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 . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (CONTINUED) TWO STAGE NON--COMMUNICATING 127A / 226A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67--69 Airflow Selection for VS Furnaces (non--comm) . . . . . . . . . . . 70 OPERATING AMBIENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Airflow Selection for FV4C Fan Coils Using Non--Comm (Non--Evolution) Thermostats . . . . . . . . . . . . . . . . . . . . . . . . . 70 Airflow Selections (ECM Furnaces) . . . . . . . . . . . . . . . . . . . .
SAFETY CONSIDERATIONS INSTALLATION GUIDELINE Installation, service, and repair of these units should be attempted only by trained service technicians familiar with standard service instruction and training material. All equipment should be installed in accordance 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.
ACCESSORIES Table 1—Required Field--Installed Accessories for Air Conditioners ACCESSORY REQUIRED FOR LOW --- AMBIENT COOLING APPLICATIONS (Below 55°F/12.8_C) REQUIRED FOR LONG LINE APPLICATIONS* REQUIRED FOR SEA COAST APPLICATIONS (Within 2 miles/3.
ACCESSORY DESCRIPTIONS Refer to Table 1 for an Accessory Usage Guide for Air Conditioners and Table 2 for Heat Pumps. Refer to the appropriate section below for a description of each accessory and its use. 1. Crankcase Heater An electric resistance heater which mounts to the base of the compressor to keep the lubricant warm during off cycles. Improves compressor lubrication on restart and minimizes the chance of liquid slugging. Usage Guideline: Required in low ambient cooling applications.
LOW--AMBIENT COOLING GUIDELINE The minimum operating temperature for these units in cooling mode is 55_F/12.7_C outdoor ambient without additional accessories. This equipment may be operated in cooling mode at ambient temperatures below 55_F/12.7_C when the accessories listed in Table 1 or 2 are installed. Wind baffles are required when operating in cooling mode at ambients below 55_F/12.7_C. Refer to Fig. 1 for wind baffle construction details for Legacy RNC through Legacy Line models and Fig.
BAFFLE-1 MA TL: 20 GA STEEL A06230 3 Sided Deluxe Units (in.) UNIT SIZE AA Medium 33 Large 40 UNIT HEIGHT A B 29--- 1/2 32--- 15/16 36--- 5/16 39--- 3/4 43--- 1/8 46--- 1/2 30--- 5/16 33--- 11/16 37--- 1/8 40--- 1/2 43--- 7/8 47--- 5/16 23--- 13/16 27--- 3/16 30--- 5/8 34 37--- 3/8 40--- 13/16 23--- 13/16 27--- 3/16 30--- 5/8 34 37--- 3/8 40--- 13/16 11--- 7/8 13--- 5/8 15--- 5/16 17 18--- 11/16 20--- 3/8 11--- 7/8 13--- 5/8 15--- 5/16 17 18--- 11/16 20--- 3/8 C D E F G H 16 81.
LONG LINE GUIDELINE CABINET ASSEMBLY Refer to Residential Piping and Long Line Guideline for air conditioner and heat pump systems using Puron refrigerant or Long Line Guideline for R--22 Air Conditioners and Heat Pumps. Basic Cabinet Designs Certain maintenance routines and repairs require removal of the 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).
Access Compressor Or Other Internal Cabinet Components NOTE: It is not necessary to remove the top cover to gain access. Removing the top cover may cause grill panels, corner posts, louvers or coils to be damaged. It is recommended to protect the top cover from damage of tools, belt buckles, etc. while servicing from the top. 1. Should the unit height allow components to be accessed from the top of the unit, follow procedures for removing fan motor assembly. Access components through the top cap. 2.
Legacy RNC and Legacy Line AC Control Box Legacy RNC and Legacy Line HP Control Box Fig.
Labeling The wiring schematic, sub--cooling charging tables with instructions, and warning labels. Refer to Fig. 5 for label location. Fig.
ELECTRICAL ! 3. Reconnect leads and apply low--voltage power to contactor coil. This may be done by leaving high--voltage power to outdoor unit off and turning thermostat to cooling. Check voltage at coil with voltmeter. Reading should be between 20v and 30v. Contactor should pull in if voltage is correct and coil is good. If contactor does not pull in, replace contactor. 4. With high--voltage power off and contacts pulled in, check for continuity across contacts with ohmmeter.
Use following formula to calculate capacitance: Capacitance (mfd)= (2650 X amps)/volts 3. Remove any capacitor that shows signs of bulging, dents, or leaking. Do not apply power to a defective capacitor as it may explode. Sometimes under adverse conditions, a standard run capacitor in a system is inadequate to start compressor. In these instances, a start assist device is used to provide an extra starting boost to compressor motor.
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. Puron pressure switches are specifically designed to operate with Puronr systems. R--22 pressure switches must not be used as replacements for the Puronr air conditioner or heat pump. Puronr pressure switches are identified by a pink stripe down each wire.
Defrost Thermostat 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 65_ ± 5_F. Defrost thermostats are used in Legacy RNC and Legacy Line models, a coil temperature thermistor is used in Preferred and Evolution series units. FEEDER TUBE STUB TUBE DEFROST THERMOSTAT A97517 Fig.
Troubleshooting (HK32EA001) If outdoor unit will not run: 1. Does the Y input has 24 volts from thermostat? If not, check thermostat or wire. If yes proceed to #2 2. The Y spade terminal on the circuit board should have 24 volts if Y input is energized. This output goes through the pressure switches and to the contactor. If 24 volts is present on the Y spade terminal, and the contactor is not closed, check voltage on contactor coil. If no voltage is present, check for opened pressure switch. 3.
14. Remove jumper between DFT and R terminals. Reconnect defrost thermostat leads. Failure to remove jumper causes unit to switch to defrost every 30, 60, or 90 minutes and remain in defrost for full 10 minutes. 15. Replace control box cover. Restore power to unit. If defrost thermostat does not check out following above items or incorrect calibration is suspected, check for defective thermostat as follows: 1. Follow items 1--5 above. 2.
Deluxe Defrost Speedup (HK32EA003 CONT.) To initiate a force defrost, speedup pins (J1) must be shorted with a flat head screwdriver for 5 seconds and RELEASED. If the defrost thermostat is open, a short defrost cycle will be observed (actual length depends on Quiet Shift switch position). When Quiet Shift is off, only a short 30 second defrost cycle is observed.
COPELAND SCROLL COMPRESSOR Compressor Failures Compressor failures are classified in 2 broad failure categories; mechanical and electrical. Both types are discussed below. Mechanical Failures 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. A compressor is a mechanical pump driven by an electric motor contained in a welded or hermetic shell.
Noisy Compressor Noise may be caused by a variety of internal and external factors. Careful attention to the “type” of noise may help identify the source. The following are some examples of abnormal conditions that may create objectionable noise: 1. A gurgling sound may indicate a liquid refrigerant floodback during operation. This could be confirmed if there is no compressor superheat. A compressor superheat of “0” degrees would indicate liquid refrigerant returning to the compressor.
(EXAMPLE) TO DETERMINE INTERNAL CONNECTIONS OF SINGLEPHASE MOTORS (C,S,R) EXCEPT SHADED-POLE ? ? DEDUCTION: POWER OFF! ? 1 3 (GREATEST RESISTANCE) 5.8Ω (OHM) RUN WINDING (R) START WINDING (S) OHMMETER 0-10Ω SCALE 2 3 (SMALLEST RESISTANCE) 0.6Ω 2 IS COMMON (C) BY ELIMINATION 1 2 (REMAINING RESISTANCE) 5.2Ω 2 IS COMMON, THEREFORE, 1 IS 1 5.2Ω 1 2 0.6Ω 5.8Ω START WINDING (S) 2 3 3 3 IS RUN WINDING (R) A88344 Electrical Failures Fig.
Ground Circuit To determine if a wire has broken or come in direct contact with shell, causing a direct short to ground, follow these steps: 1. Allow crankcase heaters to remain on for several hours before checking motor to ensure windings are not saturated with refrigerant. 2. Using an ohmmeter on R X 10,000 ohm scale or megohmmeter (follow manufacturer’s instructions). 3. Be sure all power is off. 4. Discharge all capacitors. 5. Remove wires from terminals C, S, and R. 6.
Table 4—Oil Charging REFRIGERANT COMPRESSOR MODEL PURON PURON PURON PURON--- 2 STAGE PURON--- 2 STAGE ZP16--- 26 ZP32--- 41 P54 ZPS20, ZPS30, ZPS40 ZPS49, ZPS51 PURON--- 2 STAGE PURON--- 2 STAGE PURON--- 2 STAGE T81J195 T81J285, 384 T81J515 PURON PURON XG*32--- 38 XN*41--- 56 R22 R22 ZR16--- 32 ZR38--- R22 R22 R22 XC*38--- 42 XC*43--- 47 XR*48--- 60 RECHARGE (FL OZ) COPELAND 38 42 53 34 52 BRISTOL 27 37 62 SCROLL TECHNOLOGIES 36 53 COPELAND 19 34 SCROLL TECHNOLOGIES 36 45 53 Servicing Systems o
Service Valves and Pumpdown ! WARNING CAUTION ! PERSONAL INJURY HAZARD PERSONAL INJURY AND UNIT DAMAGE HAZARD Failure to follow this caution may result in personal injury. Failure to follow this warning could result in personal injury or equipment damage. Wear safety glasses, protective clothing, and gloves when handling refrigerant. Never attempt to make repairs to existing service valves. Unit operates under high pressure. Damaged seats and o--rings should not be replaced.
Heating Piston (AccuRaterr) -- Heat Pumps Only In this product line, AccuRater pistons are used to meter refrigerant for heat pump heating mode only. All indoor coils are supplied with a bi--flow TXV for metering in the cooling mode. AccuRaterr piston has a refrigerant metering hole through it. The piston seats against the meters refrigerant in to the outdoor coil in heating and allows refrigerant to flow around it in cooling mode. There are 2 types of liquid line connections used.
Reversing Valve In heat pumps, changeover between heating and cooling modes is accomplished with a valve that reverses flow of refrigerant in system. This reversing valve device is easy to troubleshoot and replace. The reversing valve solenoid can be checked with power off with an ohmmeter. Check for continuity and shorting to ground. With control circuit (24v) power on, check for correct voltage at solenoid coil. Check for overheated solenoid.
Liquid Line Filter Drier Install Liquid--line Filter Drier Indoor -- HP Filter driers are specifically designed for R--22 or Puronr refrigerant. Only operate with the appropriate drier using factory authorized components. It is recommended that the liquid line drier be installed at the indoor unit. Placing the drier near the TXV allows additional protection to the TXV as the liquid line drier also acts as a strainer. Refer to Fig.
Accumulator The accumulator is specifically designed to operate with Puronr or R22 respectfully; use only factory--authorized components. Under some light load conditions on indoor coils, liquid refrigerant is present in suction gas returning to compressor. The accumulator stores liquid and allows it to boil off into a vapor so it can be safely returned to compressor.
Thermostatic Expansion Valve (TXV) All fan coils and furnace coils will have a factory installed thermostatic expansion valve (TXV). The TXV will be a bi--flow, hard--shutoff with an external equalizer and a balance port pin. A hard shut--off TXV does not have a bleed port. Therefore, minimal equalization takes place after shutdown. TXVs are specifically designed to operate with Puronr or R--22 refrigerant, use only factory authorized TXV’s. Do not interchange Puron and R--22 TXVs.
Replacing TXV on an Indoor Coil (pre--2006) 1. Pump system down to 2 psig and recover refrigerant. 2. Remove coil access panel and fitting panel from front of cabinet. 3. Remove TXV support clamp using a 5/16--in. nut driver. Save the clamp. 4. Remove R--22 TXV using a backup wrench on flare connections to prevent damage to tubing. 5. Using wire cutters, cut equalizer tube off flush with vapor tube inside cabinet. 6. Remove bulb from vapor tube inside cabinet. 7. Braze equalizer stub--tube closed.
REFRIGERATION SYSTEM REPAIR Leak Detection New installations should be checked for leaks prior to complete charging. If a system has lost all or most of its charge, system must be pressurized again to approximately 150 psi minimum and 375 psi maximum. This can be done by adding refrigerant using normal charging procedures or by pressurizing system with nitrogen (less expensive than refrigerant). Nitrogen also leaks faster than refrigerants.
Compressor Removal and Replacement System Clean--Up After Burnout Once it is determined that compressor has failed and the reason established, compressor must be replaced. Some compressor electrical failures can cause motor to burn. When this occurs, by--products of burn, which include sludge, carbon, and acids, contaminate system. Test the oil for acidity using POE oil acid test to determine burnout severity. If burnout is severe enough, system must be cleaned before replacement compressor is installed.
Evacuation MICRONS Proper evacuation of the system will remove non--condensibles and assure a tight, dry system before charging. The 2 methods used to evacuate a system are the deep vacuum method and the triple evacuation method. Deep Vacuum Method The deep vacuum method requires a vacuum pump capable of pulling a vacuum of 500 microns and a vacuum gauge capable of accurately measuring this vacuum depth. The deep vacuum method is the most positive way of assuring a system is free of air and moisture.
TROUBLESHOOTING WITH SUPERHEAT This troubleshooting routine was developed to diagnose cooling problems using superheat in TXV systems. It is effective on heat pumps in cooling mode as well as air conditioners. The system must utilize a TXV as the expansion device in cooling mode. Basic Diagnostics NOTE: When checking refrigerant charge and troubleshooting operating systems, the indoor airflow has significant effect on the determination.
High Superheat with Normal or High Suction Pressure NOTE: Normal to High suction pressure is considered for R--22: > ∼65 psig, Puron: > ∼110 psig. An application issue or other system component failure typically causes this condition. 15. Check airflow, sensing bulb tightness, orientation on vapor tube and ensure bulb is properly wrapped. S If OK proceed to Step 16 16.
Table 6—Puron System Suction Pressure Drop Nominal Size (Btuh) 18000 18000 18000 24000 24000 24000 30000 30000 30000 36000 36000 36000 42000 42000 42000 42000 48000 48000 48000 60000 60000 60000 Suction Line OD (in.) Pressure Drop (psi/100 ft) Suction Velocity fpm 1/2 9.9 1649 5/8 3.1 1018 3/4 1.2 678 1/2 16.7 2199 5/8 5.2 1357 3/4 2.0 904 7/8 1.0 678 5/8 7.8 1696 3/4 2.9 1130 7/8 1.5 848 5/8 10.9 2036 3/4 4.1 1356 7/8 2.0 1017 5/8 14.1 2375 3/4 5.4 1582 7/8 2.7 1187 1 1/8 0.8 696 3/4 6.9 1808 7/8 3.
Table 7—R--22 System Suction Pressure Drop Nominal Size (Btuh) 18000 18000 18000 18000 24000 24000 24000 30000 30000 30000 36000 36000 36000 42000 42000 42000 48000 48000 48000 60000 60000 60000 Line OD (in.) Pressure Drop (psi/100 ft) Suction Velocity Fpm 5/8 13.6 5/8 4.0 3/4 1.5 7/8 0.8 5/8 6.7 3/4 2.5 7/8 1.3 5/8 10.1 3/4 3.8 7/8 1.9 3/4 5.3 7/8 2.6 1 1/8 0.7 3/4 7.0 7/8 3.5 1 1/8 1.0 3/4 8.9 7/8 4.4 1 1/8 1.2 7/8 6.7 1 1/8 1.8 1 3/8 0.
Table 8—Puronr Refrigerant Pressure Temperature Chart PSIG PSIG 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 °F --38.2 --35.3 --32.5 --29.9 --27.3 --24.9 --22.6 --20.4 --18.3 --16.2 --14.2 --12.3 --10.4 --8.6 --6.9 --5.1 --3.5 --1.9 --0.3 1.3 2.8 4.2 5.7 7.1 8.5 9.8 11.1 12.4 13.7 15.0 16.2 17.4 18.6 19.8 20.9 22.0 23.2 24.3 25.3 26.4 27.4 28.5 29.5 30.5 31.5 32.5 33.4 34.4 35.3 36.
Table 9—R--22 Refrigerant Pressure Temperature Relationship psig 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 °F --25.9 --24.0 --22.1 --20.4 --18.7 --17.0 --15.4 --13.8 --12.3 --10.8 --9.3 --7.9 --6.5 --5.2 --3.9 --2.6 --1.3 0.0 1.2 2.4 3.6 4.7 5.8 6.9 8.0 9.1 10.2 11.2 12.2 13.2 14.2 15.2 16.2 17.1 18.1 19.0 19.9 20.8 21.7 22.6 23.5 24.3 25.2 26.0 26.8 27.6 28.
Table 10—Puron Subcooling Chart Liquid Line Temperature (_F) Liq Press (psig) P---T (_F) 200 70 2 68 4 66 6 64 8 62 10 60 12 58 14 56 16 54 18 52 20 50 210 73 71 69 67 65 63 61 59 57 55 53 220 76 74 72 70 68 66 64 62 60 58 56 230 79 77 75 73 71 69 67 65 63 61 59 240 82 80 78 76 74 72 70 68 66 64 62 250 84 82 80 78 76 74 72 70 68 66 64 260 87 85 83 81 79 77 75 73 71 69 67 270 89 87 85 83 81 79 77 75 73 71 69 280
Vap Press (psig) 80 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 132 134 136 138 140 142 144 146 148 150 152 154 156 158 160 162 P--T (°F) 21 22 23 24 25 26 27 29 30 31 32 33 34 35 35 36 37 38 39 40 41 42 43 44 44 45 46 47 48 48 49 50 51 52 52 53 54 55 55 56 57 58 2 23 24 25 26 27 28 29 31 32 33 34 35 36 37 37 38 39 40 41 42 43 44 45 46 46 47 48 49 50 50 51 52 53 54 54 55 56 57 57 58 59 60 4 25 26 27 28 29 30 31 33 34 35 36 37 38 39 39 40 41 42 43 44 45 46 47
Table 12—R--22 Subcooling Chart R---22 Liquid Line Temperature (_F) Liquid Pres (psig) PT (°F) 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 70 72 74 76 79 81 83 85 87 89 91 93 95 96 98 100 102 103 105 107 108 110 111 113 114 116 117 119 120 121 123 124 126 127 128 129 131 132 133 135 136 137 138 Subcooling (_F) 2 68 70 72 74 77 79 81 83 85 87 89 91 93 94 96 98 100 101 103 105
Table 13—R--22 Superheat Chart R---22 Vapor Line Temperature (_F) Vapor Press (psig) PT (°F) 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 26 27 28 28 29 30 31 32 32 33 34 35 35 36 37 38 38 39 40 40 41 42 42 43 44 44 45 46 46 47 48 48 49 50 50 51 51 52 53 53 54 54 55 Superheat (_F) 2 28 29 30 30 31 32 33 34 34 35 36 37 37 38 39 40 40 41 42 42 43 44 44 45 46 46 47 48 48 49 50 50 51 52 52 53 53 54 55 55 56 56 57 4 30 31 32
TWO--STAGE (286ANA, 288ANA, 180ANA, 187ANA) Application Guidelines Model Plug Bryant designed and tested the two--stage air conditioner and heat pump products with Puron refrigerant to operate at a minimum outdoor operating ambient in cooling mode at 55_F without low ambient cooling enabled and the maximum outdoor operating ambient in cooling is 125_F/51.6_C. On Evolution communicating systems, only low ambient cooling is available to 0_F/--17.8_C.
Airflow Selections for 187ANA / 286ANA / 180ANA024,36,48 / 180ANA060 / 288ANA024,36,48, 60 Using Non--Communicating (Non--Evolution) Thermostats Airflow Selection for 315AAV/355AAV Furnaces The 315AAV/355AAV variable--speed furnaces provide high--and low--stage blower operation to match the capacities of the compressor at high and low stages.
S The ODF fan delay defeat can be toggled by shorting the forced defrost pins for >15 seconds while in the standby mode (status LED on solid). The LED will start to flash when the toggle has taken place. S Status code 4 shows the fan delay defeat is active (no delay) Status code 3 shows that it is not active (20 second delay) The code will continue to be displayed until after the short is removed. Once the short is removed, there is a 5 second wait before the code is cancelled.
SYSTEM FUNCTIONS AND SEQUENCE OF OPERATION The outdoor unit control system has special functions. The following is an overview of the two--stage control functions: Cooling and Heating Operation 286A/187ANA and 288ANA/180ANA (with serial numbers starting with 3809 and later) utilize either a standard indoor thermostat or Evolution Communication User Interface. 288ANA/180ANA utilize an Evolution communicating User Interface only.
Fan Motor Fan motor rotates the fan blade that either draws or blows air through outdoor coil to exchange heat between refrigerant and air. Motors are totally enclosed to increase reliability. This also eliminates need for rain shield. ! WARNING ELECTRICAL SHOCK HAZARD Failure to follow this warning could result in personal injury or death. Turn off all power to unit before servicing or replacing fan motor. Be sure unit main power switch is turned off.
Time Delays Thermistors The unit time delays include: Outdoor Ambient Thermistor The Puronr two--speed air conditioner and heat pump units have an outdoor ambient air thermistor. The control board must know the outdoor air temperature so it can activate various functions. These functions include: Five minute time delay to start cooling or heating operation when there is a call from the thermostat or user interface. To bypass this feature, momentarily short and release Forced Defrost pins.
CONTROL BOX Contactor And Capacitor Removal of the information plate exposes the control components. Both air conditioner and heat pump control boxes will appear to be nearly identical. There are two contactors, two capacitors, a control board and a compressor start assist. The contactors are identical to those used in the standard single speed units. One controls low capacity operation and the second controls high speed. The capacitors also are similar to those used in standard single speed units.
MODEL PLUG MODEL PLUG UTILITY RELAY * UTILITY SIGNAL OPEN RELAY LLS * SUPPLIED BY UTILITY PROVIDER Liquid Line Solenoid A06525/.A06526 Fig. 36 – 2--Stage Control Board TROUBLESHOOTING Troubleshooting (HK38EA003, 008, 010, 015) circuit boards. The Evolution Series outdoor units all use the same control board. A model plug is used to identify the system type, and set the operating parameters for airflow, start circuit timing etc.
230v Brown--Out Protection Defeated 288ANA Compressor Thermal Cutout The brownout feature can be defeated if needed for severe noisy power conditions. This defeat should always be a last resort to solving the problem.
Unloader Test Procedure Thermistor Sensor Comparison The unloader is the compressor internal mechanism, controlled by the DC solenoid, that modulates between high and low stage. If it is suspected that the unloader is not working, the following methods may be used to verify operation. 1. Operate the system and measure compressor amperage. Cycle the unloader on and off at 30 second plus intervals at the UI (from low to high stage and back to low stage).
Status Codes Table 17 shows the status codes flashed by the amber status light. Most system problems can be diagnosed by reading the status code as flashed by the amber status light on the control board. The codes are flashed by a series of short and long flashes of the status light. The short flashes indicate the first digit in the status code, followed by long flashes indicating the second digit of the error code. The short flash is 0.25 seconds ON and the long flash is 1.0 second ON.
2 STAGE HEAT PUMP FAN COIL THERMIDISTAT O RVS/Heat Stage 2 O/B W2 Y1 W1 Heat Stage 1 W/W1 Compressor Low Y1 W2 Compressor High Y/Y2 Y/Y2 Fan G G 24VAC Hot Heating Rh R 24VAC Hot Cooling Rc Dry Contact 1 D1 Dry Contact 2 D2 DH VARIABLE SPEED FURNACE REMOVE J2 JUMPER FOR HEAT STAGING W1 Y2 R REMOVE J1 FOR DEHUMIDIFY MODES C 24VAC Common C Humidify HUM Outdoor Air Temp OAT Humidifier Solenoid Valve * Remote Room Sensor RRS Outdoor Sensor * OAT/RRS Com OAT/RRS Remot
TWO--STAGE 286B/289B/180B/187B Application Guidelines Model Plug Bryant designed and tested the two--stage air conditioner and heat pump products with Puron refrigerant to operate at a minimum outdoor operating ambient in cooling mode at 55_F without low ambient cooling enabled and the maximum outdoor operating ambient in cooling is 125_F/51.6_C. On Evolution communicating systems, only low ambient cooling is available to 0_F/--17.8_C. The maximum outdoor operating ambient in heating mode is 66_F/18.
Airflow Selections for 187B / 286B / 180B /289B Using Non--Communicating (Non--Evolution) Thermostats Airflow Selection for 315AAV/355AAV Furnaces The 315AAV/355AAV variable--speed furnaces provide high--and low--stage blower operation to match the capacities of the compressor at high and low stages. To select the recommended airflow and for adjustments to the manual switches labeled SW1--5, AC, and CF on the control board, refer to the furnace Installation Instructions.
S The ODF fan delay defeat can be toggled by shorting the forced defrost pins for >15 seconds while in the standby mode (status LED on solid). The LED will start to flash when the toggle has taken place. S Status code 4 shows the fan delay defeat is active (no delay) Status code 3 shows that it is not active (20 second delay) The code will continue to be displayed until after the short is removed. Once the short is removed, there is a 5 second wait before the code is cancelled.
SYSTEM FUNCTIONS AND SEQUENCE OF OPERATION The outdoor unit control system has special functions. The following is an overview of the two--stage control functions: Cooling and Heating Operation The 286B/187B/289B/180B model utilizes either a standard 2--stage indoor thermostat or Evolution Communication User Interface. With a call for first stage cooling, the outdoor fan, reversing valve, and low stage compressor are energized.
The outdoor Integral Control Motor (ECM), is a variable--speed motor which operates from 450 to 850 rpm. The motor is a dc permanent magnet--type motor with the electronic controls integrated into its rear cover. The control package includes a small diode bridge, capacitors, and power switching devices. It converts ac to dc power and switches the dc power to the motor windings on and off at various rates to control the motor speed.
Muffler, Accumulator, Reversing Valve (RVS) Control Box The Puronr two--stage air conditioners and heat pumps have a compressor discharge line muffler, to dampen sound pressure pulsations. The Puronr two--stage heat pumps have a specifically designed reversing valve, for Puronr application and an accumulator for storing excess liquid refrigerant during the heating mode to prevent damaging flood--back. Contactor And Capacitor Removal of the information plate exposes the control components.
MODEL PLUG MODEL PLUG UTILITY RELAY * UTILITY SIGNAL OPEN RELAY LLS * SUPPLIED BY UTILITY PROVIDER Liquid Line Solenoid A06525/.A06526 Fig. 45 – 2--Stage Control Board TROUBLESHOOTING Troubleshooting (HK38EA015) circuit board The Evolution Series outdoor units all use the same control board. A model plug is used to identify the system type, and set the operating parameters for airflow, start circuit timing etc.
230v Brown--Out Protection Defeated 289B Compressor Thermal Cutout The brownout feature can be defeated if needed for severe noisy power conditions. This defeat should always be a last resort to solving the problem.
Temperature Thermistors Thermistors are electronic devices which sense temperature. As the temperature increases, the resistance decreases. Thermistors are used to sense outdoor air (OAT) and coil temperature (OCT). Refer to Fig. 43 for resistance values versus temperature. If the outdoor air or coil thermistor should fail, the control will flash the appropriate fault code. (See Table 21.) IMPORTANT: The outdoor air thermistor and coil thermistor should be factory mounted in the final locations.
Table 20—Two--Stage Compressor Resistances (Winding Resistance at 70_F±20_) Winding 286BNA024 286BNA036 286BNA048 286BNA060 Start (S-- C) 1.40 1.29 1.52 0.60 Run (R-- C) 1.32 0.89 0.64 0.49 Status Codes Table 21 shows the status codes flashed by the amber status light. Most system problems can be diagnosed by reading the status code as flashed by the amber status light on the control board. The codes are flashed by a series of short and long flashes of the status light.
2 STAGE HEAT PUMP FAN COIL THERMIDISTAT O O Y1 Y1 W1 REMOVE J2 JUMPER FOR HEAT STAGING Variable Speed Furnace Thermidistat 2-Stage Heat Pump O RVS/Heat Stage 2 O/B W2 Heat Stage 1 W/W1 W1 Compressor Low Y1 W2 Compressor High Y/Y2 Y/Y2 Fan G G 24VAC Hot Heating Rh R 24VAC Hot Cooling Rc Dry Contact 1 D1 Dry Contact 2 D2 24VAC Common C Humidify HUM Y2 R REMOVE J1 FOR DEHUMIDIFY MODES DH C RVS Cooling Heat Stage 3 (furnace) O/B W2 W2 W/W1 W/W1 Heat/Cool Stage 1 Y1
TWO STAGE NON--COMMUNICATING 127A/226A These units are a low cost 2--stage option that is non--communicating utilizing 2 stage scroll technology. These units require Performance Boost furnace (313AAV, 353AAV), variable speed furnace (355AAV, 315AAV) or new model variable speed fan coil (FV4C). Variable speed fan coils prior to the FV4C will NOT be rated with the new Legacy Line two stage units as they are not capable of meeting the air flow requirements necessary for rating.
SYSTEM FUNCTION AND SEQUENCE OF OPERATION NOTE: Defrost control board is equipped with 5 minute lockout timer that is initiated upon any interruption of power. Turn on power to indoor and outdoor units. Transformer is energized. Cooling On a call for cooling, thermostat makes circuits R--O, R--Y, and R--G. Circuit R--O energizes reversing valve, switching it to cooling position. Circuit R--Y sends low voltage through the safeties and energizes the T1 terminal on the circuit board.
CHECK CHARGE Factory charge amount and desired subcooling are shown on unit rating plate. Charging method is shown on information plate inside unit. To properly check or adjust charge, conditions must be favorable for subcooling charging. Favorable conditions exist when the outdoor temperature is between 70_F and 100_F (21.11_C and 37.78_C), and the indoor temperature is between 70_F and 80_F (21.11_C and 26.67_C). Follow the procedure below: Unit is factory charged for 15ft (4.57 m) of lineset.
TWO STAGE COMMUNICATING 167A/266A These units provide an Evolution capable 2 stage product in the Preferred line utilizing 2 stage scroll technology. These units are designed using the full--coil cabinet with is currently used for the Legacy Line products. Although the deluxe cabinet used in other Preferred Series products provides excellent sound levels, serviceability and stylish appearance, its design does not allow for coil surface area required to achieve targeted ratings.
GENERAL INFORMATION Evolution Controlled Low Ambient Cooling This unit is capable of low ambient cooling down to 0°F (--17.8°C) without a kit ONLY when using an Evolution Control. A low ambient kit is not required for Evolution controlled low ambient operation. The Evolution Control provides an automatic evaporator freeze thermostat. Low ambient cooling must be enabled in the User Interface setup. Fan may not begin to cycle until about 40°F (4.4°C) OAT.
Quiet Shift Quiet Shift is a field--selectable defrost mode which may eliminate occasional noise that could be heard at the start of the defrost cycle and restarting of the heating cycle. On a non--communicating system, this feature must be enabled by selecting the 3rd position of the 3--position dip switch. For communicating (Evolution) systems, it must be enabled at the User Interface. When activated, the following sequence of operation will occur.
SYSTEM FUNCTIONS AND SEQUENCE OF OPERATION The 266A models utilize either an Evolution Communicating User Interface or a 2-stage cooling indoor thermostat. With a call for first stage cooling, the outdoor fan and low-stage compressor are energized. If low-stage cannot satisfy cooling demand, high-stage is energized by the second stage of indoor thermostat. After second stage is satisfied, the unit returns to low-stage operation until first stage is satisfied or until second stage is required again.
MODEL PLUG MODEL PLUG UTILITY RELAY * UTILITY SIGNAL OPEN RELAY LLS * SUPPLIED BY UTILITY PROVIDER Liquid Line Solenoid A06525 A06526 Fig. 54 – 2--Stage Control Board TROUBLESHOOTING Systems Communication Failure If communication with the Evolution control is lost with the User Interface, the control will flash the appropriate fault code. (See Table 23.) Check the wiring to the User Interface and the indoor and outdoor units.
230V Line (Power Disconnect) Detection If there is no 230v at the compressor contactor(s) when the indoor unit is powered and cooling or heating demand exists, the appropriate fault code is displayed. Verify the disconnect is closed and 230v wiring is connected to the unit. Compressor Voltage Sensing The control board input terminals labeled VS and L2 (see Fig. 54) are used to detect compressor voltage status and alert the user of potential problems.
The thermistor comparison is not performed during low ambient cooling or defrost operation. Failed Thermistor Default Operation Factory defaults have been provided in the event of failure of outdoor air thermistor (OAT) and/or outdoor coil thermistor (OCT). If the OAT sensor should fail, low ambient cooling will not be allowed and the one--minute outdoor fan off delay will not occur. Defrost will be initiated based on coil temperature and time.
Status Codes Table 23 shows the status codes flashed by the amber status light. Most system problems can be diagnosed by reading the status code as flashed by the amber status light on the control board. The codes are flashed by a series of short and long flashes of the status light. The short flashes indicate the first digit in the status code, followed by long flashes indicating the second digit of the error code. The short flash is 0.25 seconds ON and the long flash is 1.0 second ON.
CARE AND MAINTENANCE Cleaning Coil 1. Remove top cover. (See Remove Top Cover in Cabinet section of this manual.) 2. Remove coil grilles or louvers (as applicable) to gain full access to coils for cleaning. To assure high performance and minimize possible equipment malfunction, it is essential that maintenance be performed periodically on this equipment.
Final Check--Out After the unit has been operating, the following items should be checked. 1. Check that unit operational noise is not excessive due to vibration of component, tubing, panels, etc. If present, isolate problem and correct. 2. Check to be sure caps are installed on service valves and are tight. 3. Check to be sure tools, loose parts, and debris are removed from unit. 4. Check to be sure all panels and screws are in place and tight.
AIR CONDITIONER TROUBLESHOOTING CHART NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD COMPRESSOR RUNS BUT INSUFFICIENT COOLING CONTACTOR OPEN CONTACTOR CLOSED OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD LOOSE LEAD AT FAN MOTOR LOW SUCTION PRESSURE HIGH SUCTION LOW HEAD PRESSURE HIGH SUCTION LOW SUPERHEAT POWER SUPPLY COMPRESSOR POWER SUPPLY OPEN OUTDOOR AIR RESTRICTED OR RECIRCULATING MOTOR DEFECTIVE DIRTY AIR FILTERS DEFECTIVE COMPRE
HEAT PUMP TROUBLESHOOTING HEATING CYCLE NO HEATING OR INSUFFICIENT HEATING COMPRESSOR WILL NOT RUN COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD COMPRESSOR RUNS INSUFFICIENT HEATING CONTACT OPEN CONTACTOR CLOSED DIRTY FILTERS OR INDOOR COIL DEFECTIVE LOWVOLTAGE TRANSFORMER COMPRESSOR POWER SUPPLY INDOOR FAN STOPPED OR CYCLING ON OVERLOAD DEFECTIVE FAN MOTOR CAPACITOR OUTDOOR FAN STOPPED OUTDOOR FAN RUNNING OUTDOOR THERMOSTAT DEFECTIVE REMOTE CONTROL CENTER DEFECTIVE LOOSE LEADS AT COMPRESS
HEAT PUMP TROUBLESHOOTING COOLING CYCLE NO COOLING OR INSUFFICIENT COOLING COMPRESSOR WILL NOT RUN COMPRESSOR RUNS BUT CYCLES ON INTERNAL OVERLOAD COMPRESSOR RUNS BUT INSUFFICIENT COOLING CONTACTOR OPEN CONTACTOR CLOSED OUTDOOR FAN STOPPED OR CYCLING ON OVERLOAD LOOSE LEAD AT FAN MOTOR LOW SUCTION PRESSURE HIGH SUCTION LOW HEAD PRESSURE HIGH SUCTION LOW SUPERHEAT POWER SUPPLY COMPRESSOR POWER SUPPLY OPEN OUTDOOR AIR RESTRICTED OR RECIRCULATING DEFROST RELAY N.C.
INDEX OF TABLES DESCRIPTION TABLE # Required Field--Installed Accessories for Air Conditioners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Required Field--Installed Accessories for Heat Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Defrost Control Speed--Up Timing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E 2012 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231 Edition Date: 05/12 Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations. 84 Catalog No.
