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RESIDENTIAL AIR CONDITIONERS AND HEAT PUMPS
USING R- -22 AND PURONR REFRIGERANT
Application Guideline
and Service Manual
TABLE OF CONTENTS
PAGE PAGE
UNIT IDENTIFICATION ............................. 2 MAKE PIPING CONNECTIONS ...................... 30
SAFETY CONSIDERATIONS ......................... 3 REFRIGERATION SYSTEM REPAIR ............... 31--33
INTRODUCTION ................................... 3 Leak Detection .................................. 31
INSTALLATION GUIDELINE .....................
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TABLE OF CONTENTS (CONTINUED) TWO STAGE NON--COMMUNICATING Airflow Selection for VS Furnaces (non--comm) ........... 70 127A / 226A .................................... 67--69 Airflow Selection for FV4C Fan Coils Using Non--Comm OPERATING AMBIENT ............................. 67 (Non--Evolution) Thermostats ......................... 70 Airflow Selections (ECM Furnaces) ..................... 67 GENERAL INFORMATION ....................... 71--72 Airflow Selection for Variable Speed Furnaces CHECK
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SAFETY CONSIDERATIONS INSTALLATION GUIDELINE Installation, service, and repair of these units should be attempted Residential New Construction only by trained service technicians familiar with standard service Specifications for these units in the residential new construction instruction and training material. market require the outdoor unit, indoor unit, refrigerant tubing sets, All equipment should be installed in accordance with accepted metering device, and filter drier listed in Product Dat
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ACCESSORIES Table 1—Required Field--Installed Accessories for Air Conditioners REQUIREDFOR REQUIREDFORLOW---AMBIENT REQUIREDFOR SEACOAST ACCESSORY COOLING APPLICATIONS LONG LINEAPPLICA- APPLICATIONS (Below55 °F/12.8_C) TIONS* (Within2miles/3.22km) BallBearing FanMotor Yes{} No No CompressorStartAssistCapacitorandRelay Yes** Yes No Crankcase Heater Yes} Yes} No EvaporatorFreezeThermostat Yes} No No Hard Shut---Off TXV Yes Yes Yes LiquidLineSolenoidValve No No No ® MotorMaster orLow---ambientPress
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ACCESSORY DESCRIPTIONS Refer to Table 1 for an Accessory Usage Guide for Air 6. Thermostatic Expansion Valve (TXV) Conditioners and Table 2 for Heat Pumps. Refer to the appropriate A modulating flow--control valve which meters refrigerant liquid section below for a description of each accessory and its use. flow rate into the evaporator in response to the superheat of the 1. Crankcase Heater refrigerant gas leaving the evaporator. An electric resistance heater which mounts to the base of the Kit
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LOW--AMBIENT COOLING GUIDELINE The minimum operating temperature for these units in cooling through Legacy Line models and Fig. 2 for Deluxe models. First mode is 55_F/12.7_C outdoor ambient without additional production of Preferred Series units are capable of low ambient accessories. This equipment may be operated in cooling mode at cooling only with pressure switch or Evolution UI control. Motor ambient temperatures below 55_F/12.7_C when the accessories Master was not available. See most cur
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BAFFLE-1 MA TL: 20 GA STEEL A06230 3SidedDeluxeUnits(in.) UNIT AA UNITHEIGHT A B C D E F G H SIZE 29---1/2 23---13/16 11---7/8 32---15/16 27---3/16 13---5/8 36---5/16 30---5/8 15---5/16 Medium 33 16 81.9 16---3/8 80.3 12---3/4 45---7/8 39---3/4 34 17 43---1/8 37---3/8 18---11/16 46---1/2 40---13/16 20---3/8 30---5/16 23---13/16 11---7/8 33---11/16 27---3/16 13---5/8 37---1/8 30---5/8 15---5/16 Large 40 22---5/16 80.2 16---11/16 78.8 17---3/8 51---1/16 40---1/2 34 17 43---7/8 37---3/8 18---11/16
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LONG LINE GUIDELINE CABINET ASSEMBLY Refer to Residential Piping and Long Line Guideline for air Basic Cabinet Designs conditioner and heat pump systems using Puron refrigerant or Certain maintenance routines and repairs require removal of the Long Line Guideline for R--22 Air Conditioners and Heat Pumps. cabinet panels. There are 3 basic cabinet designs for air conditioning and heat pumps. Each design tier has options of standard or dense grills. (See Fig. 3). Evolution 2---Stage Preferred Evol
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Access Compressor Or Other Internal Cabinet Components NOTE: It is not necessary to remove the top cover to gain access. Remove Fan Motor Assembly -- Mid--Tier / Deluxe Removing the top cover may cause grill panels, corner posts, 1. Perform items 1 through 6 from above. louvers or coils to be damaged. It is recommended to protect the 2. Remove nuts securing fan motor to top cover. top cover from damage of tools, belt buckles, etc. while servicing 3. Remove motor and fan blade assembly. from the
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Legacy RNC and Legacy Line AC Control Box Legacy RNC and Legacy Line HP Control Box Fig. 4 – Legacy RNC and Legacy Line Control Box Identification 10
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Labeling The wiring schematic, sub--cooling charging tables with instructions, and warning labels. Refer to Fig. 5 for label location. Fig. 5 – Figure Labels 11
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3. Reconnect leads and apply low--voltage power to contactor ELECTRICAL coil. This may be done by leaving high--voltage power to outdoor unit off and turning thermostat to cooling. Check ! voltage at coil with voltmeter. Reading should be between WARNING 20v and 30v. Contactor should pull in if voltage is correct ELECTRICAL SHOCK HAZARD and coil is good. If contactor does not pull in, replace contactor. Failure to follow this warning could result in personal injury or death. 4. With high--voltag
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Use following formula to calculate capacitance: With high--voltage power off, attach voltmeter leads across T1 and T3, and set thermostat so that Y terminal is energized. Make sure Capacitance (mfd)= (2650 X amps)/volts all protective devices in series with Y terminal are closed. 3. Remove any capacitor that shows signs of bulging, dents, or Voltmeter should read 24v across T1 and T3. With 24v still leaking. Do not apply power to a defective capacitor as it applied, move voltmeter leads to T2 an
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High--Pressure Switch (AC & HP) Pressure Switches The high--pressure switch is located in liquid line and protects Pressure switches are protective devices wired into control circuit against excessive condenser coil pressure. It opens around 610 or (low voltage). They shut off compressor if abnormally high or low 670 psig for Puron and 400 psig for R22 (+/-- 10 for both). pressures are present in the refrigeration circuit. Puron pressure Switches close at 298 (+/-- 20) psig for R--22 and 420 or
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Heating Sequence of Operation Defrost Thermostat On a call for heating, thermostat makes R--Y, and R--G. Circuit Defrost thermostat signals heat pump that conditions are right for R--Y sends low voltage through the safeties and energizes the defrost or that conditions have changed to terminate defrost. It is a contactor, which starts the compressor and energizes the T1 thermally actuated switch clamped to outdoor coil to sense its terminal on the circuit board. The T1 terminal energizes the defr
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Troubleshooting (HK32EA001) 3. If all voltages are present and unit will still not run defrost, remove thermostat pigtail harness from board and perform If outdoor unit will not run: checks directly on input pins with jumper wires. The pigtail 1. Does the Y input has 24 volts from thermostat? If not, may have a bad connection or be mis--wired. check thermostat or wire. If yes proceed to #2 To fully troubleshoot defrost thermostat and control function 2. The Y spade terminal on the circuit board
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OF1 OF2 ON 120 30 60 QUIET SHIFT 60 30 90 INTERVAL TIMER OFF P3 DFT T2 C C O T1 Y P1 DFT J1 O R W Y C SPEEDUP 2 14. Remove jumper between DFT and R terminals. Reconnect Quiet Shift defrost thermostat leads. Failure to remove jumper causes This control has the option of shutting down the compressor for 30 unit to switch to defrost every 30, 60, or 90 minutes and seconds going in and coming out of defrost. This is accomplished remain in defrost for full 10 minutes. by turning DIP switch
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Deluxe Defrost Speedup (HK32EA003 CONT.) Fan Motor To initiate a force defrost, speedup pins (J1) must be shorted with a The fan motor rotates the fan blade that draws air through the flat head screwdriver for 5 seconds and RELEASED. If the defrost outdoor coil to exchange heat between the refrigerant and the air. thermostat is open, a short defrost cycle will be observed (actual Motors are totally enclosed to increase reliability. This eliminates length depends on Quiet Shift switch position).
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Compressor Failures COPELAND SCROLL COMPRESSOR Compressor failures are classified in 2 broad failure categories; mechanical and electrical. Both types are discussed below. Mechanical Failures Scroll Gas Flow A compressor is a mechanical pump driven by an electric motor Compression in the scroll is contained in a welded or hermetic shell. In a mechanical failure, created by the interaction of an orbiting spiral and a motor or electrical circuit appears normal, but compressor does not stationary
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Noisy Compressor 10. When a heat pump switches into and out of defrost, a ”swooshing” noise is expected due to the rapid pressure Noise may be caused by a variety of internal and external factors. change within the system. However customers sometimes Careful attention to the “type” of noise may help identify the complain that the noise is excessive, or it is sometimes source. The following are some examples of abnormal conditions accompanied by a ”groaning, or howling” noise. When that may creat
