the unit Listed below is the breakdown of the 10 positions Positions 1 and 2 Week of Manufacture Example 01 First week of a year A Indianapolis E Collierville Positions 6 through 10 Serial Number
18. and definition VI TROUBLESHOOTING NOTE Troubleshooting charts for air conditioning and heat pump units are provided in the back of this manual see Fig 52 53 and 54 COMPRESSOR WINDING CHECK The 2 speed compressor is nothing more than 2 single phase motors within 1 compressor shell When the compressor fails to start or run there are 3 tests that can be made open ground or short This compressor has no internal line break overload how ever it does have PTC motor protectors See Compressor PTC Overload Protection section for PTC overload information NOTE To ensure accurate ohm measurements place ohmmeter probes on flat surface of compressor terminal tabs not the brass mounting screw Open To determine if a winding has an actual break in the internal wires and current is unable to pass through 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals T1 T2 T3 T7 and T8 4 Use an ohmmeter on 0 1000 ohm scale to check resistance See Fig 38 40 and 41 and Table 18 Because winding resistances are usually less than 10 ohm each reading will appear to be approximately zero ohm If during any check the resistance remains at 1000 ohm an open or break exists and the motor or compressor should be replaced Ground To determine if any wire has broken and come in direct contact with the housing or shell causing a direct short to ground Be sure all power is off 2
19. capacitor If bleed resistor is damaged replace resistor START CAPACITOR AND RELAY The 2 speed system has a second start relay in the control box One start relay is for low speed start and the second is for high speed start Both start relays use a common start capacitor When servicing this equipment be certain system starts in both low and high speed operation REFRIGERATION SYSTEM I REFRIGERATION CYCLE In a refrigeration system refrigerant moves heat from one place to another It is useful to understand flow of refrigerant in a system In a straight cooling system compressed hot gas leaves compres sor and enters condensing coil As gas passes through condenser coil it rejects heat and condenses into liquid The liquid leaves condensing unit through liquid line and enters metering device at indoor coil As it passes through metering device it becomes a gas liquid mixture As it passes through indoor coil it absorbs heat and refrigerant and is again compressed to a hot gas The cycle then repeats In a heat pump the basic cycle is the same See Fig 42 Reversing valve in system decides which coil indoor or outdoor becomes evaporator or condenser It rejects heat into the home after heat is absorbed by outdoor evaporator coil thus the home is heated In cooling cycle the indoor coil becomes the evaporator It absorbs heat from the home and rejects it through the outdoor condenser coil thus the home is cooled
20. damaged valves can cause personal injury or death Service valve must be replaced by properly trained service technician Service valves provide a means for holding original factory charge in outdoor unit prior to hookup to indoor coil They also contain gage ports for measuring system pressures and provide shutoff convenience for certain types of repairs See Fig 44 Two types of service valves are used in outdoor residential equipment The first type is a front seating valve which has a service port that contains a Schrader fitting The service port is always pressurized after the valve is moved off the front seat position The second type is a combination front seating back seating valve which has a metal to metal seat in both the open and closed positions When it is fully back seated the service port is not FIELD SIDE STEM SERVICE PORT E W SCHRADER CORE SEAT BAR STOCK FRONT SEATING VALVE A91447 pressurized To pressurize the service port this valve must be moved off the back seating position This valve does not contain a Schrader fitting Both types of service valves are designed for sweat connection to the field tubing The service valves in the outdoor unit come from the factory front seated This means that the refrigerant charge is isolated from the line set connection ports Some heat pumps are shipped with sweat adapter tube This tube must be installed on the liquid service valv
21. left or right The correct plug can be connected easily to the compressor terminals and plug wires routed easily through the slot in the terminal cover Therefore if a Carlyle or Bristol compressor is substituted for a Tecumseh compressor a new plug must be installed If the plug is not changed proper connection and routing of the plug wires through the terminal cover will be impossible BRISTOL CARLYLE COPELAND BLK TECUMSEH MILLENNIUM LEAD 1 BLK LEAD 3 BLUE LEAD 2 YEL A94002 Fig 27 Compressor Plug XIV LOW VOLTAGE TERMINALS The low voltage terminal designations along with descriptions and or functions are used on all split system condensers and heat pumps 25 G Energizes blower circuit from indoor thermostat E Energizes emergency heat relay W2 Energizes first stage supplemental heat through defrost relay wht L Energizes light on thermostat with service alarm W3 Energizes second or third stage supplemental heat R Energizes 24v power from transformer red Y Energizes contactor for first stage cooling or first stage heat ing for heat pumps yel O Energizes reversing valve on heat pumps orn C Common side of transformer blk RECIPROCATING COMPRESSOR The compressor is the heart of the refrigeration system It pumps refrigerant through the system If it malfunctions system capacity and efficiency could be negatively affected CAUTION
22. mately 100 psig to 225 psig The control will maintain working head pressure at low ambient temperatures down to 0 F when properly installed TABLE 1 REQUIRED FIELD INSTALLED ACCESSORIES FOR AIR CONDITIONERS AND HEAT PUMPS REQUIRED FOR REQUIRED FOR REQUIRED FOR LOW AMBIENT LONG LINE SEA COAST APPLICATIONS APPLICATIONS APPLICATIONS BELOW 55 F OVER 50 FT WITHIN 2 MILES Yes No Evaporator Freeze Thermostat Yes No Winter Start Control Yest No Accumulator No No Compressor Start Assist Yes No ACCESSORY Crankcase Heater Capacitor and Relay Low Ambient Controller MotorMaster Control or Low Ambient Pressure Switch Yes No No Wind Baffle See Low Ambient Instructions No No Coastal Filter No No Yes Support Feet Recommended No Recommended Liquid Line Solenoid Valve or No Hard Shutoff TXV Ball Bearing Fan Motor See Long Line Application No Guideline Isolation Relay For tubing line sets between 50 and 175 ft refer to Residential Split System Long Line Application Guideline TOnly when low pressure switch is used tRequired for Low Ambient Controller full modulation feature and MotorMaster control only Required on Heat Pumps only IX WIND BAFFLE A field fabricated sheet metal cover used to stop prevailing winds or where outdoor ambient temperature is less than 55 F during unit operation of cooling mode X COASTAL FILTER
23. may be field installed IV CYCLE PROTECTOR Solid state cycle protector device protects unit compressor by preventing short cycling After a system shutdown cycle protector provides for a 5 2 minute delay before compressor restarts On normal start up a 5 minute delay occurs before thermostat closes After thermostat closes cycle protector device provides a 3 sec delay on HN67PA025 HN67ZA003 and HN67ZA008 See Fig 15 16 and 17 HN67ZA002 A91438 T2 G1 On T3 HN67ZA003 A91439 HN67ZA008 A94005 T3 BLK T YEL T2VIO AY ws 4 T3BLK ZS HN67PA025 A91440 Fig 15 Cycle Protector Device Cycle protector device is simple to troubleshoot Only a voltmeter capable of reading 24v is needed Device is in control circuit therefore troubleshooting is safe with control power 24v on and high voltage power off With high voltage power off attach voltmeter leads across T1 and T3 and set thermostat so that Y terminal is energized Make sure all protective devices in series with Y terminal are closed Voltmeter should read 24v across T1 and T3 With 24v still applied move voltmeter lead from T1 terminal to T2 terminal across T2 and T3 After 5 2 minutes voltmeter should read 24v indicating control is functioning normally If no time delay is encountered or device never times out change control
24. pin housing configurations TWO SPEED COMPRESSOR The 2 speed compressor contains motor windings that provide low speed 4 pole 1750 rpm and high speed 2 pole 3500 rpm operation Refer to Fig 38 to determine which windings are energized at each speed Refer to Compressor Winding Check section under Troubleshooting and Table 18 for appropriate winding resistances The 2 speed compressor is also protected by an internal pressure relief IPR which relieves discharge gas into the compressor shell low side when the differential between suction and discharge TABLE 17 FACTORY DEFAULTS FAILED COMPONENT FUNCTION DEFAULT Crankcase Heater Energized during any off cycle Second Stage Latching Does not function Balance point does not function but interface still energizes furnace and locks out heat pump with a call for W2 Unit only runs in high compressor speed Defrost is initiated based on coil temperature only Anytime there is a call for W2 W3 is also energized Defrost occurs at each time interval but terminates after 5 minutes Does not function Furnace Interface Ambient Thermistor 3 Heating Switchover Speed Point Defrost Initiation Outdoor Thermostat for Auxiliary Heat Outdoor Coil Thermistor Defrost Initiation and Termination Furnace Interface Furnace Interface Jumper
25. purge system with dry nitrogen and evacuate when replacing filter driers Continue to monitor pressure drop across suction line filter drier After 10 hr of run time remove suction line filter drier and replace liquid line filter drier Never leave suction line filter drier in system longer than 72 hr actual time 7 Charge system See unit information plate Ill SEACOAST FOR AIR CONDITIONERS ONLY Installation of these units in seacoast locations requires the use of a coastal filter See section on cleaning ACCESSORY DESCRIPTIONS Refer to Table 1 for an Accessory Usage Guide for Air Condi tioners and Heat Pumps See Model specific product literature for any kit part number Refer to the appropriate section below for a description of each accessory and its use I COMPRESSOR CRANKCASE HEATER An electric heater which mounts to base of compressor to keep lubricant warm during off cycles Improves compressor lubrication on restart and minimizes chance of refrigerant slugging and oil pumpout The crankcase heater may or may not include a thermostat control For units equipped with crankcase heaters apply power for 24 hr before starting compressor Il EVAPORATOR FREEZE THERMOSTAT An SPST temperature activated switch stops unit operation when evaporator reaches freeze up conditions Ill WINTER START CONTROL An SPST delay relay which bypasses the low pressure switch for approximately 3 minutes to permit startup for cooli
26. single phase units however they also apply to 3 phase compressors When a single phase compressor fails to start or run 3 tests can help determine the problem First all possible external causes should be eliminated such as overloads improper voltage pressure equal ization defective capacitor s relays wiring and so forth Com pressor has internal line break overload so be certain it is closed OPEN CIRCUIT To determine if any winding has a break in the internal wires and current is unable to pass through 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals C S and R 4 Check resistance from C R C S and R S using an ohmme ter on 0 1000 ohm scale Because winding resistances are usually less than 10 ohms each reading appears to be approximately 0 ohm If resistance remains at 1000 ohms an open or break exists and compressor should be replaced A CAUTION Be sure internal line break overload is not temporarily open GROUND CIRCUIT To determine if a wire has broken or come in direct contact with shell causing a direct short to ground 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals C S and R 4 On hermetic compressors allow crankcase heaters to re main on for several hours before checking motor to ensure windings are not saturated with refrigerant 5 Use an ohmmeter on R X 10 000 ohm scale A megohm meter may be us
27. switch closes It should be close to reading observed using electronic thermometer Any setting within 5 F is acceptable 24 XIII COMPRESSOR PLUG The compressor electrical plug provides a quick tight connection to the compressor terminals The plug completely covers the compressor terminals and the mating female terminals are com pletely encapsulated in the plug Therefore the terminals are isolated from any moisture so corrosion and resultant pitted or discolored terminals are reduced The plug is oriented to the relief slot in the terminal box so the cover cannot be secured if wires are not positioned in slot assuring correct electrical connection at the compressor The plug can be removed by simultaneously pulling while rocking the plug However these plugs are specialized and vary in terminal orientation in the plug Therefore plugs can be used on only the specific compressor or group as shown in Fig 27 For the Carlyle and Bristol compressors in Fig 27 the triangle formed by the fusite terminals points down and the plug is likewise oriented The fusite terminals and plug terminal orienta tion shown for the Tecumseh compressor is shown with the triangle formed by the terminals pointing toward the top The configuration around the fusite terminals is the outline of the terminal covers used on the specific compressors The slot through which the wires of the plug are routed is oriented on the bottom or slightly to the
28. the multistage zoning system to determine what speed is needed regardless of outdoor temperature or switchover point DEFROST TIME SELECTION The defrost interval can be field selected depending on local or geographic requirements It is factory set at 90 minutes and can be changed to either 30 or 50 minutes by rotating the defrost time POT See Fig 34 TABLE 15 FUNCTION LIGHT CODE AND DISPLAY LOCATION POSSIBLE CAUSE T STAT Constant flash No pause DEFINITION No demand Stand by 1 flash w pause Low speed operation 2 flashes w pause High speed operation 3 flashes w pause Ambient thermistor failure 4 flashes w pause Coil thermistor failure 3 flashes pause 4 flashes Thermistor out of range Thermistor drift wrong location Incorrect wiring Incorrect refrigerant charge Dirty indoor outdoor coil 5 flashes w pause Pressure switch trip LM1 LM2 Dirty outdoor coil Refrigerant overcharge Wrong indoor coil 6 flashes w pauset Compressor PTCs out of limit Low refrigerant charge Compressor mechanical problem Dirty indoor outdoor coil Constant light No pause No flash Board failure Equipment or electrical service not grounded Function light signals order of importance in case of multiple signal request 1 is most important tSignal at thermostat will occur after 3 consecutive attempted restarts and lockout has occurred Will
29. tion plate mentioned previously but is designed only to cover the control box V REMOVE TOP COVER AFTER 1 1 92 NOTE The section applies to all Reliant Products made after January 1 1992 1 Turn off all power to outdoor and indoor units 2 Remove 5 screws holding top cover to coil grille and coil tube sheet 3 Remove 2 screws holding control box cover 4 Remove 2 screws holding information plate 5 Disconnect fan motor wires cut any wire ties and move wires out of control box and through tube clamp on back of control box T HEAT PUMP ONLY f foL 150 MAX fe M fe f f f rue a rate A90077 Fig 7 Application with Air Conditioner or Heat Pump Installed Above Indoor Unit 6 Lift top cover from unit 7 Reverse sequence for reassembly VI REMOVE FAN MOTOR ASSEMBLY AFTER 1 1 92 NOTE This section applies to all Reliant products made after January 1 1992 1 Perform items 1 3 4 and 5 above Note item 2 is not required 2 Remove 4 screws holding wire basket to top cover 3 Lift wire basket from unit 4 Remove nuts holding fan motor to wire basket 5 Remove motor and fan blade assembly Pull wires through wire raceway to change motor M aD Revers
30. unit removes non condensibles and assures a tight dry system before charging The 2 methods used to evacuate a system are the deep vacuum method and the triple evacuation method DEEP VACUUM METHOD The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 1000 microns and a vacuum gage capable of accurately measuring this vacuum depth The deep vacuum method is the most positive way of assuring a system is free of air and liquid water TRIPLE EVACUATION METHOD The triple evacuation method can be used where the vacuum pump is capable of pumping down to only 28 in of mercury vacuum and the system does not contain any liquid water The procedure is as follows m 430 FUSE ELEMENT A88410 Fig 51 Accumulator 1 Pump the system down to 28 in of mercury vacuum and allow pump to continue to operate for additional 15 minutes 2 Close service valves and shut off vacuum pump 3 Connect a refrigerant cylinder to the system and open until system pressure is 2 psig 4 Close the service valve 5 Allow system to stand for 1 hr during which time the dry refrigerant will be able to diffuse throughout the system absorbing moisture This procedure is repeated 3 times after which the system will be free of any contaminants and water vapor XIII SYSTEM CHARGING For all approved combinations system must be charged correctly for normal system operation and reliable operation of components A CAUTION A
31. which may cause future failures A88413 Fig 10 Information Plate Removed Installed Below Control Box za A88350 Fig 11 Contactor Ill CAPACITORS CAUTION Capacitors can store electrical energy when power is off Electrical shock can result if you touch the capacitor terminals and discharge the stored energy Exercise extreme caution when working near capacitors With power off discharge stored energy by shorting across the capacitor terminals with a 15 000 ohm 2 watt resistor NOTE If bleed resistor is wired across start capacitor it must be disconnected to avoid erroneous readings when ohmmeter is applied across capacitor See Fig 12 CAUTION Always check capacitors with power off Attempting to troubleshoot a capacitor with power on can be dangerous Defective capacitors may explode when power is applied Insulating fluid inside is combustible and may ignite causing burns Capacitors are used as a phase shifting device to aid in starting certain single phase motors Check capacitors as follows 1 After power is off discharge capacitors as outlined above Disconnect capacitor from circuit Put ohmmeter on R X 10k scale Using ohmmeter check each terminal to ground use capacitor case Discard any capacitor which measures 1 2 scale deflection or less Place ohmmeter leads across capacitor and place on R X 10k scale Meter should jump to a low resistance value and slowly cli
32. 10 0 BAFFLE LEFT TYPES 12 7 94099 MAT L 20 GA STEEL 1 21 99 42 1 TYP 1 V BAFFLE RIGHT D y l MAT L 20 GA STEEL T 1 4 5 56 DIA A fae y SE mies 2w A T 114 x 31g 5 56 x 9 53 SLOT nr 63 5 D 6 REQ D H DX 144 5 56 DIA F y y 4 REQD 1 21 32 42 1 eo 1 4 x 3 8 5 56 x 9 53 SLOT ee 6 REQ D Yea 10 0 4 eq 105 2 pem pb 92 LEFT C RIGHT TYP eds J d SIDE SIDE 2 ea i 4 SCREW 52 6 pan 14 REQD 14 5 Rn 4 Ia 2 REQD 124 2 TYP gt E 12 7 OUTDOOR SUPPORT 8 5 4 205 3 TYP UNIT 3 REQ D TYP 1a eli 23 g4 9 2 SUPPORT FE MAT L 18 GA STEEL Bine 4 REQ D E Y A95446 Fig 2 Wind Baffle Construction for Cube Units ET TABLE 3 WIND BAFFLE DIMENSIONS FOR CUBE UNITS IN UNIT HEIGHT 21 15 16 23 15 16 25 15 16 27 15 16 29 15 16 31 15 16 33 15 16 21 15 16 23 15 16 25 15 16 27 15 16 29 15 16 31 15 16 33 15 16 35 15 16 37 15 16 25 15 16 27 15 16 29 15 16 31 15 16 33 15 16 35 15 16 37 15 16 39 15 16 UNIT SIZE 13 3 4 13 3 4 13 3 4 13 3 4 13 3 4 13 3 4 13 3 4 18 5 16 18 5 16 18 5 16 18 5 16 18 5 16 18 5 16 18 5 16 18 5 16 18 5 16 25 3 4 25 3 4 25 3 4 25 3 4 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 10 11 16 11 11 16 11 11
33. 16 11 11 16 11 11 16 11 11 16 11 11 16 11 11 16 16 3 16 16 3 16 16 3 16 16 3 16 16 3 16 16 3 16 16 3 16 16 3 16 16 3 16 23 11 16 23 11 16 23 11 16 23 11 16 23 11 16 23 11 16 23 11 16 23 11 16 19 13 16 21 13 16 23 13 16 25 13 16 27 13 16 29 13 16 31 13 16 19 13 16 21 13 16 23 13 16 25 13 16 27 13 16 29 13 16 31 13 16 33 13 16 35 13 16 23 13 16 25 13 16 27 13 16 29 13 16 31 13 16 33 13 16 35 13 16 37 13 16 17 13 16 19 13 16 21 13 16 23 13 16 25 13 16 27 13 16 29 13 16 17 13 16 19 13 16 21 13 16 23 13 16 25 13 16 27 13 16 29 13 16 31 13 16 33 13 16 21 13 16 23 13 16 25 13 16 27 13 16 29 13 16 31 13 16 33 13 16 35 13 16 8 1 4 8 1 4 8 1 4 8 1 4 8 1 4 15 13 16 15 13 16 15 13 16 15 13 16 15 13 16 15 13 16 15 13 16 15 13 16 Medium TABLE 4 ESTIMATED PERCENTAGE OF NOMINAL COOLING CAPACITY LOSSES LONG LINE VAPOR LINE DIAMETER IN t 5 8 3 4 5 8 3 4 5 8 3 4 3 4 7 8 3 4 7 8 1 1 8 EQUIVALENT LINE LENGTH FT a o N o W OO oO CO M E eo A EN eo O WINI MINIM OD oO a a E eo E poje NIOJA ojojo N The estimated percentage of cooling capacity that must be subtracted from the Detailed Cooling Capacities data specified in outdoor unit presale literature for any gi
34. 21 Service Alarm Control Board esses 21 Outdoor Thermostat s Compressor Plug Low Voltage Terminals RECIPROCATING COMPRESSOR eee 25 Mechanical Failures wild Electrical Failures 26 System Cleanup After Burnout mi Compressor Removal And Replacement 27 COPELAND SCROLL COMPRESSOR 28 Fe aturests disse OTIO e EES 28 Troubleshooting eiecit ero ne 28 Discharge Thermostat esses 28 Discharge Solenoid Valve sse 28 MILLENNIUM SCROLL COMPRESSOR 29 IET EL 29 Compressor Protection 209 Troubleshooting 129 Scroll Compressor 3 Phase Monitor sess 29 TWO SPEED SYSTEM 1 eere enne 29 Cautions and Warnings 29 System Functions 129 Factory Defaults 45239 Major Components esee nennen 33 LED Function Malfunction Lights esses 34 Troubleshooting 5 rir ren ER RN Ep teens 34 REFRIGERATION SYSTEM ecce 35 Refrigeration Cycle cie SPP EER 35 Leak Detection onere eee ere ied eee Ee OE UN 35 Brazing Service Valves nenia tret eet err e e tote EPI E ES 38 Check Flo Rater Bypass Type Heat Pumps Only 39 Reversing Valve e ei ea eee dee tig etetn Thermostatic
35. 445 Fig 1 Wind Baffle Construction for Reliant Units i Calculate the linear length of vapor tube required adding any losses for the total number of elbows for application See Table 5 Using this equivalent length select desired vapor line size from Table 4 Subtract the nominal percentage loss from outdoor unit presale literature Detailed Cooling Capacities data for the given indoor outdoor combination Reference all notes of Table 4 NOTE When specifying vapor line insulation be aware of the All standard accessory tubing kits are supplied with 3 8 in insu lation on vapor line For minimal capacity loss in long line application 1 2 in insula tion should be specified following standard practice TABLE 2 WIND BAFFLE DIMENSIONS FOR RELIANT UNITS WITH AEROQUIET SYSTEM TOP IN UNIT SIZE 26 3 16 UNIT HEIGHT 23 13 16 24 5 16 27 13 16 24 5 16 33 13 16 24 5 16 27 13 16 21 30 5 8 42 Medium 33 33 13 16 21 30 5 8 42 39 13 16 21 30 5 8 42 TM 4246 33 13 16 25 5 16 39 3 4 50 9 16 21 11 16 g 39 13 16 25 5 16 39 3 4 50 9 16 21 11 16 7 713 3 46 1 8 3 45 DIA 200 0 4 6 2 REQ D Het ot es 4 C C UA E 12 7 d 5 3 64 Hed 1 13 64 EN y 77i 64 M Ne 7 29 33 200 8 199 9 254
36. 4vac control system TEMPERATURE THERMISTORS Thermistors are electronic devices which sense temperature As the temperature increases the resistance decreases Two ther mistors are used to sense temperature one senses outdoor ambient and the other senses coil temperature heat pump only Refer to Fig 39 for resistance values versus temperature If the outdoor ambient thermistor should fail a malfunction signal appears on the indoor thermostat and 2 speed control The control does not initiate second stage latching crankcase heater is turned on during all off cycles heating defaults to high speed and defrost initiates on demand from coil thermistor See Table 17 THERMISTOR CURVE 90 80 70 60 50 40 30 20 10 gt RESISTANCE KOHMS 0 20 40 60 80 100 120 TEMPERATURE DEG F A91431 Fig 39 Resistance Values Versus Temperature If the outdoor coil thermistor should fail a malfunction signal appears on the indoor thermostat and 2 speed control The control defrosts every 90 minutes of heating operation and terminates in 5 minutes See Table 17 V LED FUNCTION MALFUNCTION LIGHTS The 2 speed control is equipped with an LED function malfunc tion light NOTE Only malfunction signal appears at thermostat Both function and malfunction signals appear at control board See Fig 33 for LED location Table 15 provides the function malfunction code location
37. A mesh screen inserted under top cover and inside base pan to protect condenser coil from salt damage without restricting air flow XI SUPPORT FEET Four adhesive plastic feet which raise unit 4 in above mounting pad This allows sand dirt and other debris to be flushed from unit base minimizes corrosion XII LIQUID LINE SOLENOID VALVE An electrically operated shutoff valve to be installed at outdoor or indoor unit depending on tubing configuration which stops and starts refrigerant liquid flow in response to compressor operation Maintains a column of refrigerant liquid ready for action at next compressor operation cycle and prevents liquid migration during the off cycle XIII THERMOSTATIC EXPANSION VALVE A modulating flow control device which meters refrigerant flow rate into the evaporator in response to the superheat of the refrigerant gas leaving the evaporator Only use factory specified TXV s XIV ISOLATION RELAY A DPDT relay which switches the low ambient controller out of the outdoor fan motor circuit when the heat pump switches to heating mode LOW AMBIENT GUIDELINE The minimum operating temperature for these units in cooling mode is 55 F outdoor ambient without additional accessories This equipment may be operated in cooling mode at ambient tempera tures below 55 F when the accessories listed in Table 1 are installed Wind baffles are required when operating in cooling mode at ambients below 55 F Refer to
38. A unique feature of the heat pump is that metering devices are designed to meter refrigerant in one direction of flow and allow refrigerant to pass unhindered in the other direction If indoor metering device is metering refrigerant the outdoor device by passes refrigerant and vice versa This allows both coils to serve a dual function ll LEAK DETECTION A CAUTION Always wear safety glasses and gloves when handling refrigerants 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 up to approximately 150 Ib minimum This can be done by adding refrigerant using normal charging procedures or it may be pressurized with nitrogen less expensive than refrigerant Nitrogen also leaks faster than R 22 and is not absorbed by refrigeration oil Nitrogen cannot however be detected by a leak detector See Fig 43 L SCHEMATIC DIAGRAM LADDER FORM C1 EXT MAIN LOW START T8 Fig 40 Low Speed Windings L1 SCHEMATIC DIAGRAM LADDER FORM EXT MAIN C2 LOW START T8 Fig 41 High Speed Windings 36 LS SR A91446 A91445 COOLING CYCLE REVERSING VALVE ENERGIZED OUTDOOR FAN E INDOOR COIL C ACCUMULATOR
39. ACTORS NOTE The section applies to single speed models only The contactor provides a means of applying power to unit using low voltage 24v from transformer in order to power the contactor coil See Fig 11 Depending on unit model you may encounter single double or triple pole contactors to break power One side of the line may be electrically energized so exercise extreme caution when troubleshooting The contactor coil for residential air conditioning units and heat pumps is powered by 24vac If contactor does not operate 1 With power off check whether contacts are free to move Check for severe burning or arcing on contact points 2 With power off use ohmmeter to check for continuity of coil Disconnect leads before checking A low resistance reading is normal Do not look for a specific value as different part numbers 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 heat or cool 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 change contactor 4 With high voltage power off and contacts pulled in check for continuity across contacts with ohmmeter A very low or zero resistance should be read Higher readings could indicate burned or pitted contacts
40. Application Guide and NOTE Read the entire instruction manual before starting the installation This symbol indicates a change since the last issue TABLE OF CONTENTS SAFETY CONSIDERATIONS eee 1 INTRODUCTION iiisccsiengistiencvatiteeinnti aoa ees INSTALLATION GUIDELINE Residential New Construction Sy Add On Replacement Retrofit sess 2 Seacoast For Air Conditioners Only sess 2 ACCESSORY DESCRIPTIONS i2 Compressor Crankcase Heater 552 Evaporator Freeze Thermostat eee 2 Winter Start Control essen 2 Compressor Start Assist PTC BEP Compressor Start Assist Capacitor Relay E Low Ambient Controller uA MotorMaster Control eene 2 Low Ambient Pressure Switch eee 2 Wind B ffle ice dr TUNE 3 Coastal Filter uideret Ee ert telae 3 Support Feet oe Liquid Line Solenoid Valve eee 3 Thermostatic Expansion Valve esee 3 Isolation Relay eeetieinROPR RORIS 3 LOW AMBIENT GUIDELINE eee 3 LONG LINE GUIDELINE eren 3 Approved Systems i3 Interconnecting Tubing Sizing 2 3 Metering Device Sizing sess w6 Liquid Line Solenoid And Tubing Configuration 7 Charging I
41. Discharge all capacitors 3 Remove wires from T1 T2 T3 T7 and T8 4 Allow crankcase heater to remain on for several hrs before checking motor to ensure that windings are not saturated with refrigerant 5 Using an ohmmeter on R X 10 000 ohm scale place 1 meter probe on ground motor or compressor frame Make a good metal to metal contact Place other probe on terminals T1 T2 T3 T7 and T8 in sequence Note meter scale If any reading of zero or low resistance is obtained the motor is grounding Replace the compressor Short NOTE This is an extremely critical test and is not advised unless the following conditions are met The correct motor winding resistances must be known before testing See Table 18 for cold motor winding resistance The temperature of the windings must be specified 70 F 2 F The resistance measuring instrument must have an accurate ohm meter such as a Wheatstone bridge or null balance type instru ment The motor must be dry or free from direct contact with liquid refrigerant To determine if any wires have broken through their insulation and come in direct contact with each other thereby shorting all or part of the winding s 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires from terminals T1 T2 T3 T7 and T8 4 Subtract instrument probe and lead resistance from each reading If any reading is within 20 percent of the known resistance from T
42. Fig 25 Service Alarm Wiring Connections FIELD LINE VOLTAGE SUPPLY WIRE p S 5 CYCLE PROTECTOR SERVICE ALARM 2 HIGH AND OR LOW PRESSURE AND OR DISCHARGE TEMPERATURE VIO BLK SWITCH IF USED t 10 ee ae THERMOSTAT INDOOR OUTDOOR SUBBASE UNIT UNIT TERMINAL TERMINAL BOARD BOARD A88339 7 COMMON POTENTIAL FACTORY WIRING FIELD CONNECTED FIELD SUPPLIED WIRING C CONTACTOR A88339 Fig 26 Wiring Connections for Service Alarm and Cycle Protector heat pump output drops Setting at which thermostat closes is variable depending on design of system It is set at time of installation and should not be changed without cause Up to 2 outdoor thermostats may be installed Some systems may not have any thermostat An outdoor thermostat can also be used to lock out compressor operation at low ambients in condensing unit not equipped with low ambient control Although these devices are installed in control circuit 24v turn off all power to unit before attempting to troubleshoot thermostat Use a standard ohmmeter to check for continuity through thermo stat If you suspect thermostat is out of calibration use calibrated electronic thermometer to determine correct outdoor temperature Turn thermostat dial knob until switch closes Observe this using ohmmeter across switch Read temperature setting when
43. In long line applications 2 speed units are handled basically the same way as the single speed units There are 2 major differences 1 For tubing up to 100 ft Liquid tube diameters and refrigerant connection diameters for all sizes are 3 8 in Vapor tube diameter for the 036 and 048 is 7 8 in 060 is 1 1 8 in Vapor refrigerant connection diameter for all sizes is 7 8 in DO NOT INSTALL EQUIVALENT INTERCONNECT ING TUBING LENGTHS GREATER THAN 100 FT 2 Do not increase or decrease tubing sizes For other applications see the previous sections under Long Line Guidelines UNIT IDENTIFICATION I PRODUCT NUMBER STAMPED ON UNIT RATING PLATE The unit product number has 16 positions containing groups of numbers and letters that indicate specific information about the unit Listed below is the breakdown of the 16 positions Positions 1 2 and 3 Product Series Example A 500 series number indicates a split system condensing unit and a 600 series number indicates a split system heat pump Position 4 Model Letters New models are introduced with the letter A and subsequent model changes are identified by changing to the next letter as B then C and so forth Position 5 Electrical Characteristics Example J 208 230 1 Phase 60 Hertz N 208 230 208 240 1 Phase 60 Hertz P 208 230 208 240 3 Phase 60 Hertz E 460 3 Phase 60 Hertz Q 220 3 Phase 50 Hertz S 220 240 1 Phase 50 Hertz Z 380 415 3
44. LES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT LOOSE LEAD AT FAN MOTOR MOTOR DEFECTIVE INCORRECT OFM CAPACITOR COMPRESSOR RUNS BUT INSUFFICIENT COOLING LOW SUCTION PRESSURE DIRTY AIR FILTERS DUCT RESTRICTED DAMPERS PARTLY CLOSED INDOOR COIL FROSTED SLIGHTLY LOW ON REFRIGERANT LIQUID LINE SLIGHTLY RESTRICTED PISTON RESTRICTED INCORRECT SIZE PISTON INDOOR COIL STRAINER RESTRICTED INDOOR BLOWER MOTOR DEFECTIVE OR CYCLING ON OL Fig 52 Air Conditioner Troubleshooting Chart 48 HIGH SUCTION LOW HEAD PRESSURE DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON A90208 HEAT PUMP TROUBLESHOOTING COOLING CYCLE NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN CONTACTOR OPEN POWER SUPPLY DEFECTIVE LOW VOLTAGE TRANSFORMER OPEN THERMOSTAT OPEN CONTROL CIRCUIT LOSS OF CHARGE CONTACTOR OR COIL DEFECTIVE LOOSE ELECTRICAL CONNECTION CONTACTOR CLOSED COMPRESSOR POWER SUPPLY OPEN LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH OPEN SHORTED OR GROUNDED COMPRESSOR MOTOR WINDINGS COMPRESSOR STUCK COMPRESSOR INTERNAL PROTECTION OPEN DEFECTIVE RUN CAPACITOR COMPRESSOR
45. P Fan Motor Part No Dimension A In Part No FAM Dado nae Brookside Revcor HC29GE208 LA01EB023 4 5 32 LAO1ECO19 5 1 8 HC31GE230 231 LA01EA026 4 5 8 LAO1RA015 4 7 8 HC33GE208 LAO1EWO049 5 1 4 HC33GE232 LAO1RA015 4 29 32 HC34GE231 LAO1RA015 5 5 32 HC34GE460 HC35GE208 HC35GE232 LAO1EWO048 4 15 16 LA01EA025 LA01RA024 LA01RA026 HC37GE208 LA01EA025 HC37GE230 LAO1EWO046 HC38GE221 LA01EA031 HC39GE232 HC39GE234 LAO1ECO18 LAO1RA026 LA01EA036 LA01EA024 LAO1ECO18 HC39GE461 LA01EA036 LAO1ECO18 LA01RA026 HC40GE230 LA01EA024 HC40GE461 LA01EA024 FEEDER TUBE STUB TUBE DEFROST THERMOSTAT A97517 Fig 23 Defrost Thermostat Location BASKET TOP A91428 Fig 24 Fan Position 23 24 VOLT WIRING HIGH AND OR LOW PRESSURE AND OR DISCHARGE TEMPERATURE SWITCH IF USED CERE ae c BRN O c BLK THERMOSTAT INDOOR OUTDOOR UNIT SUBBASE UNIT TERMINAL TERMINAL BOARD BOARD METALLIC LOOP TWICE ON UNITS WITH NAMEPLATE RLA OF 14 AMPS OR LESS PASS SUPPLY WIRE THROUGH S 5 METALLIC uu X ONE FIELD LOOP DTS HPS LPS 9 angle BLU YEL YEL an rT ORN YEL RED OG G9 SERVICE ALARM LINE VOLTAGE SUPPLY WIRE A88340
46. RUNS BUT CYCLES ON INTERNAL OVER OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING DAMAGED OR STUCK REVERSING VALVE RESTRICTED DISCHARGE TUBE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR COMPRESSOR BEARINGS HIGH SUPERHEAT LOAD LOOSE LEAD AT FAN MOTOR DEFROST RELAY N C CONTACTS OPEN MOTOR DEFECTIVE INCORRECT OFM CAPACITOR DEFECTIVE DEFROST THERMOSTAT COMPRESSOR RUNS BUT INSUFFICIENT COOLING LOW SUCTION PRESSURE DIRTY AIR FILTERS DUCT RESTRICTED DAMPERS PARTLY CLOSED INDOOR COIL FROSTED SLIGHTLY LOW ON REFRIGERANT LIQUID LINE SLIGHTLY RESTRICTED PISTON RESTRICTED INCORRECT SIZE PISTON INDOOR COIL STRAINER RESTRICTED INDOOR BLOWER MOTOR DEFECTIVE OR CYCLING ON OL HIGH SUCTION LOW HEAD PRESSURE REVERSING VALVE HUNG UP OR INTERNAL LEAK DEFECTIVE COMPRESSOR VALVES INTERNAL PRESSURE RELIEF OPEN Fig 53 Heat Pump Troubleshooting Chart Cooling Cycle HIGH SUCTION LOW SUPERHEAT UNIT OVERCHARGED INCORRECT SIZE PISTON A90207 HEAT PUMP TROUBLESHOOTING HEATING CYCLE NO HEATING OR INSUFFICIENT HEATING COMPRESSOR WILL NOT RUN CONTACT OPEN DEFECTIVE LOW VOLTAGE TRANSFORMER REMOTE CONTROL CENTER DEFECTIVE CONTACTOR COIL OPEN OR
47. RY TUBE DIAPHRAGM BYPASS TXV a Mm PUSHRODS SZ eeen TUBES Sa INLET ty eS i lt lt OUTLET Ze COIL A AC NEEDLE VALVE SPRING M DISTRIBUTOR Tm BULB CHECK VALVE OPEN Ae BYPASS TUBE EXTERNAL EQUALIZER TUBE A88405 Fig 50 TXV in Heating Mode 42 If the strainer must be replaced shut off all power to the unit See Fig 49 for strainer location XI ACCUMULATOR The accumulator is a device always found in heat pumps and found in some condensing unit models Under some light load condi tions on indoor coils and on outdoor coil with heat pump in heating mode some liquid refrigerant is present in suction gas returning to compressor The accumulator stores liquid and allows it to boil off into a vapor so it can be safely returned to compressor Since a compressor is designed to pump refrigerant in its gaseous state introduction of liquid into it could cause severe damage or total failure of compressor The accumulator is a passive device which seldom needs replac ing Occasionally its internal oil return orifice or bleed hole may become plugged Some oil is contained in refrigerant returning to compressor It cannot boil off in accumulator with liquid refriger ant The bleed hole allows a small amount of oil 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 fr
48. SHORTED OPEN INDOOR THERMOSTAT LIQUID LINE PRESSURE SWITCH OPEN LOSS OF CHARGE OPEN CONTROL CIRCUIT CONTACTOR CLOSED COMPRESSOR POWER SUPPLY LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH COMPRESSOR STUCK COMPRESSOR INTERNAL OVERLOAD OPEN OPEN SHORTED OR GROUNDED COMPRESSOR WINDINGS DEFECTIVE RUN CAPACITOR COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD DIRTY FILTERS OR INDOOR COIL INDOOR FAN STOPPED OR CYCLING ON OVERLOAD DAMAGED REVERSING VALVE RESTRICTION IN DISCHARGE LINE OVERCHARGE OR NON CONDENSABLES IN SYSTEM LOW REFRIGERANT CHARGE LINE VOLTAGE TOO HIGH OR LOW DEFECTIVE RUN CAPACITOR 1 PH COMPRESSOR BEARINGS HIGH LOAD CONDITION REVERSING VALVE JAMMED IN MIDPOSITION HIGH SUPERHEAT DEFECTIVE FAN MOTOR CAPACITOR LOOSE LEADS AT FAN MOTOR FAN MOTOR BURNED OUT COMPRESSOR RUNS INSUFFICIENT HEATING LOW SUCTION LOW HEAD OUTDOOR FAN STOPPED LOOSE LEADS AT OUTDOOR FAN MOTOR INTERNAL FAN MOTOR KLIXON OPEN FAN MOTOR BURNED OUT DEFROST RELAY N C CONTACTS OPEN ON CIRCUIT BOARD FAN MOTOR CONTACTS OUTDOOR FAN RUNNING REVERSING VALVE STUCK RESTRICTED LIQUID LINE PISTON RESTRICTED OR IS CLOGGED UNDER CHARGED OUTDOOR COIL DIRTY STRAINER RESTRICTED OUTDOOR COIL HEAVILY FROSTED DEFECTIVE WELDED CLOSED IN DEFROST RELA
49. SURE SWITCH E T SAFETY LF TA YEL CONTROL EL E XeX 2 SS TERMINAL YEL VIO TERMINAL BOARD BOARD CONNECTION CONNECTION 11 _Loaic_ lt T3 BLK MES T2 A88415 Fig 17 Cycle Protector Wiring DSV TDR is reset and the fan relay remains energized The TDR is a 24v device that operates within a range of 15 to 30v and draws N about 0 5 amps If the blower runs continuously instead of cycling off when the fan e switch is set on AUTO the TDR is probably defective and must be S cn UEM S A91426 Fig 18 Wiring for Single Pole Contactor thereby improving the efficiency of the system The sequence of operation is that on closure of the wall thermostat and at the end of a fixed on delay of 1 sec the fan relay is energized When the thermostat is satisfied an off delay is initiated When the fixed delay of 90 20 sec is completed the fan relay is de energized and fan motor stops If the wall thermostat closes during this delay the replaced Vil PRESSURE SWITCHES Pressure switches are protective devices wired into control circuit low voltage They shut off compressor if abnormally high or low pressures are present in the refrigeration circuit Depending on unit model you may find a low and or high pressure switch in system LOW PRESSURE SWITCH Located on suction line of condensing unit only the low pressure switch protects against low suction pressures caused by such events as loss of charge low air
50. TION The outdoor unit is equipped with high and low pressure switches wired in series If a pressure switch opens the control provides a 5 minute time delay in outdoor unit operation with the outdoor fan running A malfunction signal appears on the control when a pressure switch opens If the switch remains open for 1 hr or longer a malfunction signal is provided at the L terminal of the indoor thermostat Ill FACTORY DEFAULTS Factory defaults have been provided in the event of failure of the ambient thermistor outdoor coil thermistor and or furnace inter face jumper Refer to Table 17 for default and function IV MAJOR COMPONENTS TWO SPEED CONTROL The 2 speed control board controls the following functions High and low compressor contactor operation Outdoor fan motor operation e Crankcase heater operation Compressor protection e Pressure switch monitoring Second stage latching Time delays e 5 minute time delay speedup bypass Heat pumps Time temperature defrost e Defrost interval selection Furnace interface e Electric heat staging HEADER PIN HOUSING The header pin housing is the plastic assembly which holds the stripped lead ends for field connections The 2 speed control receives the 24vac low voltage control system inputs through the housing pins The housing also contains jumpers which the control uses for system configuration such as heat pump versus air conditioner See Fig 37 for header
51. W SPEED OPERATION AMBIENT TEMPERATURE F High Speed Low Speed 30 or less 31 or greater 33 or less 34 or greater 40 or less 41 or greater LED FUNCTION LIGHTS When using the factory authorized indoor thermostats with the 2 speed outdoor units there are 2 locations where system function LED indicator lights are available The indoor thermostat provides indicator lights for high and low speed operation system mal function and auxiliary heat for heat pumps The 2 speed control board has an LED which provides signals for several system operations See Table 15 for LED functions indicator locations and definitions Table 15 also provides the order of signal importance if more than 1 signal should occur The signal to the indoor thermostat is supplied by the low voltage L lead THREE SECOND TIME DELAY Any time the control receives a 24v input such as Y1 or Y2 there is a 3 sec time delay before the control function is initiated This helps prevent nuisance trips and thermostat jiggling ONE MINUTE SPEED CHANGE TIME DELAY When the compressor changes speeds from high to low or low to high there is a 1 minute time delay before the compressor restarts The outdoor fan motor remains running FIVE MINUTE TIME DELAY The 2 speed control logic contains a 5 minute time delay that prevents the unit from short cycling after a thermostat off cycle or power interruption The unit can be forced to operate immediately by momentari
52. W55 AG Suniso 3GS Bristol H23A H23B H24A3 H24A4 H24A5 H25A H26A H25B H26B H29B Copeland scrolls are charged initially with Sontex 200LT white oil Since this oil is not commercially available use 3GS Suniso 3GS ll TROUBLESHOOTING Troubleshooting mechanical or electrical problems in a scroll compressor is the same as for a reciprocating compressor except that a scroll compressor should never be allowed to pump into a 28 Scroll Gas Flow Compression in the scroll is created by the interaction of an orbiting spiral and a stationary spiral Gas enters an outer opening as one of the Spirals orbits ANA Ks A AQI Ww ae m As the spiral continues to orbit the gas is compressed into an increasingly smaller pocket N p e Dmt The open passage is sealed off as gas is drawn into the spiral UN SN 4 A 5 Ae Actually during operation all Six gas passages are in various stages of compression at all times resulting in nearly con tinuous suction and discharge By the time the gas arrives at the center port discharge pressure has been reached A90198 Fig 29 Scroll Compressor Refrigerant Flow vacuum If a pumpdown procedure is used the scroll compressor is capable of pumping into a vacuum very quickly which could cause fusite arcing and compressor failure See Step IV of Reciprocating Compressor section for removal and replacement
53. Y REVERSING VALVE DID NOT SHIFT UNIT NOT PROPERLY CHARGED DEFROST THERMOSTAT DEFROST THERMOSTAT IN POOR PHYSICAL CONTACT WITH TUBE DEFECTIVE CIRCUIT BOARD BAD ELECTRICAL CONNECTION ANYWHERE IN DEFROST CIRCUIT Fig 54 Heat Pump Troubleshooting Chart Heating Cycle 50 STRIP HEATERS NOT OPERATING OUTDOOR THERMOSTAT DEFECTIVE ODT SETTING TOO LOW CAP TUBE PINCHED OR BULB NOT SENSING TRUE ODT STRIP HEATER RELAY OR CONTACTOR DEFECTIVE OPENING IN POWER CIRCUIT TO HEATER ELEMENTS BROKEN FUSE LINK BROKEN HEATER ELEMENT OPEN KLIXON OVER TEMPERATURE THERMOSTAT DEFECTIVE ROOM THERMOSTAT 2ND STAGE A90206 5 2000 Bryant Heating amp Cooling Systems 7310 W Morris St Indianapolis IN 46231 a Printed in U S A sm01 025 Catalog No 5356 109
54. able 18 the motor probably does not have a short Usually a considerable difference will be noted if a turn to turn short is present CONTROL BOARD FAILURE The control board continuously monitors its own operation and the operation of the system The diagnostic feature allows easy troubleshooting of the control and system in the field If a failure occurs the LED light on the control will flash a failure code If the failure is internal to the control board the light will stay on continuously no flash Before replacing control board reset the 24v power If the fault clears check to ensure the indoor and outdoor unit and electrical service are properly grounded If the entire system is grounded the control board should be replaced as the control is not field reparable If the control board light is flashing see LED and Table 15 for function malfunction defini tion Cycling 24 vac to control board resets previous error messages and any lockouts which have occurred See Table 19 for more information regarding control board operation CONTROL BOARD POWER INPUTS AND OUTPUTS See Fig 33 and 37 for inputs and outputs BLEED RESISTOR The bleed resistor is a 150k 2 watt resistor across the compressor run capacitor to protect service technician from injury by electrical shock Capacitor will bleed off approximately 1 minute after power to outdoor unit is turned off If run capacitor is changed out be sure to place bleed resistor on new
55. accessory pressure switches are used the service valve must be cracked Then the knife set stem cap becomes the primary seal The service valve cannot be field repaired therefore only a complete valve or valve stem and service port caps are available for replacement FEEDER PISTON TUBES ORIENT AS SHOWN ep sc PISTON Pd M 7 RETAINER SEAL BRASS HEX NUT BRASS HEX BODY A91138 PISTON BODY PISTON PISTON RETAINER PRODUCTION EXCEPT 1992 A94004 Fig 45 Check Flo Rater Components 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 Wear safety glasses and gloves when han dling refrigerants Pumpdown Procedure Service valves provide a convenient shutoff valve useful for certain refrigeration system repairs System may be pumped down to make repairs on low side without losing complete refrigerant charge 1 Attach pressure gage to suction service valve gage port 2 Front seat liquid line valve 3 Start unit in cooling mode Run until suction pressure reaches 5 psig 35kPa Do not allow compressor to pump to a vacuum 4 Shut unit off Front seat suction valve 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 th
56. ad unloads when the compressor shuts down The scroll plate actually runs backwards while it unloads A 1 to 3 second unloading of refrigerant occurs The Millennium flapper valve eliminates the refrigerant unloading by not allowing the discharge head to run backwards because of its location The Millennium scroll compressor uses Zerol 150 oil with 3 percent Syn O Ad and is the only oil recommended for oil recharge See Table 13 for recharge requirements Il COMPRESSOR PROTECTION Millennium scroll compressors are protected by an internal line break mounted on the motor windings Internal protectors respond to overcurrent and high temperature These protectors are automatic reset devices containing a snap action bi metal switch Ill TROUBLESHOOTING Troubleshooting mechanical and electrical problems in a scroll compressor is similar to a reciprocating compressor except that a scroll compressor should never be allowed to pump into a vacuum 29 The scroll compressor is capable of pumping into a vacuum very quickly which could cause fusite arcing and compressor failure See Step IV of Reciprocating Compressor section for removal and replacement IV SCROLL COMPRESSOR 3 PHASE MONITOR CES0130075 PHASE MONITOR This control is factory installed on all 3 phase scroll compressor models See Fig 31 and 32 On start up the control will energize the pilot relay for 2 seconds The monitor will check for correct compressor rota
57. aks There are various types of electronic leak detectors Generally speaking they are all portable and most are lightweight consist ing of a box with several switches and a probe or sniffer Detector is turned on and probe is passed around all fittings and connections in system Leak is detected by either a movement of a pointer on detector dial by a buzzing sound or a light In all instances when a leak is found system charge must be bled down and leak repaired before final charging and operation After leak testing or leak is repaired evacuate system and recharge with correct refrigerant charge v EAAS A88401 Fig 43 Leak Detector Ill BRAZING When brazing is required in the refrigeration system certain basics should be followed 1 Clean joints make the best joints To clean a Remove all oxidation from surfaces to a shiny finish before brazing TABLE 19 24V PIN CONNECTION TROUBLESHOOTING MODE OF OPERATION TERMINAL LOCATION ON 18 PIN CONNECTOR DESIGNATION CONTROL BOARD All R C VOLTAGE VOLTAGE POSSIBLE SOURCE PATH REQUIRED OF PROBLEM Input Check transformer secondary Low speed Cooling Y1 0 C Input Check thermostat High speed Cooling Y1 Y2 0 C Input Check thermostat Low speed Heating Y1 C Input Check thermostat Y1 C Input Check thermostat High speed Heating Y2 C Outdoor temperature below Output speed change temperature Y1 C
58. ard will occur 10 Unit is now operating in defrost mode Using voltmeter check between C and W2 as shown in Fig 21 Reading on voltmeter should indicate 24v This step ensures defrost relay contacts have closed energizing supplemental heat W2 and reversing valve solenoid O 11 Unit should remain in defrost no longer than 10 minutes Actual time in defrost depends on how quickly speed up jumper is removed If it takes 3 sec to remove speed up jumper after unit has switched to defrost only 7 minutes of defrost cycle remains 12 After a few minutes in defrost cooling operation liquid line should be warm enough to have caused defrost thermostat contacts to open Check resistance across defrost thermostat Ohmmeter should read infinite resistance indi cating defrost thermostat has opened at approximately 80 F 13 Shut off unit power and reconnect fan lead 14 Remove jumper wire from speed up terminal and reinsert cover on speed up terminals Failure to remove jumper causes unit to speed up operating cycles continuously 15 Remove jumper between DFT and R terminals Reconnect defrost thermostat leads 16 Replace control box cover Restore power to unit If defrost thermostat does not check out following above items or incorrect calibration is suspected check for a defective thermostat as follows 1 Follow items 1 5 above O ora Jor1 4 n n n n n a a a a Ei n n n n
59. ation is suspected check for a defective thermostat 10 minute cycle as follows 5 minutes 1 Follow items 1 5 above 4 Restart unit in heating 2 Rotte SPSO ODP r be nderneath coik or other convenient 5 Within a few minutes liquid line temperature drops within location using thermocoup le temperature measuring de a range causing defrost thermostat contacts to close Tem vice Attach to liquid line near defrost thermostat Insulate perature range is from 33 F to 27 F Notice temperature at for more accurate reading which ohmmeter reading goes from to zero ohms 3 Turn on power to outdoor unit Thermostat contacts close at this point 20 6 Short between the speed up terminals using a small slotted screwdriver 7 Unit changes over to defrost within 21 sec depending on timing cycle setting Liquid line temperature rises to range where defrost thermostat contacts open Temperature range is from 75 F to 85 F Resistance goes from zero to o when contacts open 8 If either opening or closing temperature does not fall within above ranges or thermostat sticks in 1 position replace thermostat to ensure proper defrost operation CES0130024 DEFROST CONTROL Some heat pumps built in 1993 and later incorporated a new defrost control similar to the CES0110063 except the 5 minute cycle protector has been removed This control is used on heat pump units with reciprocating compressors where short cycle pro
60. ay coil is wired across start and common terminals of compressor The added capacitance gets the compressor started As compressor comes up to speed voltage across start and common terminals increases to a value high enough to cause start relay to energize This opens normally closed contacts and removes start capacitor from circuit In actual practice this occurs in a fraction of a second NOTE If bleed resistor is wired across start capacitor it must be disconnected to avoid erroneous readings when ohmmeter is applied across capacitor To check start relay and capacitor 1 Turn off all power to unit 2 Discharge start and run capacitors as outlined earlier 3 Most start capacitors will have a 15 000 ohm 2 watt bleed resistor Disconnect these devices from system Start capacitor can be inspected visually It is designed for short duration or intermittent duty If left in circuit for prolonged period start capacitor blows through a specially designed bleed hole If it appears blown check for welded contacts in start relay Start capacitor can be checked by ohmmeter method discussed earlier Start relay is checked with ohmmeter Check for continuity across coil of relay You should encounter a high resistance Since relay contacts are normally closed you should read low resistance across them Both PTC device and capacitor relay start system are standard equipment on some of these units They are also available as accessories and
61. be energized if pressure switch remains open for 1 hr Check both thermistors to determine which is faulty HIGH SPEED BALANCE POINT __ STRUCTURE BALANCE PO LOW SPEED BALANCE POINT 50 60 70 80 90 100 110 120 TEMPERATURE F A91282 Fig 35 Typical Cooling Balance Points DEFROST The 2 speed control logic for the defrost function is the standard time and temperature initiated time or temperature terminated Defrost occurs only at outdoor temperatures less than 50 F The control initiates defrost when the outdoor coil thermistor is 30 F 2 or less and the selected defrost time interval has been accumulated during unit operation Termination occurs when the coil thermistor reaches 80 F 5 or the defrost period reaches a maximum of 10 minutes Defrost always occurs in high speed unless the stage 2 latch POT is set at ZONE During defrost the unit operates in high speed energizes the reversing valve O and auxiliary heat W2 and de energizes the outdoor fan Upon termination there is a 20 sec delay in the outdoor fan being energized If the stage 2 latch POT is set to ZONE and the heat pump is in low speed it defrosts in low speed 32 FIELD INITIATED FORCED DEFROST By placing a jumper across the speedup terminals for a minimum of 5 sec and then removing it the unit initiates a defrost cycle See Fig 34 The cycle occurs only if the outdoor amb
62. cations The purpose of having 2 solenoids is to minimize the valve internal pressure drop in accordance with refrigerant flow direction and liquid migration to the compressor The bi flow solenoid is designed to have minimal refrigerant pressure drop in either flow direction which makes it suitable for heat pump usage Refer to Table 9 for liquid line solenoid kit part numbers TABLE 8 COMMON PISTON SIZES CHECK FLO CHECK FLO RATER RATER CHATLEFF CHATLEFF NOTE When installing a liquid line solenoid the system may require a minimum 60va low voltage transformer Each type of solenoid has an indicator flow arrow stamped on the valve body When solenoid is closed not energized and pressure is applied in direction of flow arrow complete shutoff occurs If pressure is applied against direction of flow arrow leakage through valve occurs When determining proper installation of valve within liquid line 2 considerations must be made 1 Direction of flow arrow 2 Where solenoid is installed in system TXVs can only be substituted for liquid line solenoids in single flow air conditioning systems Bi flow TXVs allow liquid migra tion to coldest point during off cycles which could allow liquid into compressor Fig 4 through 7 detail proper installation of liquid line solenoid and provide applications where TXVs may be substituted Refer ence a
63. ciprocating Compressor Section H Electrical Failures for proper compressor winding check 15 CAUTION Do not check winding at compressor termi nals with pressure in the system Check resistance by removing wires attached at the compressor contactor and run capacitor 3 Obtain a start capacitor in the range of 150 180uF 0330 volts rating Connect 8 gauge wires with insulated clips or terminals to the H and C terminals of the run capacitor 4 Turn power on to unit If compressor starts immediately remove start capacitor wires from H and C terminals of run capacitor using a pair of insulated needle nose pliers DO NOT leave start capacitor attached to run capacitor for more than 3 seconds even if compressor doesn t start 5 Discharge start capacitor by using a pair of insulated needle nose pliers and shorting a 15 000 ohm 2 watt resistor across terminals NOTE Some start capacitors already have a bleed resistor attached If so it will discharge itself over a short period of time 6 Run compressor 10 minutes Stop and allow unit to sit idle for 5 minutes 7 Check system pressure equalization 8 Attempt to restart without capacitance boost If PTC thermistor device is inadequate as start device a start capacitor and relay may be added to system to ensure positive start Capacitor is wired in parallel with run capacitor through normally closed set of contacts on a device called start relay The rel
64. d with a Flathead screwdriver for 5 seconds and released a short defrost cycle will be observed actual length is dependent upon the selected Quiet Shift position When Quiet Shift switch is in ON position the length of defrost is 1 minute 30 seconds compressor off period followed by 30 seconds of defrost with compressor operation On return to heat operation compressor will again turn off for an additional 30 seconds and the fan for 40 seconds When the Quiet Shift is in OFF position only a brief 30 second cycle will be observed If it is desirable to observe a complete defrost in warmer weather the thermostat must be closed as follows Turn off power to outdoor unit 2 Disconnect outdoor fan motor lead from OF2 on control board See Fig 22 Tape to prevent grounding 3 Restart unit in heating mode allowing frost to accumulate on outdoor coil 4 After a few minutes in heating mode liquid line tempera ture should drop below closing point of defrost thermostat approximately 30 F NOTE Unit will remain in defrost until defrost thermostat reopens at approximately 80 F coil temperature at liquid line or remainder of defrost cycle time 5 Turn off power to outdoor unit and reconnect fan motor lead to OF2 on control board after above forced defrost cycle Compressor Shut Down This control has the option of shutting down the compressor for 30 seconds while going into and out of defrost modes This is accomplish
65. e After connecting the sweat adapter to the liquid service valve of a heat pump the valves are ready for brazing The interconnecting tubing line set can be brazed to the service valves using either silver bearing or non silver bearing brazing material Consult local codes Before brazing the line set to the valves the belled ends of the sweat connections on the service valves must be cleaned so that no brass plating remains on either the inside or outside of the bell joint To prevent damage to the valve and or cap O ring use a wet cloth or other acceptable heat sinking material on 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 evapo rator coil have been evacuated the valve stem can be turned counterclockwise until it opens or back seats which releases refrigerant into tubing and evaporator coil The system can now be operated Back seating service valves must be back seated turned counter clockwise until seated before the service port caps can be re moved and hoses of gage manifold connected In this position refrigerant has access from and through outdoor and indoor unit The service valve stem cap is tightened to 20 2 ft lb torque and the service port caps to 9 2 ft lb torque The seating surface of the valve stem has a knife set edge against which the caps are tightened to attain a metal to metal seal If
66. e the outdoor fan delays come on for 20 sec This allows the refrigeration system to recover the outdoor coil heat and minimize the steam cloud effect SECOND STAGE LATCHING When low speed cooling operation no longer satisfies the first stage of the indoor thermostat the indoor temperature will increase by 2 until second stage is energized After high speed cooling satisfies second stage it returns to low speed cooling operation If desired the installer may select to have high speed cooling by energizing Y1 High speed will stay energized until Y 1 is satisfied This eliminates the temperature drop between the first and second stages of indoor thermostat holding room temperature closer to set point To utilize this function the unit capacity should be plotted versus the heat gain of the structure which provides the system s balance point when the structure requires high speed capacity See Fig 35 Second stage latching can be selected by rotating the potentiom eter POT to the desired outdoor second stage latching tempera ture See Fig 34 The temperatures that can be selected are 85 90 95 100 and 105 F The POT is factory set at 105 F ZONE SELECTION If the stage 2 latch POT is set to ZONE position the compressor operating speed in either heat or cool mode is determined by the Y1 and or Y2 inputs The system operates in low speed with a Y1 input and high speed with Y2 or Y1 and Y2 input This allows
67. e a 2 stage cooling indoor thermostat With a call for first stage cooling Y1 the outdoor fan and low speed compressor are energized If low speed cannot satisfy the cooling demand high speed will be energized Y1 and Y2 by the second stage of the indoor thermostat The thermostat has a 2 differential between first and second stages After second stage is satisfied the unit returns to low speed operation until first stage is satisfied or until second stage is again required CONTACTOR 24VAC Oo 000 e ON O0K FLASH PHA S o OFF NO 24VAC L Q HK S5ACO02 E PROBLEM z JY A00010 Fig 31 CES0130075 3 Phase Monitor Board INDOOR THERMOSTAT li CESO130075 EXTERNAL POWER SUPPLY 24 V A00011 Fig 32 CESO130075 3 Phase Monitor Wiring Diagram 30 HEATING OPERATION HEAT PUMP ONLY The 2 speed products utilize a 2 stage heating indoor thermostat The first stage of heating is heat pump operation Y1 Auxiliary backup heat is controlled by second stage W2 There is a 2 differential between first and second stage The control board determines the compressor speed based on ambient temperature See Table 14 for ambient temperatures at which speed changes occur When high speed heat pump heating is required the control provides a Y2 24vac signal back to the thermostat to energize high speed indicator LED TABLE 14 AMBIENT TEMPERATURE FOR HIGH AND LO
68. e during heating season reducing supplementary electric heat costs and during cooling season reducing period of heat discomfort The service alarm is an accessory device Service alarm locks out compressor under certain adverse operating conditions System is manually reset by shutting it off at thermostat subbase then turning it back on If adverse condition is corrected system restarts One example of an adverse condition would be a system located in a desert climate where high operating temperatures may cause system to shut down on the high pressure switch or on the compressor internal overload Connect service alarm to outdoor unit control circuit terminal board See Fig 25 and wiring diagram on unit Connect all field line power wires to unit in usual manner Route field line power supply wire through metallic loop on bottom of service alarm then to normal unit connection Units with RLA of less than 14 amps will require 2 passes through the metallic loop Refer to Fig 25 or 26 for wiring connections for service alarm or service alarm with solid state cycle protector accessories when used NOTE The wire from the X terminal on the service alarm to L on the outdoor terminal board indoor terminal board and thermostat subbase is field supplied and wired when using defrost controls HK32FA003 or HK32FA006 When defrost control CES0110063 or CES0130024 is used field supplied wire from X terminal on service alarm to L on indo
69. e sequence for reassembly 8 Prior to applying power check that fan rotates freely 1 SM c SSS SSS D D 2 YX NAINA IN SN D E Z I Ii H Al H Zi L4 Z E Z 2 OON Y VERA iin E E 1 EL ZE p e ELE Se _ _ Ss SSS yD AZ Teen f AK ETE TT JL LLL LLL ELL LIAL A94003 Fig 8 Basic Cabinet Designs ALUMINUM WIRE ELECTRICAL it 55 pa amp Ee RE BS u V o N 3s o S n Sz Bo o oO Ais 3 ds Eo as A ts nS z 2 E 25 E o WARNING Exercise extreme caution when working on any electrical components Shut off all power to system prior to troubleshooting Some troubleshooting tech niques require power to remain on In these instances o o 3 amp o ES 2 o n 3 o ES gt ec o Ez 3 5 e a o o gt 2 g 5 3 Eel E disconnect the unit disconnect and the unit on Bryant systems exercise extreme caution to avoid danger of electrical shock ONLY TRAINED SERVICE PERSONNEL SHOULD PERFORM ELECTRICAL TROUBLE SHOOTING Whenever aluminum wire is used in the branch circuit wiring with this unit adhere to the following recommendations Connections must be made in accordance with the National Electrica
70. e valve panel Cube unit holding coil tube sheet CAUTION Cut tubes to reduce the possibility of fire and personal injury 7 Use midget tubing cutter to cut liquid and vapor lines at both sides of coil Cut in convenient location for easy reassembly with copper slip couplings 8 Lift coil vertically from basepan Place aside carefully 9 Reverse procedure to reinstall coil X LIQUID LINE STRAINER HEAT PUMPS ONLY The liquid line strainer is upstream of the heating piston The strainer catches debris in the liquid line during heating mode If it becomes plugged system operation and pressure become abnor mal and the compressor may become hot and cycle off on the overloads or pressure relief CAPILLARY TUBE DIAPHRAGM BYPASS TXV vA PUSHRODS FA FEEDER TUBES Sa INLET we A OUTLET 3 LMA COIL I NEEDLE VALVE SPRING KY oon BULB 7 A CHECK VALVE CLOSED Be BYPASS TUBE EXTERNAL EQUALIZER TUBE A88406 Fig 49 TXV in Cooling Mode CAPILLA
71. eat The bi flow TXV is used on split system heat pumps In the cooling mode the TXV operates the same as the standard TXV previously explained See Fig 49 However when the system is switched to the heating mode of operation the refrigerant flow is reversed The bi flow TXV has an additional internal check valve and external tubing See Fig 50 These additions allow the refrigerant to bypass the TXV when refrigerant flow is reversed with only a 1 to 2 psig pressure drop through the device When the heat pump switches to the defrost mode the refrigerant flows through a completely open unthrottled TXV and the bulb senses the residual heat of the outlet tube of the coil that had been operating in the heating mode about 85 F and 155 psig This temporary unthrottled valve decreases the indoor pressure drop which in turn increases the refrigerant flow rate decreases overall defrost time and enhances defrost efficiency IX COIL REMOVAL Coils on this family of units are easy to remove if required for compressor removal or replacement coil A CAUTION Wear safety glasses and gloves when han dling refrigerants To remove or replace coil 1 Shut off all power to unit 2 Remove and recover refrigerant from system through ser vice valves 3 Remove top cover See Remove Top Cover section 4 Remove screws in base pan to coil grille 5 Remove coil grille from unit 6 Remove screws on corner post Reliant servic
72. echanical systems appear normal Compressor must be checked electrically for abnormali ties Before troubleshooting compressor motor review this description of compressor motor terminal identification SINGLE PHASE MOTORS To identify terminals C S and R Turn off all unit power 2 Short the run and start capacitors to prevent shock 3 Remove all wires from motor terminals 4 Read resistance between all pairs of terminals using an ohmmeter on 0 10 ohm scale 5 Determine 2 terminals that provide greatest resistance reading Through elimination remaining terminal must be common C Greatest resistance between common C and another terminal indicates start winding because it has more turns This terminal is start S Remaining terminal will be run winding R See Fig 28 NOTE If compressor is hot allow time to cool and internal line break to reset There is an internal line break protector which must be closed THREE PHASE MOTORS Resistance readings between all 3 sets of windings should be the same All compressors are equipped with internal motor protection If motor becomes hot for any reason protector opens Compressor should always be allowed to cool and protector to close before troubleshooting Always turn off all power to unit and disconnect leads at compressor terminals before taking readings Most common motor failures are due to either an open grounded or short circuit Directions below are specifically for
73. ection determines to the aluminum fins of the coil and can cause premature coil necessary failure due to corrosion 3 Protecting the unit in off season with cover that allows air to circulate through but prevents sand from sifting in such 1 Locating the unit on side of structure opposite the prevailing as canvas material Do not use plastic as plastic will hold winds moisture Preventive measures can be taken during installations such as 2 Elevating the unit to height where drifting sand cannot pile up against coil Four in high mounting feet or an 18 in high mounting rack are available as accessories and can be used to elevate the unit AIR CONDITIONER TROUBLESHOOTING CHART NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN CONTACTOR OPEN POWER SUPPLY DEFECTIVE LOW VOLTAGE TRANSFORMER OPEN THERMOSTAT OPEN CONTROL CIRCUIT LOSS OF CHARGE CONTACTOR OR COIL DEFECTIVE LOOSE ELECTRICAL CONNECTION CONTACTOR CLOSED COMPRESSOR POWER SUPPLY OPEN LOOSE LEADS AT COMPRESSOR FAULTY START GEAR 1 PH OPEN SHORTED OR GROUNDED COMPRESSOR MOTOR WINDINGS COMPRESSOR STUCK COMPRESSOR INTERNAL PROTECTION OPEN DEFECTIVE RUN CAPACITOR COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD OUTDOOR AIR RESTRICTED OR RECIRCULATING RESTRICTED DISCHARGE TUBE OVERCHARGE OR NON CONDENSAB
74. ectric shock death or injury from rotating fan blade The bearings are permanently lubricated therefore no oil ports are provided For suspected electrical failures check for loose or faulty electrical connections or defective fan motor capacitor Fan motor is equipped with thermal overload device in motor windings which may open under adverse operating conditions Allow time for motor to cool so device can reset Further checking of motor can be done with an ohmmeter Set scale on R X 1 position check for continuity between 3 leads Replace motors that show an open circuit in any of the windings Place 1 lead of ohmmeter on each motor lead At same time place other ohmmeter lead on motor case ground Replace any motor that shows resistance to ground signs of arcing burning or overheating XI SERVICE ALARM CONTROL BOARD NOTE If the proper night setback thermostat is not used the service alarm control will work but there will be no light indication on thermostat The service alarm control provides immediate warning when outdoor heat pump requires servicing It turns on indoor thermostat malfunction light if compressor does not operate for O m lt O EREEREER gt dndssdSs LEi d L JdO H3INLL IWAYSLNI Speedup Pins EN exp res CESO 130076 00 Defrost interval DIP switches A99442 Fig 22 Defrost Control either heating or cooling This enables owner to obtain timely heat pump servic
75. ed by turning DIP switch 3 to the ON position See Fig 22 for switch position Factory default is in the OFF position Five Minute Time Delay This control has a 5 minute time delay on startup The speedup terminals can be used to bypass this delay Momentary shorting across the speedup terminals will upon release bypass 5 minute time delay Do not short out the speedup terminals for more than 5 seconds or defrost mode will be initiated Troubleshooting Troubleshooting this control is done in the same manner as the CES0130063 control with the exceptions listed above DEFROST THERMOSTAT LOCATION On most residential outdoor heat pump models the defrost thermostat is located on the return bend side of the coil The 5 16 OD feeder tube from the header will enter a 1 1 2 in to 2 in long 3 8 OD stub prior to entering the coil There is only one stub tube per coil All other feeder tubes enter the coil directly The defrost thermostat attaches to this stub tube See Fig 23 X FAN MOTORS Fan motor rotates the fan blade that either draws or blows air through outdoor coil to perform heat exchange Motors are totally enclosed to increase reliability This also eliminates need for rain shield For the correct position of the fan blade assembly see Fig 24 and Table 12 WARNING Turn off all power to unit before servicing AA 9r replacing fan motor Be sure unit main power switch is turned off Failure to do so may result in el
76. ed in place of ohmmeter Follow manufac turer s instructions 6 Place 1 meter probe on ground or on compressor shell Make a good metal to metal contact Place other probe on terminals C S and R in sequence 7 Note meter scale 8 If reading of zero or low resistance is obtained motor is grounded Replace compressor A ton or less capacity compressor is probably grounded if resistance is below 1 million ohms On larger sized single phase compressors resistance to ground should not be less than 1000 ohms per volt of operating voltage Example 230 volts X 1000 ohms volt 230 000 ohms minimum SHORT CIRCUIT To determine if any wires within windings have broken through their insulation and made contact with other wires thereby shorting all or part of the winding s be sure the following conditions are met 1 Correct motor winding resistances must be known before testing either from previous readings or from manufactur er s specifications 2 Temperature of windings must be as specified usually about 70 F 3 Resistance measuring instrument must have an accuracy within 5 to 10 percent This requires an accurate ohmme ter such as a Wheatstone bridge or null balance type instrument 4 Motor must be dry or free from direct contact with liquid refrigerant MAKE THIS CRITICAL TEST Not advisable unless above conditions are met 1 Be sure all power is off 2 Discharge all capacitors 3 Remove wires fro
77. est method of troubleshooting is to apply voltmeter across crankcase heater leads to see if heater has power Do not touch heater Carefully feel area around crankcase heater If warm crankcase heater is probably functioning Do not rely on this method as absolute evidence heater is functioning If compressor has been running the area will still be warm With power off and heater leads disconnected check across leads with ohmmeter Do not look for a specific resistance reading Check for resistance or an open circuit Change heater if an open circuit is detected Some crankcase heaters in this series of units are equipped with a crankcase heater switch This energy saving device shuts off power to heater when temperatures are high enough that heater is not needed Be sure this switch is functioning normally before condemning crankcase heater VI TIME DELAY RELAY The time delay relay TDR is a solid state controlled recycle delay timer which keeps the indoor blower operating for 90 sec after thermostat is satisfied This delay enables the blower to remove residual cooling in the coil after compression shutdown OPERATING p TIME SESS ue BLK DENOTES CLOSED CONTACTS OPERATING are e MSN BLK DENOTES CLOSED CONTACTS HN67ZA002 HN67PA025 HN67ZA003 HN67ZA008 A91436 A91437 Fig 16 Cycle Protector Sequence CUT YELLOW WIRE BETWEEN CONTACTOR AND LOW PRES
78. flow across indoor coil dirty filters etc It opens on a pressure drop at about 27 psi If system pressure is above this switch should be closed To check switch turn off all power to unit disconnect leads on switch and apply ohmmeter leads across switch You should have continuity on a good switch Because these switches are attached to refrigeration system under pressure it is not advisable to remove this device for troubleshooting unless you are reasonably certain that a problem exists If switch must be removed remove and recover all system charge so that pressure gages read 0 psi CAUTION Wear safety glasses and gloves when work ing with refrigerants AN Apply heat with torch to solder joint and remove switch Wear safety glasses when using torch Have quenching cloth available Oil vapor in line may ignite when switch is removed Braze in 1 4 in flare fitting and screw on replacement pressure switch HIGH PRESSURE SWITCH Located on discharge line the high pressure switch protects against high discharge pressures caused by such events as over charge condenser fan motor failure system restriction etc It opens on pressure rise at about 435 psi If system pressures go above this setting during abnormal conditions the switch opens Do not attempt to simulate these system abnormalities as high pressures pose a serious safety hazard High pressure switch is also checked with an ohmmeter similar to checking low pressure s
79. h a remote reading electronic type thermometer with multiple probes Route thermo couple leads to inside of coil area through service valve mounting plate area underneath coil Fig 47 and 48 show test points TP on reversing valve for recording temperatures Insulate points for more accurate reading NEW SOLENOID COIL 3 PORT DESIGN A91457 4 PORT DESIGN A91456 Fig 46 Reversing Valve If valve is defective 5 Use slip couplings to install new valve with stubs back into system Even if stubs are long wrap valve with a wet rag to 1 Shut off all power to unit and remove all charge from prevent overheating system 6 After valve is brazed in check for leaks Evacuate and charge system Operate system in both modes several times to be sure valve functions properly 2 Check valve design If valve is of the 3 port design and new replacement is of the 4 port design replacement of the solenoid coil and wire leads is necessary Valve bodies are interchangeable but solenoid and wires are not Three port reversing valve and solenoid coil with leads must be used together New solenoid coil cannot be used on a 3 port valve Four port reversing valve uses solenoid with quick connect terminals for leads connection Old solenoid coil cannot be used on 4 port reversing valve If for any reason a new wire cord is not available cut the leads on the old solenoid coil as close to the coil as possible Terminate the leads wi
80. he previous control board have been replaced by a connector plug with stripped wire leads This control board also contains the feature that allows the heat pump to restart in defrost if the room thermostat is satisfied during defrost The board also contains a 5 minute cycle protector that prevents the unit from short cycling after it cycles off or after a power interruption To troubleshoot the board perform the follow ing items 1 Turn thermostat to OFF Shut off all power to outdoor unit 2 Remove control box cover for access to electrical compo nents and defrost control board 3 Disconnect defrost thermostat leads from control board and connect to ohmmeter Thermostat leads are the black insulated wires connected to DFT and R terminals on control board Resistance reading may be zero indicating closed defrost thermostat or infinity co for open thermo stat depending on outdoor temperature 4 Jumper between DFT and R terminals on control board as shown in Fig 21 5 Disconnect outdoor fan motor lead from OF2 Tape lead to prevent grounding Turn on power to outdoor unit 7 Restart unit in heating mode allowing frost to accumulate on outdoor coil 8 After a few minutes in heating mode liquid line tempera ture at defrost thermostat should drop below closing set point of defrost thermostat of approximately 30 F Check resistance across defrost thermostat leads using ohmmeter Resistance of zero indicates defrost ther
81. ient is less than 50 F regardless of outdoor coil temperature The cycle terminates when the coil thermistor reaches 80 F 5 or the defrost period reaches a maximum of 10 minutes FURNACE INTERFACE This feature provides a heat pump lockout upon a demand for auxiliary heat W2 and must be used when interfacing a heat pump with a gas oil furnace Field selection of the furnace interface option is done by connecting the factory supplied jumper to the ON position of the 3 terminal connectors See Fig 33 When the option is selected the heat pump will be locked out of operation any time there is a thermostat demand for W2 or the outdoor ambient is below the balance point POT setting selection See Fig 34 When the unit requires defrost auxiliary heat W2 energizes the furnace After defrost is terminated the heat pump shuts down and the furnace satisfies the thermostat To utilize this function the economic and or thermal balance point must be determined See the appropriate heat pump balance point work sheet available from your distributor or branch BALANCE POINT This feature can be used in 2 different options furnace interface or electric heat staging Refer to the Furnace Interface section for its application If the heat pump is installed with a fan coil with multistages of electric heat this option can be used to stage the banks of heat by outdoor ambient This eliminates the need for accessory outdoor thermostats When u
82. in effect removes it from the circuit 12 5 22 5 OHMS 12 5 OHM BEIGE COLOR 20 36 OHMS EA 20 OHM BLUE COLOR 25 45 OHMS 25 OHM BLUE COLOR A88414 Fig 13 PTC Devices After system shutdown resistor cools and resistance value returns to normal until next time system starts If indoor coil does not have a bleed type expansion device it may be necessary to remove start thermistor and replace with accessory start capacitor and relay Consult pre sale literature for application of start kits Thermistor device is adequate for most conditions however in systems where off cycle is short device cannot cool fully and becomes less effective as a start device It is an easy device to troubleshoot 1 Shut off all power to system 2 Check thermistor with ohmmeter as described below 3 Shut off all power to unit 4 Remove PTC from unit Wait at least 10 minutes for PTC to cool to ambient temperature 5 Measure resistance of PTC with ohmmeter as shown in Fig 13 The cold resistance RT of any PTC device should be approxi mately 100 180 percent of device ohm rating 12 5 ohm PTC 12 5 22 5 ohm resistance beige color 25 ohm PTC 25 45 ohm resistance blue color 20 ohm PTC 20 36 ohm resistance blue color If PTC resistance is appreciably less than rating or more than 200 percent higher than rating device is defective If thermistor is good and compressor does not start 1 Disconnect therm
83. ions for this unit in the residential new construction market require the outdoor unit indoor unit refrigerant tubing sets metering device and filter drier listed in Product Data Sheet PDS DO NOT DEVIATE FROM PDS Consult unit Installation Instructions for detailed information Il ADD ON REPLACEMENT RETROFIT Specifications for this unit in the add on replacement retrofit market require change out of outdoor unit metering device and all capillary tube coils Change out of indoor coil is recommended There can be no deviation 1 If system is being replaced due to compressor electrical failure assume acid is in system If system is being replaced for any other reason use approved acid test kit to determine acid level If even low levels of acid are detected install factory approved suction line filter drier in addition to the factory supplied liquid line filter drier Remove the suction line filter drier as soon as possible with a maximum of 72 hr 2 Drain oil from low points or traps in suction line and evaporator if they were not replaced 3 Change out indoor coil or verify existing coil is listed in the Product Data Sheets 4 Replace outdoor unit 5 Install liquid line filter drier 6 If suction line filter drier was installed for system clean up operate system for 10 hr Monitor pressure drop across drier If pressure drop exceeds 3 psig replace suction line and liquid line filter driers Be sure to
84. istor from starting circuit 2 Give compressor a temporary capacitance boost see next section 3 Run compressor for 10 minutes shut off and allow system pressure to equalize 4 Reconnect start thermistor 5 Try restarting compressor without boost capacitor If after 2 attempts compressor does not start remove thermistor Add an accessory start capacitor relay package TEMPORARY CAPACITANCE BOOST WARNING Do not under any circumstances attach a temporary boost capacitor directly to the compressor A terminals Serious personal injury can result Exercise extreme caution with this procedure when high voltage power is on There are times when a temporary capacitance boost is needed to get compressor started See Fig 14 If compressor motor does not start it may be due to low line voltage improper pressure equalization weak run capacitor or a seized compressor Check each possibility and attempt capacitance boost before adding auxiliary start capacitor and relay 220 V FROM UNIT CONTACTOR START BOOST CAPACITOR A88349 Fig 14 Capacitance Boosting 1 Turn off all power to unit There may be more than one power source to condensing unit NOTE If a PTC is already installed remove it from the system by pulling PTC wires from H and C terminals on run capacitor 2 Check compressor for ground or open windings If wind ing s resistance is within manufacturer s recommendations proceed See Re
85. k Evidence of burning may be present in tubing connected to compressor An acid test of compressor oil will be positive Complete system must be reverse flushed with refrigerant Check Flo Rater or TXV must be cleaned or re placed In a heat pump accumulator and reversing valve are replaced These components are also removed and bypassed during reverse flushing procedure Remove and discard liquid line strainer After system is reassembled install liquid line and suction line filter driers Run system for 2 hrs Discard both driers and install new liquid line drier only IV COMPRESSOR REMOVAL AND REPLACEMENT Once it is determined that compressor has failed and the reason established compressor must be replaced A CAUTION Wear safety glasses and gloves when han dling refrigerants and when using brazing torch 1 Shut off all power to unit 2 Remove and recover all refrigerant from system until pressure gages read zero psi Use all service ports 3 Disconnect electrical leads from compressor Disconnect or remove crankcase heater and remove compressor holddown bolts 4 Cut compressor from system with tubing cutters Do not use brazing torch for compressor removal Oil vapor may ignite when compressor is disconnected 5 Scratch matching marks on stubs in old compressor Make corresponding marks on replacement compressor 6 Use torch to remove stubs from old compressor and to reinstall them in replacement compressor
86. l the second auxiliary stage W3 is energized This ensures all available heat is energized if the indoor thermostat is switched to emergency heat COMPRESSOR PTC OVERLOAD PROTECTION The control senses the resistance of the compressor internal positive temperature coefficient PTC overloads If the resistance of the PTCs is out of range the control shuts off the unit until the resistance range is acceptable See Table 16 for compressor PTC ranges TABLE 16 COMPRESSOR PTC RANGES COMPRESSOR INTERNAL PTC RESISTANCE Safe Range 77 F 1 5k to 7 8k ohms To trip 26k to 34k ohms To reset 8 4k to 10k ohms When the control turns off the outdoor unit due to out of range PTCs the unit remains off for 15 minutes with the outdoor fan running After 15 minutes the control checks the resistance every 5 minutes until it reaches the reset range During this time a malfunction signal appears on the control board If this happens remove the wires on control board at S1 and S2 and measure the resistance across the leads When the resistance reaches 8 400 to 10 000 ohms system operation may be resumed If the resistance remains outside this range a quick check of the leads at the compressor should be made Loose connections can cause inaccu rate readings If a PTC trip occurs 3 times the control will lock out the outdoor unit operation and provide malfunction signals at both the control and indoor thermostat PRESSURE SWITCH PROTEC
87. l Code NEC using connectors approved for aluminum wire The connectors must be UL approved marked Al Cu with the UL symbol for the application and wire size The wire size Troubleshooting charts for air conditioning and heat pump units are provided in the back of this manual They enable the service technician to use a systematic approach to locate the cause of a problem and correct system malfunctions selected must have a current capacity not less than that of the copper wire specified and must not create a voltage drop between the service panel and the unit in excess of 2 percent of the unit rated voltage To prepare the wire before installing the connector all aluminum and coated with a corrosion inhibiter such as Pentrox A When it is suspected that the brush scratched wire must be A88411 Fig 9 Information Plate connection will be exposed to moisture it is very important to cover the entire connection completely to prevent an electrochemi cal action that will cause the connection to fail very quickly Do not reduce the effective size of wire such as cutting off strands so that the 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 the unit has reached operating temperatures especially if aluminum conductors are used A88412 Il CONT
88. leads are the black insulated wires connected to DFT and R terminals on control board Resistance reading may be zero indicating closed defrost thermostat or infinity co for open thermo stat depending on outdoor temperature 4 Jumper between DFT and R terminals on control board as shown in Fig 19 5 Disconnect outdoor fan motor lead from OF2 Tape lead to prevent grounding 6 Turn on power to outdoor unit 7 Restart unit in heating allowing frost to accumulate on outdoor coil 8 After a few minutes in heating liquid line temperature at defrost thermostat should drop below closing set point of defrost thermostat of approximately 30 F Using ohmmeter check resistance across defrost thermostat leads Resistance of zero indicates defrost thermostat is closed and operating properly 9 Remove protective cover from TP1 and TP2 speed up terminals Install jumper wire on speed up terminals This reduces the timing sequence to 1 60 of original time See Fig 20 Since Fig 20 shows timing cycle set at 30 minutes unit initiates defrost within approximately 30 sec if setting is at 50 minutes within 50 sec 90 minutes within 90 sec When you hear the reversing valve change position remove protective cover jumper Otherwise control will terminate normal 10 minute defrost cycle in approximately 10 sec CAUTION Exercise extreme caution when shorting speed up pins If pins are accidentally grounded damage to the control bo
89. ll kinks through metering hole Do not damage metering hole sealing surface around piston cones or fluted portion of piston 5 Clean piston refrigerant metering hole 6 Always replace Teflon seal with new seal Never try to reuse old seals 7 Reassemble brass nut and brass hex body Be sure orienta tion is as shown in Fig 45 VI REVERSING VALVE In heat pumps changeover between heating and cooling modes is accomplished with a valve that reverses flow of refrigerant in system See Fig 46 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 normally inlet and outlet temperatures on appropriate lines should be close Any difference would be due to heat loss or gain across valve body Temperatures are best checked wit
90. ll notes of the appropriate figures TABLE 9 LIQUID LINE SOLENOID KIT PART NUMBERS TYPE OF VALVE PART NO Single Flow KAALSO101LLS Bi Flow KHALS0401LLS V CHARGING INFORMATION Weigh in appropriate refrigerant charge then use the standard practices of superheat charging method for piston applications and subcooling charging method for TXV applications to confirm correct charge The standard charging methods can be found on outdoor unit information plate in unit Installation Instructions or in the Service Manual Since total system charge is increased for long line applications it may be necessary to calculate the additional refrigerant charge Since long line applications only involve 3 8 in liquid lines the additional refrigerant charge required is 0 6 oz of Refrigerant 22 R 22 per ft of 3 8 in liquid line over 15 ft Dg EXAMPLE To calculate additional charge required for a 25 ft line set 25 ft 15 ft 10 ft X 0 6 oz ft 6 oz of additional charge The rating plate charge of a given outdoor unit is for a standard application of 15 ft of interconnecting tubing The rating plate charge can be found on outdoor unit rating plate or in outdoor unit presale literature Long line applications do not require addi tional oil charge VI 2 SPEED APPLICATIONS Outdoor units may be connected to indoor section using accessory tubing package or field supplied refrigerant grade tubing of correct size and condition
91. lways wear safety glasses and gloves when handling refrigerants If system has lost all charge weigh in charge using dial a charge or digital scale System charge should be fine tuned by using the superheat or subcooling method whichever is appropriate These methods are covered in the Checking Charge section below NOTE Heat pump check charts are for checking charge and performance and for adding a small amount of charge During heating mode correct method of charging is the weight method In heating mode check should be made approximately 15 minutes after a defrost with unit running with a clean coil In cooling cycle system should run at least 10 minutes for temperatures and pressures to stabilize All charts assume there are no system abnormalities and indoor coil airflows are correct If system abnormalities exist correct them before checking system charge XIV CHECKING CHARGE Superheat charging is the process of charging refrigerant into a system until the temperature superheat of the suction gas entering the compressor reaches a prescribed value Small variations of charge affect suction gas superheat temperatures greatly There fore this method of charging is very accurate This method can be used only on split system condensing units and heat pumps operating in the cooling mode with fixed restrictor type metering devices such as Check Flo Rater cap tube etc For units using TABLE 21 SUPERHEAT CHARGING TABLE
92. ly touching a jumper between the speed up terminals of the control board See Fig 33 and 34 The speed up feature will not bypass any other function or time delay HIGH VOLTAGE LOW VOLTAGE O LM LM2 DFTIDFT2 Ti T2 S2 S1 PW2 PWI 988 1 Pi 18 FURN INT NINE OFF ON SPEED UP STAGE 2 DEFROST BALANCE LATCH TIME POINT A93569 Fig 33 Two Speed Control Board TWO MINUTE LOW SPEED MINIMUM If the unit has not operated within the past 30 minutes the unit operates for a minimum of 2 minutes in low speed upon the next thermostat high or low demand 31 LM1 LM2 DFT1DFT2 T1 T2 S2 Si PW2 PW1 FURN INT SPEED UP STAGE2 DEFROST BALANCE LATCH TIME POINT A93568 Fig 34 Speedup Terminals CRANKCASE HEATER OPERATION The 2 speed control energizes the crankcase heater during the unit s off cycle when the outdoor ambient is below 75 F OUTDOOR FAN MOTOR OPERATION The 2 speed control energizes the outdoor fan any time the compressor is operating The outdoor fan remains energized during the 1 minute speed change time delay and if a pressure switch or compressor PTC overload should trip If the outdoor fan motor won t run check the header pin housing See Fig 37 There should be NO jumper wire between Terminals 15 and 16 Heat Pumps After the termination of a defrost cycl
93. m terminals C S and R 4 Place instrument probes together and determine probe and lead wire resistance Nn Check resistance readings from C R C S and R S 6 Subtract instrument probe and lead resistance from each reading If any reading is within 20 percent of known resistance motor is probably normal Usually a considerable difference in reading is noted if a turn to turn short is present Ill SYSTEM CLEANUP AFTER BURNOUT CAUTION Turn off all power to unit before proceed ing Wear safety glasses and gloves when handling refrigerants Acids formed as a result of motor burnout can cause burns NOTE To analyze level of suspected contamination from com pressor burnout use Total Test See your distributor branch Some compressor electrical failures can cause motor to overheat When this occurs by products which include sludge carbon and acids can contaminate system If burnout is severe enough system must be cleaned before replacement compressor is installed The 2 types of motor burnout are classified as mild or severe In mild burnout there is little or no detectable odor Compressor oil is clear or slightly discolored An acid test of compressor oil will be negative This type of failure is treated the same as mechanical failure Liquid line strainer should be removed and liquid line filter drier installed In a severe burnout there is a strong pungent rotten egg odor Compressor oil is very dar
94. mb to higher value Failure of meter to do this indicates an open capacitor If resistance stays at zero or a low value capacitor is inter nally shorted 2 Capacitance testers are available which read value of capacitor If value is not within 10 percent value stated on capacitor it should be changed If capacitor is not open or shorted the capacitance value is calculated by measuring voltage across capacitor and current it draws WARNING Exercise extreme caution when taking readings while power is on Electrical shock can cause personal injury or death jy A91455 Fig 12 Capacitors Use the following formula to calculate capacitance Capacitance mfd 2650 X amps divided by volts 3 Remove any capacitor that shows signs of bulging dents or leaking Do not apply power to a defective capacitor as it may explode START CAPACITORS AND PTC DEVICES Sometimes under adverse conditions a standard run capacitor in a system is inadequate to start compressor In these instances a start assist device is used to provide an extra starting boost to compressor motor The first device is called a positive temperature coefficient PTC or thermistor See Fig 13 It is a resistor wired in parallel with the run capacitor As current flows through the PTC at start up it heats up As it heats up its resistance increases greatly until it effectively lowers the current through it to an extremely low value This
95. mostat is closed and operating properly 9 Short between the speed up terminals using a thermostat screwdriver This reduces the timing sequence to 1 256 of original time See Fig 20 and Table 10 NOTE Fig 20 shows timing cycle set at 30 minutes however for the CES30110063 board the timing cycle will be set for 90 min and unit initiates defrost within approximately 21 sec When you hear the reversing valve change position remove screwdriver immediately Otherwise control will terminate normal 10 minute defrost cycle in approximately 2 sec ej CAUTION Exercise extreme caution when shorting speed up pins If pins are accidentally shorted to other terminals damage to the control board will occur 10 Unit is now operating in defrost mode Check between C and W2 using voltmeter as shown in Fig 21 Reading on voltmeter should indicate 24v This step ensures defrost relay contacts have closed energizing supplemental heat W2 and reversing valve solenoid O 11 Unit should remain in defrost no longer than 10 minutes Actual time in defrost depends on how quickly speed up jumper is removed If it takes 2 sec to remove speed up jumper after unit has switched to defrost the unit will switch back to heat mode 12 After a few minutes in defrost cooling operation liquid line should be warm enough to have caused defrost thermostat contacts to open Check resistance across defrost thermostat Ohmmeter should read infinite
96. ndoor coil wet bulb tem perature with a sling psychrometer 6 Locate outdoor temperature and evaporator entering air wet bulb temperature in Table 21 At this intersection note the superheat 7 Locate superheat temperature located in previous step and vapor pressure in Table 22 At this intersection note vapor line temperature 8 If unit has a higher vapor line temperature than charted temperature add refrigerant until charted temperature is reached 9 If unit has a lower vapor line temperature than charted temperature bleed refrigerant until charted temperature is reached 10 If outdoor air temperature or pressure at vapor valve changes charge to new vapor line temperature indicated on chart SUBCOOLING CHARGING METHOD 1 Operate unit a minimum of 15 minutes before checking charge TABLE 23 SUBCOOLING AT LIQUID SERVICE VALVE FOR UNITS PRODUCED THROUGH DECEMBER 1992 RELIANT AIR CONDITIONERS 591A 592A 593A 594A Series 014 018 024 030 036 038 042 048 060 698A Model 691A 692A Cooling Heating High Low High Low Series A B A A A A 014 018 16 16 024 16 16 030 20 20 036 14 14 042 18 18 048 19 14 MODEL 561A 571A 661A 671A Series 014 018 024 030
97. nformation esses 8 2 Speed Applications eesssssseeeseeeeeeeeeennennnennens 8 UNIT IDENTIFICATION n nennen 8 Product Number Stamped on Unit Rating Plate 8 Serial Number Identification esses 9 CABINET 5 2 5 atio e d UR e eee bati ders 10 Remove Top Cover Before 1 1 92 sss 10 Remove Fan Motor Assembly Before 1 1 92 10 Information Plate Reliant Products ssues 10 Control Box Cover Cube Products sussss 10 Remove Top Cover After 1 1 92 sess 10 Remove Fan Motor Assembly After 1 1 92 11 ELECTRICA Dania 1 eii nren n ed i e 12 Al min mi Wite eaaeo ei ene reed aeaea ta 12 Contactors esnan ddan t cse e a a 13 Capacitors eeen eeen a ae ree B eiras 14 Cycle Protector s eere anaE RARE ar 15 Crankcas Heater 4r ERE QU 16 Time Delay Rel y rrt ainean iinei eian 16 Pressure SWItCles 4 oes eere paese nene rove gi operose xe Ehe veds cases 17 Defrost Thermostats oo nes dette tdt oes 18 Defrost Control Board ccccccccccssscessccessecesscesssecesseeesseeenses 18 Service Manual AIR CONDITIONERS AND HEAT PUMPS USING R 22 REFRIGERANT Cancels AP01 3 SM01 02 4 SM01 02 5 10 00 F n Motors ee eere eerte teret etuer ee ves een o ea Ade
98. ng operation under low load conditions IV COMPRESSOR START ASSIST PTC Solid state electrical device which gives a soft boost to the compressor at each start V COMPRESSOR START ASSIST CAPACITOR RELAY Start capacitor and start relay gives hard boost to compressor motor at each start Required with Liquid Line Solenoid or hard shutoff TXV for all equipment VI LOW AMBIENT CONTROLLER Low ambient controller is a cycle control device activated by a temperature sensor mounted on a header tube of the outdoor coil It is designed to cycle the outdoor fan motor in order to maintain condensing temperature within normal operating limits approxi mately 100 F high and 60 F low The control will maintain working head pressure at low ambient temperatures down to 0 F when properly installed Vil MOTORMASTER CONTROL A fan speed control device activated by a temperature sensor It is designed to control condenser fan motor speed in response to the saturated condensing temperature during operation in cooling mode only For outdoor temperature down to 20 F it maintains condensing temperature at 100 F 10 F Requires a ball bearing fan motor Vill LOW AMBIENT PRESSURE SWITCH A long life pressure switch which is mounted to outdoor unit service valve It is designed to cycle the outdoor fan motor in response to condenser pressure in cooling mode in order to maintain head pressure within normal operating limits approxi
99. ns In this type of failure compressor motor runs and turns compres sor and compressor is pumping Usually an internal problem such as blown head gasket or broken internal discharge line causes compressor to pump hot discharge gas back into its own shell rather than through system Using pressure gages on service valves shows high suction and low discharge pressure readings Motor currents are lower than normal Because hot gas is being discharged into shell the shell becomes hot The hot gas causes compressor motor to cycle off on its internal protection RUNS AND PUMPS LOW CAPACITY This failure type is difficult to pinpoint because extent of damage varies Compressor is a pump with internal valves that enable compressor to pump properly The cylinder has a set of suction and discharge valves Any of these parts may become damaged or broken causing loss in pumping capacity Severity of damage determines amount of capacity loss Use pressure gages to find any abnormal system pressures if system charge and other conditions are normal An owner may complain that a unit is not handling the building s heating or cooling load The compressor current draw may be abnormally low or high Although this type of failure does occur all other possible causes of capacity loss must be eliminated before condemning compressor NOISY COMPRESSOR Noise may be caused by a variety of internal problems such as loosened hardware broken mounting spring
100. om lack of lubrication If bleed hole is plugged accumulator must be changed Bleed hole is so tiny that cleaning efforts are usually not successful The accumu lator has a fusible element located in the bottom end bell See Fig 51 This fusible element melts at 430 F and vents the refrigerant if this temperature is reached either internal or external to the system If fuse melts the accumulator must be replaced To change accumulator 1 Shut off all power to unit 2 Remove and reclaim all refrigerant from system NOTE Coil may be removed for access to accumulator Refer to appropriate sections of service manual for instructions A CAUTION Wear safety glasses and gloves when work ing on refrigerants and when using brazing torch 3 When accumulator is exposed remove it from system with tubing cutter 4 Scratch matching marks on tubing stubs and old accumu lator Scratch matching marks on new accumulator Un braze stubs from old accumulator and braze into new accumulator UA Thoroughly rinse any flux residue from joints and paint with corrosion resistant coating such as zinc rich paint 6 Reinstall accumulator into system with copper slip cou plings Evacuate and charge system 8 Pour and measure oil quantity if any from old accumula tor If more than 20 percent of oil charge is trapped in accumulator add oil to compressor to make up for this loss XII CONTAMINANT REMOVAL Proper evacuation of a
101. on This is the safety alert symbol N When you see this symbol on the unit and in instructions or manuals be alert to the potential for personal injury Understand the signal words DANGER WARNING and CAU TION These words are used with the safety alert symbol DAN GER identifies the most serious hazards which will result in severe personal injury or death WARNING signifies hazards which could result in personal injury or death CAUTION is used to identify unsafe practices which would result in minor personal injury or product and property damage NOTE is used to highlight suggestions which will result in enhanced installation reliability or operation WARNING Improper installation adjustment alter ation service maintenance or use can cause explosion fire electrical shock or other conditions which may cause personal injury death or property damage Consult a qualified installer service agency or your distributor or branch for information or assistance The qualified in staller or agency must use factory authorized kits or accessories when modifying this product INTRODUCTION This service manual enables a service technician to service repair and maintain a family of similar air conditioners and heat pumps It covers standard single speed products and 2 speed products only For variable speed products refer to the respective service manuals INSTALLATION GUIDELINE l RESIDENTIAL NEW CONSTRUCTION Specificat
102. on clean all parts and stripped wires and reassemble Use a new connector if old one is burned or corroded and crimp tightly CAUTION Coil fin damage can result in higher oper ating costs or compressor damage Do not use flame high pressure water steam or volatile or corrosive clean ers on fins or tubing 3 Reconnect electrical power to the indoor and outdoor units and observe unit through 1 complete operating cycle 2 Clean coil using vacuum cleaner and its crevice tool Move 4 crevice tool vertically close to area being cleaned making sure tool touches only the dirt on the fins and not the fins To prevent fin damage do not scrub fins with tool or move If there are any discrepancies in the operating cycle troubleshoot to find the cause and correct REFRIGERANT CIRCUIT tool horizontally against fins 1 Check the refrigerant charge using the superheat or sub 3 If oil deposits are present spray coil with ordinary house cooling method whichever is applicable If low on charge hold detergent Wait 10 minutes and proceed to next step check unit for leaks using an electronic leak detector 4 Using garden hose spray coil vertically downward with 2 If any leaks are found recover or isolate charge pump constant stream of water at moderate pressure Keep nozzle down if applicable and make necessary repairs at a 15 to 20 angle about 3 in from coil face and 18 in SE te recharge and Ir it through en
103. ons 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 1 Superheat temperature sensed by cap tube sensing bulb on suction tube at outlet of evaporator coil As long as this bulb and cap tube contains some liquid refrigerant this tempera ture is converted into suction pressure pushing downward on the diaphragm which tends to open the valve via the pushrods 2 The suction pressure at the outlet of the evaporator coil is transferred via the external equalizer tube to the underside of the diaphragm 3 The needle valve on the pin Bryant is spring loaded which also exerts pressure on the underside of the diaphragm via the pushrods which tends to close the valve Therefore bulb pressure equals evaporator pressure at outlet of coil plus spring pressure If the load increases the temperature increases at the bulb which increases the pressure on the topside of the diaphragm which pushes the pin Bryant away from the seat opening the valve and increasing the flow of refrigerant The increased refrigerant flow causes Ay 2 Speed Indoor Unit increased leaving evaporator pressure which is transferred via the equalizer tube to the underside of the diaphragm This tends to cause the pin Bryant spring pressure to close the valve The refrigerant flow is effectively stabilized to the load demand with negligible change in superh
104. or thermostat subbase is required Service alarm requires 2 inputs 1 It must sense a 24v input from thermostat As thermostat calls for heating or cooling it supplies 24v to service alarm device 2 A current transformer or induction loop similar to a clamp on ammeter senses current draw in the compressor lead Induction loop must sense a minimum current draw when thermostat is calling for heating or cooling NOTE On a single phase compressor induction loop senses current in common leg On a 3 phase compressor induction loop senses current in any 1 of the phases WARNING If service alarm needs replacing shut off all power to unit before attempting removal Electrical shock can cause personal injury or death Troubleshooting service alarm device is easy With thermostat calling for heating or cooling and compressor running indoor thermostat light should be off If on check for wiring errors or replace the service alarm To check for correct operation shut off circuit breaker or discon nect switch to outdoor unit while it is running Signal light on thermostat should light If this does not occur check for wiring errors or replace the service alarm XII OUTDOOR THERMOSTAT S The outdoor thermostat s is installed in the control box The sensing bulb s remain in the control box Outdoor thermostat brings on stages of electric heat as outdoor temperature and TABLE 12 FAN POSITION AEROQUIET SYSTEM AND AEROMAX TO
105. overheating pressure equalization occurs within approximately 1 to 2 minutes TABLE 20 TXV SUPERHEAT SETTING AT OUTLET OF EVAPORATOR COIL PRODUCT USAGE Air Conditioner Indoor Unit SUPERHEAT SETTING Heat Pump Indoor Unit Indoor Fan Coil Unit 2 Speed Heat Pump Outdoor Unit INSTALLATION TXV TYPE Field Accessory RPB HSO Field Accessory RPB HSO Field Accessory Factory Installed HSO Factory Installed HSO Factory Shipped Field Installed HSO FROM V TO INDOOR COIL A MULATOR OUTDOOR SEU 2 VIA SERVICE VALVE COIL ON OUTDOOR COIL INSULATE FOR TP 3 e ACCURATE READING TP 4 INSULATE FOR ACCURATE READING FROM COMPRESSOR DISCHARGE LINE ELECTRONIC THERMOMETER A88341 Fig 48 Reversing Valve Heating Mode Solenoid De Energized Hard Shutoff HSO Has no bleed port and allows no bleed through after system shutdown No pressure equalization occurs Because of unequalized system pressures a start capacitor and relay must be installed on single phase reciprocating compressors to start the compressor See Table 20 for TXV superheat settings These settings are factory set and are not field adjustable Table 17 settings are for Bryant approved accessories and factory installed TXVs only VII THERMOSTATIC EXPANSION VALVE BI FLOW TXV The standard TXV is a metering device that is used in condensing and heat pump systems to adjust to changing load conditi
106. replace electrome chanical timer and defrost relay found on older defrost systems The defrost control board can be field set to check need for defrost every 30 50 or 90 minutes of operating time by connecting the jumper labeled W1 on the circuit board to the terminal for the defrost time desired The board is set at factory for 90 minutes The defrost period is field selectable depending upon geographic areas and defrost demands Two types of defrost boards are used and functions are described in the sections to follow Troubleshooting defrost control involves a series of simple steps that indicate whether or not board is defective NOTE This procedure allows the service technician to check control board and defrost thermostat for defects First troubleshoot to make sure unit operates properly in heating and cooling modes This ensures operational problems are not attributed to the defrost control board HK32FA003 006 DEFROST CONTROL This control board utilizes screw terminals for the low voltage field wiring The board has a feature that allows the heat pump to restart in defrost if room thermostat is satisfied during defrost To troubleshoot the board perform the following items 1 Turn thermostat to OFF Shut off all power to outdoor unit 2 Remove control box cover for access to electrical compo nents and defrost control board 3 Disconnect defrost thermostat leads from control board and connect to ohmmeter Thermostat
107. resistance indi cating defrost thermostat has opened at approximately 80 F O O O OF1 OF2 Ge OF1 EO 14 qe q o o o q o Li qa o o o q o u u s n u u n u n u u u u O R T2 Y TI DFT in c TEST 30 50 90 PME a wij e popo o R wa HK32FA003 HK32FA006 CES0110063 A88404 CES0130024 A91444 Fig 20 Inserting Jumper Wire d s JU 00 5 q aad F OR T2 Y TUBE Ee n Iouis ILII i i O aged o HK32FA003 HK32FA006 R w2 A88403 me md CESO1 10068 CES0130024 A91443 Fig 21 Checking Between C and W2 13 Shut off unit power and reconnect fan lead TABLE 10 DEFROST CONTROL SPEED UP TIMING SE 14 Remove jumper between DFT and R terminals Reconnect QUENCE FOR CES0110063 CES0130024 defrost thermostat leads Failure to remove jumper causes unit to switch to defrost every 30 50 or 90 minutes and PARAMETER MINIMUM MAXIMUM NOMAD remain in defrost for full 10 minutes 30 minute cycle 15 Replace control box cover Restore power to unit 50 minute cycle If defrost thermostat does not check out following above items or 90 minute cycle incorrect calibr
108. rough internal pressure relief valve indicated by sudden rise of suction pressure before suction pressure reaches 5 psig 35kPa If this occurs shut off unit immediately front seat suction valve and recover remain ing pressure V CHECK FLO RATER BYPASS TYPE HEAT PUMPS ONLY REFRIGERANT METERING HOLE THROUGH IT THE RETAINER FORMS A STOP FOR PISTON IN REFRIGERANT BYPASS MODE AND A SEAL ING SURFACE FOR LIQUID LINE FLARE CONNECTION SEE FIG 45 TO CHECK CLEAN OR REPLACE PIS TON RELIANT PRODUCTS EXCEPT 1992 PRODUCTION 1 Shut off power to unit 2 Pump unit down using pumpdown procedure described in this service manual 3 Loosen nut and remove liquid line flare connection from Check Flo Rater M 4 Pull retainer out of body being careful not to scratch flare sealing surface If retainer does not pull out easily carefully use locking pliers to remove it 5 Slide piston out by inserting a small soft wire with small kinks through metering hole Do not damage metering hole sealing surface around piston cones or fluted portion of piston 6 Clean piston refrigerant metering hole 7 Install a new retainer O ring or retainer assembly before reassembling bypass type Check Flo Rater M RELIANT AND CUBE PRODUCTS PRODUCED IN 1992 1 Shut off power to unit 2 Reclaim outdoor unit refrigerant 3 Loosen brass hex nut and remove line from brass hex body 4 Slide piston out by inserting a small soft wire with sma
109. s etc System prob lems such as overcharged compressor especially at start up or too much oil in compressor may also cause excessive noise Excess oil in compressor is normally encountered only after a replacement compressor has been added without purging oil from previous compressor As new compressor pumps excess oil in system returns and adds to volume already present causing noise COMPRESSOR LEAKS A CAUTION Use safety glasses and gloves when han dling refrigerants Sometimes a leak is detected at weld seam around girth of compressor or a fitting that joins compressor shell Many of these leaks can be repaired and the compressor saved if correct proce dure is followed 1 Turn off all power to unit 26 2 Remove and recover all refrigerant from system so that gage pressures are 0 psi 3 Clean area around leak to bare metal 4 Apply flux and repair joint with silver solder Do not use low temperature solder such as 50 50 5 Clean off excess flux check for leaks and apply paint over repaired area to prevent corrosion Do not use this method to repair a compressor leak due to severe corrosion Never attempt to repair a compressor leaking at electric terminals This type of failure requires compressor replacement ll ELECTRICAL FAILURES The compressor mechanical pump is driven by an electric motor within its hermetic shell In electrical failures compressor does not run although external electrical and m
110. s necessary but clean at least once each heating heat pump CARE AND MAINTENANCE only and cooling season To assure high performance and minimize possible equipment 2 Check fan motor and blade for cleanliness each heating and malfunction it is essential that maintenance be performed periodi cooling season and clean as necessary TABLE 24 REQUIRED LIQUID LINE TEMPERATURE PRESSURE PSIG REQUIRED SUBCOOLING TEMPERATURE F AT SERVICE FITTING 134 141 148 156 163 171 179 187 196 205 3 Check electrical connections for tightness and controls for 3 Check fan blade setscrew for tightness proper operation each heating heat pump only or cooling 4 Reinstall fan motor and blade to top cover and check for season and service as necessary alignment CAUTION Because of possible damage to the equip 5 Reinstall top cover and position blade as per Fig 24 A ment or personal injury maintenance should be per 6 formed By qu litiedtdersdanel only Reconnect electrical power and check for proper operation ELECTRICAL CONTROLS AND WIRING 1 Disconnect power to both the outdoor and indoor units COIL CLEANING 1 Remove top cover See Remove Top Cover section 2 Check all electrical connections for tightness Tighten all screws on electrical connections If any connections appear to be burned or smoky disassemble the connecti
111. sing this option to stage electric heat first stage is energized by a W2 demand and second stage is energized by a W3 demand Select the W3 desired temperature by rotating the balance point POT See Fig 34 Temperatures that may be selected are 10 15 20 25 30 35 40 and 45 F The POT is factory set at 45 F LOW SPEED HEATING WITH AUXILIARY HEAT If the system is operating in low speed heating and there is a demand for auxiliary heat W2 the system changes to high speed operation W2 is energized unless the low voltage control wiring is configured as described in Fig 36 TWO SPEED FAN TWO SPEED THERMOSTAT COIL HEAT PUMP we Wie Asm tunt we T l W3 J CONTROL i H 6cic i W3 I A93572 Fig 36 Low Voltage Control Wiring AUXILIARY HEAT W2 LOCKOUT In some areas it is necessary to disable the auxiliary heat except for defrost until the outdoor ambient is less than the structure s balance point This is accomplished by using the low voltage wiring as shown in Fig 36 Wire the 24vac W2 signal from the indoor thermostat to W3 of the control and W2 of the control to W2 of the indoor unit When the outdoor ambient is less than the setting of the balance point POT the 24vac signal energizes the auxiliary heat W2 of the indoor unit EMERGENCY HEAT If the 2 speed control receives a call for auxiliary heat W2 without a heat pump heating Y1 cal
112. stalled in long line applications must use only 3 8 in liquid lines Equivalent line length equals the linear length measured of interconnecting vapor tubing plus losses due to elbows See Table 5 and Fig 3 Liquid lines larger than 3 8 in OD greatly increase charge quantity of the system Excessive charge increases risk of migration and compressor damage Table 4 provides the estimated percentage of nominal cooling capacity losses based on the stan dard required vapor line size versus what is selected for the long line application Since the vapor line is the discharge line in heating mode losses are minimal 114 x lg 5 56 x 9 53 SLOT Z 4 REQ D m g 3 45 DIA HOLE 2 REQ D Y i P H __ gt l jy 5 5 16 9 6 l J 151 5 A 1 4 5 56 DIA HOLE 2 REQ D PY he G y 1 12 7 SUPPORT TYP MAT L 18 GA STEEL C t The 11 6 l a lt _e A E a 12 7 1 8 3 45 DIA HOLE 1 REQD K B The J mii 11 6 Lr 1 4 5 56 DIA HOLE ye REQ D Y 2L 6 Uu 3 8 9 6 152 4 6 3 e L e D 17 x2 BAFFLE 5 56 x 50 8 SLOT MAT L 20 GA STEEL SCREW 10 REQ D SUPPORT 4 REQD OUTDOOR 22 BAFFLE UNIT 2 REQ D BAFFLE ASSEMBLY A95
113. te If compressor draws locked rotor amps and all other external sources of problems have been eliminated compressor must be replaced Because compressor is a sealed unit it is impossible to determine exact mechanical failure However complete system should be checked for abnormalities such as incorrect refrigerant charge restrictions insufficient airflow across indoor or outdoor coil and so forth which could be contributing to the failure RUNS DOES NOT PUMP In this type of failure compressor motor runs and turns compres sor but compressor does not pump the refrigerant A clamp on ammeter on common leg of a single phase compressor or any 1 lead of a 3 phase compressor shows a very low current draw much lower than RLA rated load amps value stamped on compressor nameplate Because no refrigerant is being pumped there is no return gas to cool compressor motor It eventually overheats and shuts off on its internal protection RUNS DOES NOT PUMP HIGH TO LOW SIDE LEAK e EXAMPLE e H e POWER OFF DEDUCTION TO DETERMINE INTERNAL CONNECTIONS OF SINGLE PHASE MOTORS C S R EXCEPT SHADED POLE GREATEST RESISTANCE 5 80 OHM SMALLEST RESISTANCE 0 60 REMAINING RESISTANCE 5 20 RUN WINDING R START WINDING S 2 is COMMON C BY ELIMINATION 2 is COMMON THEREFORE O IS START WINDING S 3 IS RUN WINDING R A88344 Fig 28 Identifying Internal Connectio
114. tection is not required Troubleshooting this control will be the same as the CES0110063 control except for the cycle protector function The CES0130024 control is identical to the CESO110063 except the T2 terminal and cycle protector logic have been removed CES0130076 DEFROST CONTROL This defrost control is the same size as the CES0130063 control but is not backwards compatible See Fig 22 To upgrade to the new control you must have replacement defrost thermostat and harness kit See your replacement component representative for kit part number Defrost Settings The defrost control is a time temperature control which includes a field selectable time period DIP switch 1 and 2 on board see Table 11 between defrost cycles of 30 60 90 and 120 minutes factory set at 90 minutes TABLE 11 DEFROST TIMER SETTINGS To initiate a forced defrost two options are available depending on the status of the defrost thermostat If defrost thermostat is closed speedup pins J1 must be shorted by placing a Flathead screwdriver in between for 5 seconds and releasing to observe a complete defrost cycle When the Quiet Shift switch is selected compressor will be turned off for two 30 second intervals during this complete defrost cycle When Quiet Shift switch is in factory default OFF position a normal and complete defrost cycle will be observed If defrost thermostat is in open position and speedup pins are shorte
115. th 2 female 1 4 in quick connects Connect terminals to new solenoid and tape connection to insulate and provide moisture barrier Replace these wires as soon as wire cord is available See RCD Replacement Component Catalog for proper cord part number FROM INDOOR COIL VIA SERVICE VALVE ON OUTDOOR COIL TO OUTDOOR COIL TO ACCUMULATOR 3 Remove solenoid coil from valve body Remove valve by EROM COMPRESSOR cutting it from system with tubing cutter Repair person DISCHARGE LINE should cut in such a way that stubs can be easily rebrazed back into system Do not use hacksaw This introduces chips into system that cause failure After defective valve is Fig 47 Reversing Valve Cooling Mode or Defrost removed wrap it in wet rag and carefully unbraze stubs Mode Solenoid Energized Save stubs for future use Because defective valve is not overheated it can be analyzed for cause of failure when it is returned VII THERMOSTATIC EXPANSION VALVES TXV The types of TXVs used in condensing unit and heat pump systems are as follows A88342 4 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 Rapid Pressure Balance RPB Has a special bleed port that new valve properly When brazing stubs into valve protect allows rapid bleed through of pressure after system shutdown until valve body with wet rag to prevent
116. ti le from tube Spray so debris is washed out of coil and 3 Ev ctate recharge QUO LODS cals unit TORRE cmb cycle FINAL CHECKOUT basepan 5 Restore power to unit After the unit has been operating the following items should be CLEANING OUTDOOR FAN MOTOR AND BLADE checked 1 Remove fan motor and blade Refer to Remove Fan Motor 1 Check that unit operational noise is not excessive due to Assembly section of this manual Be careful not to bend or vibration of components tubing panels etc If present dent fan blade isolate problem and correct 2 Clean motor and blade with soft brush or cloth Be careful 2 Check to be sure caps are installed on service valves and not to disturb balance weights on fan blade that they are tight 46 3 Check to be sure tools loose parts and debris are removed 3 Addition of coastal filter see pre sale literature for acces from the unit sory listing 4 Check to be sure all panels and screws are in place and Special maintenance requirements are as follows tight 1 Frequent inspection of coil and base pan especially after Desert and Seacoast Locations storms and or high winds Special consideration must be given to the installation and main tenance of condensing units and heat pumps installed in seacoast 2 Cleaning coil by flushing out sand from between coil fins or desert locations Salt and the alkali content of the sand adhere and out of base pan as frequently as insp
117. tion If rotation is correct unit will continue to run If rotation is incorrect the control will break the 24vac power at the contactor and an LED light on the control will flash If LED is flashing turn off power reverse L1 and L3 field power leads and restart unit This control will check incoming power at every restart TWO SPEED SYSTEM I CAUTIONS AND WARNINGS CAUTION For proper unit operation and reliability the 2 speed units must be installed with the factory supplied balance port hard shutoff TXV Do not install with indoor coils having piston or capillary tube metering devices CAUTION Do not install equivalent interconnecting tubing lengths greater than 100 ft Do not decrease or increase interconnecting tubing diameters CAUTION To avoid electrical shock bleed resistor must be connected across run capacitor Replace if missing or damaged CAUTION Contactor is mechanically interlocked Do not disable mechanical interlock Compressor damage may occur A WARNING Contactor control voltage is 240vac WARNING Do not attempt to operate this equipment below 55 F outdoor ambient temperature NOTE Sections that follow describe the 598A Series B and 698A Series B products which started production March 1994 For 598A Series A and 698A Series A products refer to the Split System Service Manual dated 3 1 94 Catalog No BDP 3356 115 ll SYSTEM FUNCTIONS COOLING OPERATION The 2 speed products utiliz
118. unit 7 Reverse sequence for reassembly ll R EMOVE FAN MOTOR ASSEMBLY BEFORE 1 1 92 NOTE This section applies to all Reliant products made prior to January 1 1992 1 2 3 4 5 Perform items 1 through 6 above Remove nuts holding fan motor top cover Remove motor and fan blade assembly Reverse sequence for reassembly Prior to applying power check that fan rotates freely 10 Ill INFORMATION PLATE RELIANT PRODUCTS The information plate is secured to the front of the control box and provides a cover for it See Fig 9 This plate also provides a surface to attach the wiring schematic superheat charging tables with instructions and warning labels The plate has 2 tabs on the top edge that are bent down at slightly more than 90 When the information plate is removed these tabs can be inserted into 2 mating slots in the bottom front edge of the control box and the plate will hang down forming a lower front panel See Fig 10 This is convenient where access to the controls is required while the unit is operating The information plate on the small size casing completely covers the opening below the control box On larger models the information plate may not cover the entire opening In this instance the top cover can be removed and placed on its side to cover the additional space IV CONTROL BOX COVER CUBE PRODUCTS This panel contains much of the same information as the informa
119. ven indoor outdoor combination TVapor line diameter that may be selected for a long line application If smaller vapor lines are selected but not specified within the table large capacity losses will occur and defrost capabilities will be reduced If larger vapor lines are selected but not specified within the table refrigerant oil return will be impaired due to velocity losses N R Not recommended due to excessive loss of capacity For reference only the close cell insulation material specified for accessory tubing kits is a compound of vinyl neoprene or nitrile blends of these polymers Performance requirements include thermal range of 0 F to 200 F 17 8 C to 93 C and a maximum thermal conductivity of 0 28 lines and installed system design indoor coil above or below outdoor unit The piston or TXV provides such flexibility The piston should be changed for both indoor coil and outdoor heat pump unit depending on system configuration and line length Tables 6 and 7 provide necessary changes for a given application NOTE Special consideration must be given to isolating intercon necting tubing from building structure Isolate tubing so that vibration or noise is not transmitted into structure Ill METERING DEVICE SIZING The metering device for a long line application must be flexible enough to compensate for frictional losses due to long refrigerant egt Use Tables 6 and 7 when selecting correct piston size Outdoor
120. witch If system pressure is below 435 psi the switch shows continuity It is replaced in the same manner as low pressure switch Observe all safety precautions LIQUID LINE PRESSURE SWITCH Located on liquid line of heat pump only the liquid line pressure switch functions similar to conventional low pressure switch Because heat pumps experience very low suction pressures during normal system operation a conventional low pressure switch cannot be installed on suction line This switch is installed in liquid line instead and acts as loss of charge protector The liquid line is the low side of the system in heating mode It operates identically to low pressure switch except it opens at 7 psi when the heating piston is in the liquid valve or 27 psi when the heating piston is in the liquid line Troubleshooting and removing this switch is identical to procedures used on other switches Observe same safety precautions Vill DEFROST THERMOSTATS Defrost thermostat signals heat pump that conditions are right for defrost or that conditions have changed to terminate defrost It is a thermally actuated switch clamped to outdoor coil to sense its temperature Normal temperature range is closed at 30 3 F and open at 80 5 F NOTE The defrost thermostat must be located on the liquid side of the outdoor coil on the bottom circuit and as close to the coil as possible IX DEFROST CONTROL BOARD Solid state defrost boards used on heat pumps

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